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NASA NTRS1994

Thermal balance testing of MSAT 2 spacecraft

The present work reports on the recently completed infrared thermal balance/thermal vacuum testing of a MSAT satellite, the first satellite to provide mobile communications service for all of continental North America. MSAT is a two spacecraft program, using a three-axis stabilized Hughes HS-601 series Bus as the vehicle for the Canadian designed Payload. The thermal tests which were performed at the Canadian Space Agency's David Florida Laboratory in Ottawa, Canada, lasted approximately 35 days. The infrared (IR) heating rig was designed to provide radiant heat inputs into seven spacecraft zones during Thermal Vacuum (TV) testing. The TV test was divided into multiple phases. It began with a thermal balance cold phase, followed by a thermal cold cycle and a hot balance phase, complemented by a thermal hot cycle to finish with a thermal cycle with continuous monitoring of the Bus and Payload. The spacecraft's external heat fluxes were provided by IR lamp sources. To ensure flux uniformity, highly reflective baffles and IR East and West faces; the Earth facing (Nadir); and the inside of the thrust cylinder. The aft-end panel heat fluxes were provided by a heated LN2 shroud. The radiation flux intensity on the spacecraft zones from the various rig elements was measured using Monitored Background Radiometers (MBR's) and compared with direct calculations and with pretest predictions. The temperature measurement system was based on Uniform Temperature References (UTR's) located inside the chamber such that all feedthroughs were copper-copper. This system was devised to achieve a temperature measurement accuracy of plus/minus 0.5 C for over 850 thermocouples used in the test. A PC-(QNX-based) based real-time data acquisition system was utilized to provide continuous monitoring of all channels based on a 30-second time scan. In addition, the data acquisition system was able to retrieve telemetry stream from the Satellite Test Equipments (STE) station for real-time data manipulation. Preliminary results showed the test to be successful from both the thermal balance side and the electrical testing side.

Samson, Serge↗

NASA NTRS1994

High Temperature Calibration Furnace System user's guide

The High Temperature Calibration Furnace System (HTCFS) was developed by Summitec Corporation. It is a high precision instrument providing a constant temperature which can be used to calibrate high temperature thermocouples. Incorporating the many recent technological advances from the fields of optical fiber thermometry, material science, computer systems interfacing, and process control, the engineers at Summitec Corporation have been able to create a system that can reach a steady operating temperature of 1700 C. The precision for the system requires the measurement of temperature to be within 1 C in two hours and within 2 C in 24 hours. As documented, the experimental result shows that this system has been able to stay within .5 C in 5 hours. No other systems commercially available have been able to achieve such high temperature precision. This manual provides an overview of the system design, instructions for instrument setup, and operation procedures. Also included are a vendor list and the source codes for the custom-designed software.

Source record↗

NASA NTRS1995

Experimental results for a hypersonic nozzle/afterbody flow field

This study was conducted to experimentally characterize the flow field created by the interaction of a single-expansion ramp-nozzle (SERN) flow with a hypersonic external stream. Data were obtained from a generic nozzle/afterbody model in the 3.5 Foot Hypersonic Wind Tunnel at the NASA Ames Research Center, in a cooperative experimental program involving Ames and McDonnell Douglas Aerospace. The model design and test planning were performed in close cooperation with members of the Ames computational fluid dynamics (CFD) team for the National Aerospace Plane (NASP) program. This paper presents experimental results consisting of oil-flow and shadow graph flow-visualization photographs, afterbody surface-pressure distributions, rake boundary-layer measurements, Preston-tube skin-friction measurements, and flow field surveys with five-hole and thermocouple probes. The probe data consist of impact pressure, flow direction, and total temperature profiles in the interaction flow field.

Spaid, Frank W.↗

NASA NTRS1994

Heat flux instrumentation for HYFLITE thermal protection system

Tasks performed in this project were defined in a September 9, 1994 meeting of representatives of Vatell, NASA Lewis and Virginia Tech. The overall objective agreed upon in the meeting was 'to demonstrate the viability of thin film techniques for heat flux and temperature sensing in HYSTEP thermal protection systems'. We decided to attempt a combination of NASA's and Vatell's best heat flux sensor technology in a sensor which would be tested in the Vortek facility at Lewis early in 1995. The NASA concept for thermocouple measurement of surface temperature was adopted, and Vatell methods for fabrication of sensors on small diameter substrates of aluminum nitride were used to produce a sensor. This sensor was then encapsulated in a NARloy-Z housing. Various improvements to the Vatell substrate design were explored without success. The basic NASA and Vatell sensor layouts were analyzed by finite element modeling, in an attempt to better understand the effects of material properties, dimensions and thermal differential element location on sensor symmetry, bandwidth and sensitivity. This analysis showed that, as long as the thermal resistivity of the thermal differential element material is much larger (10X) than that of the substrate material, the simplest arrangement of layer is best. During calibration of the sensor produced in this project, undesirable side-effects of combining the heat flux and temperature sensor return leads were observed. The sensor did not cleanly separate the heat flux and temperature signals, as sensors with four leads have consistently done before. Task 7 and 8 discussed in the meeting will be performed with a continuation of funding in 1995. The following is a discussion of each of the tasks performed as outlined in the statement of work dated september 26, 1994. Task 1A was added to cover further investigation into the NASA sensor concept.

