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NASA NTRSDate not supplied

Overview of Advanced Stirling Convertor Dual Convertor Controller Development and Testing at NASA Glenn Research Center

For over two decades, NASA Glenn Research Center (GRC) has been supporting the development of Radioisotope Power Systems (RPS). NASA desires higher conversion efficiency RPS options that are reliable and robust with long life design. Dynamic conversion, such as Stirling offer the potential for higher conversion efficiencies than current RPS but have yet to be demonstrated in a flight application. GRC developed a non-nuclear representation of a RPS consisting of a pair of Advanced Stirling Convertors (ASC), a Dual Convertor Controller (DCC), and associated support equipment. The DCC was designed by the Johns Hopkins University/Applied Physics Laboratory (JHU/APL) to actively control a pair of ASCs. Based on lessons learned, three generations of DCCs were developed over the past decade. After each generation of the DCC was completed, tests were performed to verify functionality. These tests include acceptance testing, fault testing, characterization testing, and testing with the Radioisotope Power System Systems Integration Laboratory (RSIL). Acceptance testing verifies that the DCC can control a pair of ASCs to produce full convertor power output. The fault testing verifies that the DCC can maintain control of the ASCs during either internal or external faults. Characterization testing verifies the functionality of the DCC over a range of bus voltage values. RSIL provides insight into the electrical interactions between a representative radioisotope power generator, its associated control schemes, and realistic electric system loads. The DCC design, development, lessons learned, test results, and future work are presented in this paper.

Stirling↗

NASA NTRSDate not supplied

Pick-and-Eat Space Crop Production Flight Testing on the International Space Station

Growing fresh, nutritious, palatable produce for crew consumption during spaceflight may provide health-promoting, bioavailable nutrients and enhance the astronaut dietary experience as we move toward longer-duration missions. However, requirements to support consistent growth of a variety of high-quality crops under spaceflight environmental conditions remain unclear. This study explores the potential to grow crops for consumption on the International Space Station (ISS) using Veggie, NASA’s vegetable production chamber system. VEG-04A and VEG-04B were two flight tests with ground components conducted with the leafy green crop mizuna mustard. In each location, mizuna was grown in two Veggie units simultaneously, with the chambers set to different red-to-blue-to-green light formulations. Preflight verification testing with various lighting treatments was conducted to down-select two treatments that contributed to the best desirable growth and sensory qualities in mizuna mustard. For the flight tests, one Veggie was programmed as “red-rich” with an average of 270 μmol m-2 s-1 of 630 nm red light, 30 μmol m-2 s-1 of 455 nm blue light, and 30 μmol m-2 s-1 of 530 nm green light. The second Veggie was “blue-rich” with an average of 150 µmol m-2 s-1 of 630 nm red light, 150 µmol m-2 s-1 of 455 nm blue light, and 30 µmol m-2 s-1 of 530 nm green light. Light quality is known to impact plant growth, nutrition, microbiology, and sensory characteristics on Earth, and the Veggie flight tests examined how these impacts might differ in microgravity. VEG-04A, a 35-day growth test with a single harvest, was initiated in June and harvested in July 2019. VEG-04B, a 56-day test with three harvests from the same plants, assessed sustained productivity. Preflight testing for VEG-04B was conducted after the VEG-04A flight test to improve the operations, approaches, and watering requirements, which resulted in better crop establishment in the VEG-04B flight test. VEG-04B was initiated in October 2019 with harvests at four, six, and eight weeks after initiation. At all of the harvests, the astronauts froze half of the edible plant tissue to return to Earth and weighed the remaining half using the Mass Measurement Device (MMD). Weighed samples were then cleaned with produce-sanitizing wipes, and consenting crew members participated in sensory evaluations of the fresh produce. The remaining sanitized produce was available for crew consumption as desired. Frozen flight samples were returned to Earth for chemical and microbial analyses to assess nutritional quality and food safety. Flight-grown mizuna was generally more acceptable to the crew and had higher nutrient levels, although mizuna grown in the ground control performed better in terms of higher yield and lower microbial load. This presentation will focus on results from the nutritional and sensory analyses, including how nutrients identified as key for supplementing the crew diet varied across lighting treatments, harvest approaches, and spaceflight versus ground conditions. It is our hope that these tests on the ISS will help mitigate the risk of an inadequate food supply for long-duration missions by adding fresh vegetables to the crew diet. This study was supported by NASA’s Human Research and Space Biology Programs through the HERO NNJ13ZSA002N-ILSRA grant solicitation.

