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At least 1,693 records · Page 94

Design, construction and long life endurance testing of cathode assemblies for use in microwave high-power transmitting tubes

The cathode life test program sponsored by NASA Lewis Research Center at Watkins-Johnson Company has been in continuous operation since 1972. Its primary objective has been to evaluate the long life capability of barium dispenser cathodes to produce emission current densities of 2 A sq. cm. or more in an operational environment simulating that of a highpower microwave tube. The life test vehicles were equipped with convergent flow electron guns, drift space tubes with solenoid magnets for electron beam confinement and water-cooled depressed collectors. A variety of cathode types has been tested, including GE Tungstate, Litton Impregnated, Philips Type B and M, Semicon types S and M, and Spectra-Mat Type M. Recent emphasis has been on monitoring the performance of Philips Type M cathodes at 2 A sq. cm. and Sprectra-Mat and Semicon Type M cathodes at 4 A sq. cm. These cathodes have been operated at a constant current of 616 mA and a cathode anode voltage on the order of 10 kV. Cathode temperatures were maintained at 1010 C true as measured from black body holes in the backs of the cathodes. This report presents results of the cathode life test program from July l982 through April l986. The results include hours of operation and performance data in the form of normalized emission current density versus temperature curves (Miram plots).

Batra, R.↗

Characteristics of Space Shuttle Main Engine failures

During development and operation of the Space Shuttle Main Engine (SSME), 27 ground test failures of sufficient severity to be termed 'major incident' have occurred. Resourecs including NASA Failure Investigation Board reports, contractor failure reports, originally recorded data, along with engineering notes, data bases, and presentations connected with the failures were available for compilation into the engine failure review presented in this paper. Most SSME failures were a result of design deficiencies stemming from inadequate definition of dynamic loads. High cycle fatigue was the most frequent mechanism leading to failure. Eighteen of the 27 failures occurred during constant power level operation. Formal board reports were not available for all failures. Therefore, the failure history presented in this paper is not complete or of uniform quality.

Cikanek, Harry A., III↗

Automatic detection of anomalies in Space Shuttle Main Engine turbopumps

A prototype expert system (developed on both PC and Symbolics 3670 lisp machine) for detecting anomalies in turbopump vibration data has been tested with data from ground tests 902-473, 902-501, 902-519, and 904-097 of the Space Shuttle Main Engine (SSME). The expert system has been utilized to analyze vibration data from each of the following SSME components: high-pressure oxidizer turbopump, high-pressure fuel turbopump, low-pressure fuel turbopump, and preburner boost pump. The expert system locates and classifies peaks in the power spectral density of each 0.4-sec window of steady-state data. Peaks representing the fundamental and harmonic frequencies of both shaft rotation and bearing cage rotation are identified by the expert system. Anomalies are then detected on the basis of sequential criteria and two threshold criteria set individually for the amplitude of each of these peaks: a prior threshold used during the first few windows of data in a test, and a posterior threshold used thereafter. In most cases the anomalies detected by the expert system agree with those reported by NASA. The two cases where there is significant disagreement will be further studied and the system design refined accordingly.

Lo, Ching F.↗

The design and development of signal-processing algorithms for an airborne x-band Doppler weather radar

Improved measurements of precipitation will aid our understanding of the role of latent heating on global circulations. Spaceborne meteorological sensors such as the planned precipitation radar and microwave radiometers on the Tropical Rainfall Measurement Mission (TRMM) provide for the first time a comprehensive means of making these global measurements. Pre-TRMM activities include development of precipitation algorithms using existing satellite data, computer simulations, and measurements from limited aircraft campaigns. Since the TRMM radar will be the first spaceborne precipitation radar, there is limited experience with such measurements, and only recently have airborne radars become available that can attempt to address the issue of the limitations of a spaceborne radar. There are many questions regarding how much attenuation occurs in various cloud types and the effect of cloud vertical motions on the estimation of precipitation rates. The EDOP program being developed by NASA GSFC will provide data useful for testing both rain-retrieval algorithms and the importance of vertical motions on the rain measurements. The purpose of this report is to describe the design and development of real-time embedded parallel algorithms used by EDOP to extract reflectivity and Doppler products (velocity, spectrum width, and signal-to-noise ratio) as the first step in the aforementioned goals.