Diller, T. E.↗

NASA NTRS1995

Evaluation of Oxygen Interactions with Materials 3: Mission and induced environments

The Evaluation of Oxygen Interactions with Materials 3 (EOIM-3) flight experiment was developed to obtain benchmark atomic oxygen/material reactivity data. The experiment was conducted during Space Shuttle mission 46 (STS-46), which flew July 31 to August 7, 1992. Quantitative interpretation of the materials reactivity measurements requires a complete and accurate definition of the space environment exposure, including the thermal history of the payload, the solar ultraviolet exposure, the atomic oxygen fluence, and any spacecraft outgassing contamination effects. The thermal history of the payload was measured using twelve thermocouple sensors placed behind selected samples and on the EOIM-3 payload structure. The solar ultraviolet exposure history of the EOIM-3 payload was determined by analysis of the as-flown orbit and vehicle attitude combined with daily average solar ultraviolet and vacuum ultraviolet (UV/VUV) fluxes. The atomic oxygen fluence was assessed in three different ways. First, the O-atom fluence was calculated using a program that incorporates the MSIS-86 atmospheric model, the as-flown Space Shuttle trajectory, and solar activity parameters. Second, the oxygen atom fluence was estimated directly from Kapton film erosion. Third, ambient oxygen atom measurements were made using the quadrupole mass spectrometer on the EOIM-3 payload. Our best estimate of the oxygen atom fluence as of this writing is 2.3 +/- 0.3 x 10(exp 20) atoms/sq cm. Finally, results of post-flight X-ray photoelectron spectroscopy (XPS) surface analyses of selected samples indicate low levels of contamination on the payload surface.

Koontz, Steven L.↗

NASA NTRS1992

Process and control systems for composites manufacturing

A precise control of composite material processing would not only improve part quality, but it would also directly reduce the overall manufacturing cost. The development and incorporation of sensors will help to generate real-time information for material processing relationships and equipment characteristics. In the present work, the thermocouple, pressure transducer, and dielectrometer technologies were investigated. The monitoring sensors were integrated with the computerized control system in three non-autoclave fabrication techniques: hot-press, self contained tool (self heating and pressurizing), and pressure vessel). The sensors were implemented in the parts and tools.

Tsiang, T. H.↗

NASA NTRS1995

Nonequilibrium Flow Expansion Experiment Around a Blunted Cone

Eleven tests were carried out in DLR's high enthalpy tunnel in Goettingen (HEG), Germany, for reservoir conditions ranging from 10 to 23 MJ/kg and a free stream Mach number of approximately 10. A blunted cone model with a cylindrical afterbody (sting) was investigated. To obtain information on the influence of defined parameters on the body back flow, especially of the reacting gas, the heat transfer rate along the body contour was measured with fast response surface thermocouples on the forebody and sensitive thin film heat transfer gauges on the base and sting of the model. Flow visualization with a holographic interferometry system was provided. Tests are described, and a preliminary interpretation of the observed flow effects are given.

Kastell, Dirk↗

NASA NTRS1994

Ifluence of crystallization and entrainment of cooler material on the emplacement of basaltic aa lava flows

A theoretical model is used to describe and investigate the effects of simultaneous crystallization, radiation loss, and entrainment of cooler material on the temperature of a well-mixed core of an active aa lava flow. Entrainment of crust, levee debris, and base material into the interior of active flows has been observed, but the degree of assimilation and the thermal consequences are difficult to quantify. The rate of entrainment can be constrained by supplementing the theoretical model with information on the crystallization along the path of the flow and estimation of the radiative loss from the flow interior. Application of the model is demonstrated with the 1984 Mauna Loa flow, which was erupted about 30 C undercooled. Without any entrainment of cooler material, the high crystallization rates would have driven temperatures in the core wall above temperatures measured by thermocouple and estimated from glass geothermometry. One plausible scenario for this flow, which agrees with available temperature and crystallinity measurements, has a high initial rate of entrainment during the first 8 hours of travel (a mass ratio of entrained material to fluid core of about 15% if the average temperature of the entrained material was 600 C), which counterbalances the latent heat from approximately 40% crystallization. In this scenario, the model suggests an additional 5% crystallization and a 5% entrainment mass ratio over the subsequent 16-hour period. Measurements of crystallization, radiative losses, and entrainment factors are necessary for understanding the detailed thermal histories of active lava flows.