Jess Bunchek↗

NASA NTRS2024

Exploration Extravehicular Mobility Unit (xEMU) Lunar Boot Chamber B Thermal Vacuum Testing Results

NASA’s Exploration Extravehicular Mobility Unit (xEMU) is the government reference next-generation spacesuit design and is engineered to protect astronauts from extreme lunar environmental temperatures. To evaluate the xEMU hardware thermal requirements, the xEMU Testing Team invented, designed, and executed a dual-suit, uncrewed thermal vacuum (TVAC) test at Johnson Space Center’s (JSC) Chamber B. This paper details the test methodology, hardware setup, and results from the xEMU lunar boots. Eleven unique thermal profiles were tested including both cold and hot environmental cases over the course of five continuous days of testing. This paper will address only the cold environment testing results. The radiative thermal environment was controlled through exposure to liquid-nitrogen shrouds on the chamber walls and through a heater cage surrounding the boots. Notably, the xEMU boots also contacted the liquid-nitrogen chilled floor inside of Chamber B, which provided a conduction pathway to simulate the thermal effects of the lunar surface. Test hardware was developed to extend the water tubing from the Liquid Cooling Ventilation Garment (LCVG) into the boots to set the internal thermal boundary nominally provided by the astronaut’s foot. Thirty-three temperature sensors were used to collect data in critical locations in the xEMU boot assembly as well as for calorimetry to determine heat flux to and from the boots. This paper will document the testing results and provide a high-level interpretation of the testing results. To conclude, this paper will address possible forward work and knowledge gaps present in lunar boot thermal performance and testing.

xEMU↗

NASA NTRSDate not supplied

Performance Testing of TRL4-6 LISA Laser System

The Laser Interferometer Space Antenna (LISA) is an ESA-led future mission to measure gravitational waves from astronomical sources in space. LISA has been adopted as a formal mission by ESA in January 2024, and is expected to become a formal project at NASA within 2024. The laser system (LS), which includes four laser heads (LH) each containing a laser optical module (LOM) and laser electronics module (LEM), a frequency reference system (FRS, optical frequency reference) and four power monitor detectors (PMON), is one of the three U.S. contributions to LISA from NASA. The Lasers and Electro-Optics Branch at NASA GSFC has been developing and managing the design of the LISA LS. Currently, the TRL (technology readiness level) of the NASA LISA laser system is transitioning from 4 to 6. TRL 4/5 LISA LOM was sent to ESA in early 2023 and has undergone optical performance testing. [1] By late summer of 2024, NASA plans to deliver the TRL 6 LOM to ESA for performance evaluation. Since the delivery of the TRL4/5 LOM to ESA, we have taken steps to advance the TRL of the overall LS and have also started end-to-end system level testing involving other subsystems. They include 1) optical performance test of TRL6 LOM and TRL 5 LEM under thermal cycling, 2) end-to-end test of the laser head (LH) and the GSE (ground support equipment) FRS, driven by TRL 4 FRS electronics (FRS-E) provided by Ball Aerospace, 3) end-to-end test of the laser head (LH) with the GSE phase meter system (PMS) provided by Albert Einstein Institute, and 4) optical performance test of the LH with the PMON subsystem developed by NASA. The FRS, PMS, and PMON provide necessary frequency stability, relative phase stability between lasers, and output power stability, respectively. Since they are all vital for the sensitive laser interferometry performed in LISA, it is necessary to perform these system level testing by combining the LH and other subsystems, and to prove the optical performance at an early stage during the LS development. Our recent work has successfully demonstrated the intra-connectivity of the LS, as well as critical external interface with the PMS to meet the LISA’s performance requirements. In this talk, we will report on the latest status of the LH testing and system level test. We will also discuss the paths to bring each subsystem to TRL6+ and plans for future system level testing.