Nicholson, Shaun R.↗

Scale Model Experiments on Sound Propagation From a Mach 2.5 Cold Nitrogen Jet Flowing Through a Rigid-Walled Duct With a J-Deflector

The Launch Systems Testbed (LST) represents the evolution of vibroacoustics research and development work performed at NASA John F. Kennedy Space Center (KSC) over the last 15 years. The LST is located at the Launch Equipment Test Facility (LETF) in the KSC industrial complex. The LETF is operated by Sierra Lobo, Inc., as a member of University-Affiliated Technology Development Contract (USTDC) to KSC Spaceport and Engineering and Technology Directorate (YA), with ASRC Aerospace Corporation as a the prime contractor. Trajectory Simulation Mechanism (TSM) is a major component of the LST, developed specifically to simulate nonstationary acoustic loads on launch pad structures, vehicles, and payloads. TSM enhances the capabilities within LST for simulating launch environments of future vehicles. The scaled launch environments will be used to predict the full-scale launch environment via an appropriate scaling procedure. Air Force Research Laboratory (AFRL) has tasked NASA KSC to perform a basic technology test program in support of developing a low-cost clean pad (incorporating passive mitigation techniques) for future launch vehicles. The overall goal of the program is to develop innovative launch exhaust management systems, which effectively reduce launch acoustic environment with innovative duct designs, while eliminating traditional sound suppression water systems. Passive techniques, such as nontraditional duct geometries, resonators, and diffusers, etc., will be investigated. The overall goals are to advance innovative concepts for a clean pad while developing ideas to reduce transmitted sound via investigation and modeling of jet exhaust acoustic and flow field characteristics. The series of tests outlined in this report represent baseline tests and are geared towards defining the acoustic load environment on the TSM pad for open and closed duct configurations. This report summarizes the cold jet acoustic testing for Mach 2.5 supersonic nitrogen jet issuing from a nozzle with 1-inch exit diameter. Acoustic data, including spectral sound power and Overall Sound Pressure Level (OASPL), are obtained both for a free jet and with the jet flowing through a rigid-walled duct with a J-deflector. The relative performance of closed duct and open duct is evaluated. The results show that the closed duct is superior to the partially open duct, and results in about 3-decibel (dB) noise reduction (near the duct axis) relative to the free jet. The location of the nozzle exit plane (NEP) relative to the duct inlet plane (DIP) has a significant effect on the acoustic field. The results suggest that the location of NEP at 10 inches above the DIP results in reduced acoustic loads relative to 5 inches above the duct inlet and 1 inch into the duct inlet.

Kandula, Max↗

Quenching Combustible Dust Mixtures Using Electric Particulate Suspensions (EPS): A New Testing Method For Microgravity

The Electric Particulate Suspension (EPS) is a combustion ignition system being developed at Iowa State University for evaluating quenching effects of powders in microgravity (quenching distance, ignition energy, flammability limits). Because of the high cloud uniformity possible and its simplicity, the EPS method has potential for "benchmark" design of quenching flames that would provide NASA and the scientific community with a new fire standard. Microgravity is expected to increase suspension uniformity even further and extend combustion testing to higher concentrations (rich fuel limit) than is possible at normal gravity. Two new combustion parameters are being investigated with this new method: (1) the particle velocity distribution and (2) particle-oxidant slip velocity. Both walls and (inert) particles can be tested as quenching media. The EPS method supports combustion modeling by providing accurate measurement of flame-quenching distance as a parameter in laminar flame theory as it closely relates to characteristic flame thickness and flame structure. Because of its design simplicity, EPS is suitable for testing on the International Space Station (ISS). Laser scans showing stratification effects at 1-g have been studied for different materials, aluminum, glass, and copper. PTV/PIV and a leak hole sampling rig give particle velocity distribution with particle slip velocity evaluated using LDA. Sample quenching and ignition energy curves are given for aluminum powder. Testing is planned for the KC-135 and NASA s two second drop tower. Only 1-g ground-based data have been reported to date.

Colver, Gerald M.↗

Progress in Spacecraft Environment Interactions: International Space Station (ISS) Development and Operations

The set of spacecraft interactions with the space flight environment that have produced the largest impacts on the design, verification, and operation of the International Space Station (ISS) Program during the May 2000 to May 2007 time frame are the focus of this paper. In-flight data, flight crew observations, and the results of ground-based test and analysis directly supporting programmatic and operational decision-making are reported as are the analysis and simulation efforts that have led to new knowledge and capabilities supporting current and future space explorations programs. The specific spacecraft-environment interactions that have had the greatest impact on ISS Program activities during the first several years of flight are: 1) spacecraft charging, 2) micrometeoroids and orbital debris effects, 3) ionizing radiation (both total dose to materials and single event effects [SEE] on avionics), 4) hypergolic rocket engine plume impingement effects, 5) venting/dumping of liquids, 6) spacecraft contamination effects, 7) neutral atmosphere and atomic oxygen effects, 8) satellite drag effects, and 9) solar ultraviolet effects. Orbital inclination (51.6deg) and altitude (nominally between 350 km and 460 km) determine the set of natural environment factors affecting the performance and reliability of materials and systems on ISS. ISS operates in the F2 region of Earth s ionosphere in well-defined fluxes of atomic oxygen, other ionospheric plasma species, solar UV, VUV, and x-ray radiation as well as galactic cosmic rays, trapped radiation, and solar cosmic rays. The micrometeoroid and orbital debris environment is an important determinant of spacecraft design and operations in any orbital inclination. The induced environment results from ISS interactions with the natural environment as well as environmental factors produced by ISS itself and visiting vehicles. Examples include ram-wake effects, hypergolic thruster plume impingement, materials out-gassing, venting and dumping of fluids, and specific photovoltaic (PV) power system interactions with the ionospheric plasma. Vehicle size (L) and velocity (v), combined with the magnitude and direction of the geomagnetic field (B) produce operationally significant magnetic induction voltages (VxB.L) in ISS conducting structure during high latitude flight (>+/- 45deg) during each orbit. In addition, ISS is a large vehicle and produces a deep wake structure from which both ionospheric plasma and neutrals species are largely excluded. ISS must fly in a very limited number of approved flight attitudes, so that exposure of a particular material or system to environmental factors depends upon: 1) location on ISS, 2) ISS flight configuration, 3) ISS flight attitude, and 4) variation of solar exposure (Beta angle), and hence thermal environment, with time. Finally, an induced ionizing radiation environment is produced by trapped radiation and solar/cosmic ray interactions with the relatively massive ISS structural shielding.