Crisp, Joy↗

NASA NTRS1995

Apparatus Measures Permeation Of Gases Through Coupons

Apparatus measures permeation of any variety of commercially available pure or mixed gases through polymeric or other material coupons of various thicknesses. Permeability measured at wide range of temperatures and pressures. Includes residual-gas-analyzer (RGA) sensor head and associated circuitry, and vacuum system. Also includes manifold with valves, through which gas of interest allowed to permeate through test coupon before traveling downstream to evacuated RGA sensor head. Temperature of test coupon monitored by thermocouple and maintained at specified value above ambient by use of electrical heating mantle or below ambient by use of bath of ethylene glycol, water, and dry ice.

Adam, Steven J.↗

NASA NTRS1995

Probes For Measuring Changing Internal Temperatures

Improved thermocouple probes devised for measuring rapidly changing temperatures within layers of solid materials. In original application, layers in question are carbon-cloth phenolic liners in solid-rocket motor nozzles, and probes inserted in layers to various depths of order of 0.5 in. measure changing temperatures in layers during hot-fire tests. Probe concept adapted to measurements of temperatures inside various other layers, materials, and components, including material test specimens.

Hunt, S. B.↗

NASA NTRS1995

Design and development of a high-speed bearing test rig

The development of a high-speed test rig, to be used for compiling an experimental data base of bearing signatures for bearings with known faults, is described. This bearing test rig can be adapted to test oil-film bearings as well as rolling element bearings. This is achieved by mounting the test bearing in one of two special test housings, either of which can be mounted onto a common test shaft which can be driven up to 30,000 rpm. The test bearing housing for rolling element bearings can accommodate proximity displacement transducers, accelerometers, thermocouples, and acoustic emission sensors. The test bearing housing for the fluid-film bearings can accommodate the same instrumentation as well as Bourdon tube-type transducers for measuring oil film pressures around the bearing circumference.

Cockburn, J. A.↗

NASA NTRS1995

Solid surface combustion experiment flame spread in a quiescent, microgravity environment implications of spread rate and flame structure

A unique environment in which flame spreading, a phenomenon of fundamental, scientific interest, has importance to fire safety is that of spacecraft in which the gravitational acceleration is low compared with that of the Earth, i.e., microgravity. Experiments aboard eight Space Shuttle missions between October 1990 and February 1995 were conducted using the Solid Surface Combustion Experiment (SSCE) payload apparatus in an effort to determine the mechanisms of gas-phase flame spread over solid fuel surfaces in the absence of any buoyancy induced or externally imposed oxidizer flow. The overall SSCE effort began in December of 1984. The SSCE apparatus consists of a sealed container, approximately 0.039 cu m, that is filled with a specified O2/N2 mixture at a prescribed pressure. Five of the experiments used a thin cellulosic fuel, ashless filter paper, 3 cm wide x 10 cm long, 0.00825 cm half-thickness, ignited in five different ambient conditions. Three of the experiments, the most recent, used thick polymethylmethacrylate (PMMA) samples 0.635 cm wide x 2 cm long, 0.32 cm half-thickness. Three experiments, STS 41, 40 and 43, were designed to evaluate the effect of ambient pressure on flame spread over the thin cellulosic fuel while flights STS 50 and 47 were at the same pressure as two of the earlier flights but at a lower oxygen concentration in order to evaluate the effect of ambient oxygen level on the flame spread process at microgravity. For the PMMA flights, two experiments, STS 54 and 63, were at the same pressure but different oxygen concentrations while STS 64 was at the same oxygen concentration as STS 63 but at a higher pressure. Two orthogonal views of the experiments were recorded on 16 mm cine-cameras operating at 24 frames/s. In addition to filmed images of the side view of the flames and surface view of the burning samples, solid- and gas-phase temperatures were recorded using thermocouples. The experiment is battery powered and follows an automated sequence upon activation by the Shuttle Crew. In this study we separate the SSCE data into two groups according to the fuel type: (1) thin cellulose; and (2) thick PMMA. The experimental spread rates are compared with prediction from a number of models in an effort to uncover the important physics that characterize microgravity flame spread. Both steady and unsteady solutions are employed to explore the flame evolution, especially for thick fuels. Finally, the flame structure in downward spread is compared with the microgravity flame structure and modeling results to delineate the difference between the two configurations and the influence of normal gravity.