LISA↗

NASA NTRSDate not supplied

FT-01: Autonomous Helicopter Flight Testing Over Long Island Sound Special Session - Hazard Perception and Avoidance Tech Area

This presentation is included as part of a panel reporting on the Integration of Automated Systems (IAS) flight test series. The IAS series concluded in October 2023 and was conducted under NASA’s Advanced Air Mobility project and in partnership with Sikorsky and the Defense Advanced Research Projects Agency (DARPA). The flight test effort included two crewed rotorcraft platforms. The first, a modified S-76B helicopter, served as the “ownship” for the duration of the flight test. The second vehicle, a modified S-70, served as the intruder aircraft. One Sikorsky pilot and one NASA test pilot was onboard each aircraft for every test point, with the NASA test pilot responsible for interacting with the research systems under test. This portion of the panel presentation focuses on the results of the flight test that assessed the Federal Aviation Administration’s (FAA) next-generation collision avoidance system, the Airborne Collision Avoidance System X for Rotorcraft (ACAS Xr). The two configurations available within ACAS Xr – the Collision Avoidance System (CAS) configuration and the Detect and Avoid (DAA) configuration – were flown with an onboard pilot under Visual Flight Rules in controlled airspace over the Long Island Sound (Connecticut, USA). A total of 33 flight test cards were flown with ACAS Xr active. Results showed that the ACAS Xr alerting and guidance was largely effective and rated positively by the NASA test pilots, exemplified by zero instances of the pilots overriding an ACAS Xr Resolution Advisory (RA). Key areas of improvement, however, were noted, particularly with regards to the lack of an aural alert indicating a need to accelerate when receiving an RA at low speed and the occurrence of multiple RAs that the pilots found to be unacceptable.

detect and avoid↗

NASA NTRSDate not supplied

Developmental and Cryogenic Thermal Vacuum (TVAC) Testing Lessons Learned

Developmental thermal vacuum (TVAC) testing is a critical step in maturing hardware designs and validating performance prior to flight qualification. Unlike qualification or acceptance testing, developmental testing provides flexibility to explore design margins, uncover integration challenges, and refine test approaches before formal verification activities begin. This presentation highlights the value of developmental testing while sharing common pitfalls encountered during developmental TVAC campaigns. Lessons learned from hands-on testing experience, including extensive developmental testing at cryogenic temperatures, will be shared in this presentation. Topics include test planning and preparation, instrumentation strategies, contamination control considerations, troubleshooting unexpected anomalies, and approaches for staying on schedule while meeting test objectives. The audience will gain practical insights and best practices that can improve test efficiency, reduce risk, and enhance the overall success of future developmental TVAC efforts.

Mackenzie Byrnes↗

NASA NTRS1994

Basic principles of flight test instrumentation engineering, volume 1, issue 2

Volume 1 of the AG 300 series on ´Flight Test Instrumentation´ gives a general introduction to the basic principles of flight test instrumentation. The other volumes in the series provide more detailed treatments of selected topics on flight test instrumentation. Volume 1, first published in 1974, has been used extensively as an introduction for instrumentation courses and symposia, as well as being a reference work on the desk of most flight test and instrumentation engineers. It is hoped that this second edition, fully revised, will be used with as much enthusiasm as the first edition. In this edition a flight test system is considered to include both the data collection and data processing systems. In order to obtain an optimal data flow, the overall design of these two subsystems must be carefully matched; the detail development and the operation may have to be done by separate groups of specialists. The main emphasis is on the large automated instrumentation systems used for the initial flight testing of modern military and civil aircraft. This is done because there, many of the problems, which are discussed here, are more critical. It does not imply, however, that smaller systems with manual data processing are no longer used. In general, the systems should be designed to provide the required results at the lowest possible cost. For many tests which require only a few parameters, relatively simple systems are justified, especially if no complex equipment is available to the user. Although many of the aspects discussed in this volume apply to both small and large systems, aspects of the smaller systems are mentioned only when they are of special interest. The volume has been divided into three main parts. Part 1 defines the main starting points for the design of a flight test instrumentation system, as seen from the points of view of the flight test engineer and the instrumentation engineer. In Part 2 the discussion is concentrated on those aspects which apply to each individual measuring channel, and in Part 3 the main emphasis is on the integration of the individual data channels into one data collection system and on those aspects of the data processing which apply to the complete system.

channels (data transmission)↗

NASA NTRS2014

Ice Crystal Icing Engine Testing in the NASA Glenn Research Center's Propulsion Systems Laboratory: Altitude Investigation

The National Aeronautics and Space Administration (NASA) conducted a full scale ice crystal icing turbofan engine test using an obsolete Allied Signal ALF502-R5 engine in the Propulsion Systems Laboratory (PSL) at NASA Glenn Research Center. The test article used was the exact engine that experienced a loss of power event after the ingestion of ice crystals while operating at high altitude during a 1997 Honeywell flight test campaign investigating the turbofan engine ice crystal icing phenomena. The test plan included test points conducted at the known flight test campaign field event pressure altitude and at various pressure altitudes ranging from low to high throughout the engine operating envelope. The test article experienced a loss of power event at each of the altitudes tested. For each pressure altitude test point conducted the ambient static temperature was predicted using a NASA engine icing risk computer model for the given ambient static pressure while maintaining the engine speed.

Altitude Testing↗

NASA NTRS2023

Finite Element Simulation of Three Full-Scale Crash Tests for Cessna 172 Aircraft

The NASA Emergency Locator Transmitter Survivability and Reliability project was initiated in 2013 to assess the crash performance standards for the next generation of emergency locator transmitter (ELT) systems. Three Cessna 172 aircraft were acquired to perform crash testing at the NASA Langley Research Center Landing and Impact Research Facility. Full-scale crash tests were conducted in the summer of 2015 and each test article was subjected to severe, but survivable, impact conditions including a flare-to-stall during emergency landing, and two controlled-flight-into-terrain scenarios. Finite element analyses were performed to numerically simulate the aircraft response to the crash tests. The first test simulated impacting a concrete surface represented analytically by a rigid plane. Tests 2 and 3 simulated impacting a dirt surface represented analytically by an Eulerian grid of bric k elements using a Mohr-Coulomb material model. The objective of this paper is to summarize the test and analysis results for the three full-scale crash tests. Simulation models of the airframe which correlate well with the tests are needed for future studies of alternate ELT mounting configurations.

Finite Element Analysis↗

NASA NTRS2023

Finite Element Simulation of Three Full-Scale Crash Tests for Cessna 172 Aircraft

The NASA Emergency Locator Transmitter Survivability and Reliability project was initiated in 2013 to assess the crash performance standards for the next generation of emergency locator transmitter (ELT) systems. Three Cessna 172 aircraft were acquired to perform crash testing at the NASA Langley Research Center Landing and Impact Research Facility. Full-scale crash tests were conducted in the summer of 2015, and each test article was subjected to severe, but survivable, impact conditions including a flare-to-stall during emergency landing and two controlled-flight-into-terrain scenarios. Finite element analyses were performed to numerically simulate the aircraft response to the crash tests. The first test simulated impacting a concrete surface represented analytically by a rigid plane. Tests 2 and 3 simulated impacting a dirt surface represented analytically by an Eulerian grid of brick elements using a Mohr–Coulomb material model. The objective of this paper is to summarize the test and analysis results for the three full-scale crash tests. Simulation models of the airframe that correlate well with the tests are needed for future studies of alternate ELT mounting configurations.

Finite Element Analysis↗

NASA NTRSDate not supplied

The Use of Immersion Rigs for High Temperature Hydrogen Exposure Testing within the Nuclear Thermal Rocket Element Environmental Simulator (NTREES): Thermal Soak Rig (TSR)