Bundy, Matthew↗

NASA NTRS1995

An imaging spectrometer for microgravity application

Flame structure is the result of complex interaction of mechanisms operating in both unwanted fires and controlled combustion systems. The scientific study of gas-jet diffusion flames in reduced-gravity environment is of interest because the effects of buoyancy on flow entrainment and acceleration are lessened. Measurements of flames have been restricted to cinematography, thermocouples, and radiometers. SSG, Inc. is developing an MWIR imaging spectrometer (MIS) for microgravity flame measurements. The device will be delivered to NASA Lewis at the end of this project to demonstrate flame measurements in the laboratory. With proper modifications, the MIS can be used to monitor a gas-jet flame under microgravity on a NASA Learjet or DC-9.

Wong, Wallace K.↗

NASA NTRS1995

User's manual for the one-dimensional hypersonic experimental aero-thermodynamic (1DHEAT) data reduction code

A FORTRAN computer code for the reduction and analysis of experimental heat transfer data has been developed. This code can be utilized to determine heat transfer rates from surface temperature measurements made using either thin-film resistance gages or coaxial surface thermocouples. Both an analytical and a numerical finite-volume heat transfer model are implemented in this code. The analytical solution is based on a one-dimensional, semi-infinite wall thickness model with the approximation of constant substrate thermal properties, which is empirically corrected for the effects of variable thermal properties. The finite-volume solution is based on a one-dimensional, implicit discretization. The finite-volume model directly incorporates the effects of variable substrate thermal properties and does not require the semi-finite wall thickness approximation used in the analytical model. This model also includes the option of a multiple-layer substrate. Fast, accurate results can be obtained using either method. This code has been used to reduce several sets of aerodynamic heating data, of which samples are included in this report.

Hollis, Brian R.↗

NASA NTRS1995

Verification of a three-dimensional resin transfer molding process simulation model

Experimental evidence was obtained to complete the verification of the parameters needed for input to a three-dimensional finite element model simulating the resin flow and cure through an orthotropic fabric preform. The material characterizations completed include resin kinetics and viscosity models, as well as preform permeability and compaction models. The steady-state and advancing front permeability measurement methods are compared. The results indicate that both methods yield similar permeabilities for a plain weave, bi-axial fiberglass fabric. Also, a method to determine principal directions and permeabilities is discussed and results are shown for a multi-axial warp knit preform. The flow of resin through a blade-stiffened preform was modeled and experiments were completed to verify the results. The predicted inlet pressure was approximately 65% of the measured value. A parametric study was performed to explain differences in measured and predicted flow front advancement and inlet pressures. Furthermore, PR-500 epoxy resin/IM7 8HS carbon fabric flat panels were fabricated by the Resin Transfer Molding process. Tests were completed utilizing both perimeter injection and center-port injection as resin inlet boundary conditions. The mold was instrumented with FDEMS sensors, pressure transducers, and thermocouples to monitor the process conditions. Results include a comparison of predicted and measured inlet pressures and flow front position. For the perimeter injection case, the measured inlet pressure and flow front results compared well to the predicted results. The results of the center-port injection case showed that the predicted inlet pressure was approximately 50% of the measured inlet pressure. Also, measured flow front position data did not agree well with the predicted results. Possible reasons for error include fiber deformation at the resin inlet and a lag in FDEMS sensor wet-out due to low mold pressures.

Fingerson, John C.↗

NASA NTRS1995

Fuel decomposition and boundary-layer combustion processes of hybrid rocket motors

Using a high-pressure, two-dimensional hybrid motor, an experimental investigation was conducted on fundamental processes involved in hybrid rocket combustion. HTPB (Hydroxyl-terminated Polybutadiene) fuel cross-linked with diisocyanate was burned with GOX under various operating conditions. Large-amplitude pressure oscillations were encountered in earlier test runs. After identifying the source of instability and decoupling the GOX feed-line system and combustion chamber, the pressure oscillations were drastically reduced from +/-20% of the localized mean pressure to an acceptable range of +/-1.5% Embedded fine-wire thermocouples indicated that the surface temperature of the burning fuel was around 1000 K depending upon axial locations and operating conditions. Also, except near the leading-edge region, the subsurface thermal wave profiles in the upstream locations are thicker than those in the downstream locations since the solid-fuel regression rate, in general, increases with distance along the fuel slab. The recovered solid fuel slabs in the laminar portion of the boundary layer exhibited smooth surfaces, indicating the existence of a liquid melt layer on the burning fuel surface in the upstream region. After the transition section, which displayed distinct transverse striations, the surface roughness pattern became quite random and very pronounced in the downstream turbulent boundary-layer region. Both real-time X-ray radiography and ultrasonic pulse-echo techniques were used to determine the instantaneous web thickness burned and instantaneous solid-fuel regression rates over certain portions of the fuel slabs. Globally averaged and axially dependent but time-averaged regression rates were also obtained and presented.