The Nuclear Thermal Rocket Element Environmental Simulator (NTREES) facility was purpose constructed to perform non-nuclear evaluations of nuclear thermal propulsion (NTP) system fuel materials and structures within prototypic thermochemical environments. This system has been utilized steadily in its ability to subject test specimens to thermochemical and thermohydraulic environments simulating that of an operating nuclear rocket engine. Fission heat is simulated by induction power and experiments are conducted within a ~1000 psi pressure vessel. Hydrogen is conventionally passed through the heated fuel surrogate test specimen while pressure, temperature, and gas species data are collected at various points along the experiment. In order to test fuel and material coupon samples, a class of test apparatus named “immersion rigs” are being developed and employed to more rapidly test these smaller and more technically challenging test specimen. One example of a promising potential fuel structure, Tristructural-isotropic (TRISO) particles, presents unique challenges for testing of this type. TRISO fuel micro-particles are spheroids typically on the order of 500 – 1000 μm in diameter, and exposing a batch sample to hot hydrogen requires purpose-built special test equipment. Thusly, an immersion rig was developed and successfully demonstrated to expose ~1 g of micro-particles to hydrogen gas at temperatures and pressures relevant to NTP systems for the purpose of fuel evaluation. The rig, comprised primarily of graphite and pure tungsten, houses in its core a batch of micro-particles between pucks of porous silicon carbide (SiC). This approach permits gas flow while simultaneously retaining the particles in place. Herein is a discussion of the design, analysis, fabrication, and testing of the NTREES Thermal Soak Rig (TSR).

Space Nuclear Propulsion↗

NASA NTRS2012

Magnetic Testing, and Modeling, Simulation and Analysis for Space Applications

The Aerospace Corporation (Aerospace) and Lockheed Martin Space Systems (LMSS) participated with Jet Propulsion Laboratory (JPL) in the implementation of a magnetic cleanliness program of the NASA/JPL JUNO mission. The magnetic cleanliness program was applied from early flight system development up through system level environmental testing. The JUNO magnetic cleanliness program required setting-up a specialized magnetic test facility at Lockheed Martin Space Systems for testing the flight system and a testing program with facility for testing system parts and subsystems at JPL. The magnetic modeling, simulation and analysis capability was set up and performed by Aerospace to provide qualitative and quantitative magnetic assessments of the magnetic parts, components, and subsystems prior to or in lieu of magnetic tests. Because of the sensitive nature of the fields and particles scientific measurements being conducted by the JUNO space mission to Jupiter, the imposition of stringent magnetic control specifications required a magnetic control program to ensure that the spacecraft's science magnetometers and plasma wave search coil were not magnetically contaminated by flight system magnetic interferences. With Aerospace's magnetic modeling, simulation and analysis and JPL's system modeling and testing approach, and LMSS's test support, the project achieved a cost effective approach to achieving a magnetically clean spacecraft. This paper presents lessons learned from the JUNO magnetic testing approach and Aerospace's modeling, simulation and analysis activities used to solve problems such as remnant magnetization, performance of hard and soft magnetic materials within the targeted space system in applied external magnetic fields.

magnetics↗

NASA NTRS2016

Performance of the Primary Mirror Center-of-curvature Optical Metrology System During Cryogenic Testing of the JWST Pathfinder Telescope

The James Webb Space Telescope (JWST) primary mirror (PM) is 6.6 m in diameter and consists of 18 hexagonal segments, each 1.5 m point-to-point. Each segment has a six degree-of-freedom hexapod actuation system and a radius-of-curvature (RoC) actuation system. The full telescope will be tested at its cryogenic operating temperature at Johnson Space Center. This testing will include center-of-curvature measurements of the PM, using the Center-of-Curvature Optical Assembly (COCOA) and the Absolute Distance Meter Assembly (ADMA). The COCOA includes an interferometer, a reflective null, an interferometer-null calibration system, coarse & fine alignment systems, and two displacement measuring interferometer systems. A multiple-wavelength interferometer (MWIF) is used for alignment & phasing of the PM segments. The ADMA is used to measure, and set, the spacing between the PM and the focus of the COCOA null (i.e. the PM center-of-curvature) for determination of the ROC. The performance of these metrology systems was assessed during two cryogenic tests at JSC. This testing was performed using the JWST Pathfinder telescope, consisting mostly of engineering development & spare hardware. The Pathfinder PM consists of two spare segments. These tests provided the opportunity to assess how well the center-of-curvature optical metrology hardware, along with the software & procedures, performed using real JWST telescope hardware. This paper will describe the test setup, the testing performed, and the resulting metrology system performance. The knowledge gained and the lessons learned during this testing will be of great benefit to the accurate & efficient cryogenic testing of the JWST flight telescope.