Chiaverini, Martin J.↗

NASA NTRS1995

Combustion of solid fuel slabs with gaseous oxygen in a hybrid motor analog

Using a high-pressure, two-dimensional hybrid motor, an experimental investigation was conducted on fundamental processes involved in hybrid rocket combustion. HTPB (Hydroxyl-terminated- Polybutadiene) fuel cross linked with diisocyanate was burned with GOX under various operating conditions. Large amplitude pressure oscillations were encountered in earlier test runs. After identifying the source of instability and decoupling the GOX feed line system and combustion chamber, the pressure oscillations were drastically reduced from +/- 20% of the localized mean pressure to an acceptable range of +/- 1.5%. Embedded fine-wire thermocouples indicated that the surface temperature of the burning fuel was around 1000 K depending upon axial locations and operating conditions. Also, except near the leading-edge region, the subsurface thermal wave profiles in the upstream locations arc thicker than those in the downstream locations since the solid-fuel regression rate, in general, increases with distance along the fuel slab. The recovered solid fuel slabs in the laminar portion of the boundary layer exhibited smooth surfaces, indicating the existence of a liquid melt layer on the burning fuel surface in the upstream region. After the transition section, which displayed distinct transverse striations, the surface roughness pattern became quite random and very pronounced in the downstream turbulent boundary-layer region. Both real time X-ray radiography and ultrasonic pulse-echo techniques were used to determine the instantaneous web thicknesses and instantaneous solid-fuel regression rates over certain portions of the fuel slabs. Globally averaged and axially dependent but time-averaged regression rates were also obtained and presented. Several tests were conducted using, simultaneously, one translucent fuel slab and one fuel slab processed with carbon black powder. The addition of carbon black did not affect the measured regression rates or surface temperatures in comparison to the translucent fuel slabs.

Chiaverini, Martin J.↗

NASA NTRS1996

Blunt body near wake flow field at Mach 6

Tests were conducted in a Mach 6 flow to examine the reattachment process of an axisymmetric free shear layer associated with the near wake of a 70 deg. half angle, spherically blunted cone with a cylindrical after body. Model angle of incidence was fixed at 0 deg. and free-stream Reynolds numbers based on body diameter ranged from 0.5 x 10(exp 6) to 4 x 10(exp 6). The sensitivity of wake shear layer transition on reattachment heating was investigated. The present perfect gas study was designed to compliment results obtained previously in facilities capable of producing real gas effects. The instrumented blunted cone model was designed primarily for testing in high enthalpy hypervelocity shock tunnels in both this country and abroad but was amenable for testing in conventional hypersonic blowdown wind tunnels as well. Surface heating rates were inferred from temperature - time histories from coaxial surface thermocouples on the model forebody and thin film resistance gages along the model base and cylindrical after body. General flow feature (bow shock, wake shear layer, and recompression shock) locations were visually identified by schlieren photography. Mean shear layer position and growth were determined from intrusive pitot pressure surveys. In addition, wake surveys with a constant temperature hot-wire anemometer were utilized to qualitatively characterize the state of the shear layer prior to reattachment. Experimental results were compared to laminar perfect gas predictions provided by a 3-D Navier Stokes code (NSHYP). Shear layer impingement on the instrumented cylindrical after body resulted in a localized heating maximum that was 21 to 29 percent of the forebody stagnation point heating. Peak heating resulting from the reattaching shear layer was found to be a factor of 2 higher than laminar predictions, which suggested a transitional shear layer. Schlieren flow visualization and fluctuating voltage time histories and spectra from the hot wire surveys across the shear layer substantiate this observation. The sensitivity of surface heating to forebody roughness was characterized for a reattaching shear layer. For example, at R(sub infinity), d = 4 x 10(exp 6), when the shear layer was transitional, the magnitude of peak heating from shear layer impingement was reduced by approximately 24 percent when transition grit was applied to the forebody. The spatial location of the local peak, however, remained unchanged.

Horvath, Thomas J.↗