optical testing↗

NASA NTRS2017

Examination of the Structural Response of the Orion European Service Module to Reverberant and Direct Field Acoustic Testing

The NASA Orion Multi-Purpose Crew Vehicle (MPCV), comprised of the Service Module, the Crew Module, and the Launch Abort System, is the next generation human spacecraft designed and built for deep space exploration. Orion will launch on NASAs new heavy-lift rocket, the Space Launch System. The European Space Agency (ESA) is responsible for providing the propulsion sub-assembly of the Service Module to NASA, called the European Service Module (ESM). The ESM is being designed and built by Airbus Safran Launchers for ESA. Traditionally, NASA has utilized reverberant acoustic testing for qualification of spaceflight hardware. The ESM Structural Test Article (E-STA) was tested at the NASA Plum Brook Stations (PBS) Reverberant Acoustic Test Facility in April-May 2016. However, Orion is evaluating an alternative acoustic test method, using direct field acoustic excitation, for the MPCVs Service Module and Crew Module. Lockheed Martin is responsible for the Orion proof-of-concept direct field acoustic test program. The E-STA was exposed to direct field acoustic testing at NASA PBS in February 2017. This paper compares the dynamic response of the E-STA structure and its components to both the reverberant and direct field acoustic test excitations. Advantages and disadvantages of direct field acoustic test excitation method are discussed.

Acoustics↗

NASA NTRS2017

Examination of the Structural Response of the Orion European Service Module to Reverberant and Direct Field Acoustic Testing

Acoustics↗

NASA NTRS2017

Packaging Technology for Dielectric-Coating-Less Heavy Ion Radiation Testing of High-Voltage (HV) Electronic Parts

Testing high voltage (HV) electronic parts (greater than 300 V) for sudden event effects (SEE) caused by cosmic rays in the space environment, consisting of energetic heavy-ions, and neutron radiation in the upper atmosphere is a crucial step towards using these parts in spacecraft and aircraft. Due to the nature of cosmic radiation and neutrons, electronic parts are tested for SEE without any packaging and/or shielding over the top of the device. In the case of commercial HV parts, the top of the packaging is etched off and then a thin dielectric coating is placed over the part in order to avoid electrical arcing between the device surface and wire bonds and other components. Even though the effects of the thin dielectric layer on SEE testing can be accounted for, the dielectric layer significantly hinders post testing failure analysis. Replicating the test capability of state-of-the-art packaging while eliminating the need for post radiation test processing of the die surface (that obscures failure analysis) is the goal. To that end, a new packaging concept for HV parts has been developed that requires no dielectric coating over the part. Testing of prototype packages used with Schottky diodes (rated at 1200V) has shown no electrical arcing during testing and leakage currents during reverse bias testing are within the manufactures specifications.

High Voltage↗

NASA NTRS2018

NASA Electronic Parts and Packaging (NEPP) Field Programmable Gate Array (FPGA) Single Event Effects (SEE) Test Guideline Update

The following are updated or new subjects added to the FPGA SEE Test Guidelines manual: academic versus mission specific device evaluation, single event latch-up (SEL) test and analysis, SEE response visibility enhancement during radiation testing, mitigation evaluation (embedded and user-implemented), unreliable design and its affects to SEE Data, testing flushable architectures versus non-flushable architectures, intellectual property core (IP Core) test and evaluation (addresses embedded and user-inserted), heavy-ion energy and linear energy transfer (LET) selection, proton versus heavy-ion testing, fault injection, mean fluence to failure analysis, and mission specific system-level single event upset (SEU) response prediction. Most sections within the guidelines manual provide information regarding best practices for test structure and test system development. The scope of this manual addresses academic versus mission specific device evaluation and visibility enhancement in IP Core testing.

Test guidelines↗

NASA NTRS2018

NASA Electronic Parts and Packaging Field Programmable Gate Array Single Event Effects Test Guideline Update

Field Programmable Gate Array (FPGA)↗