Koontz, Steve↗

SDBI 1904: Human Factors Assessment of Vibration Effects on Visual Performance during Launch

The primary objective of the of Human Factors Short Duration Bioastronautics Investigation (SDBI) 1904 is to determine visual performance limits during operational vibration and g-loads, specifically through the determination of minimal usable font sizes using Orion-type display formats. Currently there is little to no data available to quantify human visual performance under these extreme conditions. Existing data on shuttle vibration magnitude and frequency is incomplete, does not address seat and crew vibration in the current configuration, and does not address human visual performance. There have been anecdotal reports of performance decrements from shuttle crews, but no structured data has been collected. The SDBI is a companion effort to the Detailed Test Objective (DTO) 695, which will measure shuttle seat accelerations (vibration) during ascent. Data from the SDBI will serve an important role in interpreting the DTO vibration data. This data will be collected during the ascent phase of three shuttle missions (STS-119, 127, and 128). Both SDBI1904 and DTO 695 are low impact with respect to flight resources, and combined they represent an efficient and focused problem solving approach. The SDBI and DTO data will be correlated to determine the nature of perceived visual performance under varying vibrations and g-loads. This project will provide: * Immediate data for developing preliminary human performance vibration requirements * Flight validated inputs for ongoing and future ground-based research * Information of functional needs that will drive Orion display format design decisions

Shelby G Thompson↗

Possible Mechanisms for Turbofan Engine Ice Crystal Icing at High Altitude

A thermodynamic model is presented to describe possible mechanisms of ice formation on unheated surfaces inside a turbofan engine compression system from fully glaciated ice crystal clouds often formed at high altitude near deep convective weather systems. It is shown from the analysis that generally there could be two distinct types of ice formation: (1) when the "surface freezing fraction" is in the range of 0 to 1, dominated by the freezing of water melt from fully or partially melted ice crystals, the ice structure is formed from accretion with strong adhesion to the surface, and (2) when the "surface melting fraction" is the range of 0 to 1, dominated by the further melting of ice crystals, the ice structure is formed from accumulation of un-melted ice crystals with relatively weak bonding to the surface. The model captures important qualitative trends of the fundamental ice-crystal icing phenomenon reported earlier1,2 from the research collaboration work by NASA and the National Research Council (NRC) of Canada. Further, preliminary analysis of test data from the 2013 full scale turbofan engine ice crystal icing test3 conducted in the NASA Glenn Propulsion Systems Laboratory (PSL) has also suggested that (1) both types of ice formation occurred during the test, and (2) the model has captured some important qualitative trend of turning on (or off) the ice crystal ice formation process in the tested engine low pressure compressor (LPC) targeted area under different icing conditions that ultimately would lead to (or suppress) an engine core roll back (RB) event.

Crystal Icing↗

Determining Damping Trends from a Range of Cable Harness Assemblies on a Launch Vehicle Panel from Test Measurements

The team of authors at Marshall Space Flight Center (MSFC) has been investigating estimating techniques for the vibration response of launch vehicle panels excited by acoustics and/or aero-fluctuating pressures. Validation of the approaches used to estimate these environments based on ground tests of flight like hardware is of major importance to new vehicle programs. The team at MSFC has recently expanded upon the first series of ground test cases completed in December 2010. The follow on tests recently completed are intended to illustrate differences in damping that might be expected when cable harnesses are added to the configurations under test. This validation study examines the effect on vibroacoustic response resulting from the installation of cable bundles on a curved orthogrid panel. Of interest is the level of damping provided by the installation of the cable bundles and whether this damping could be potentially leveraged in launch vehicle design. The results of this test are compared with baseline acoustic response tests without cables. Damping estimates from the measured response data are made using a new software tool that employs a finite element model (FEM) of the panel in conjunction with advanced optimization techniques. This paper will report on the \damping trend differences. observed from response measurements for several different configurations of cable harnesses. The data should assist vibroacoustics engineers to make more informed damping assumptions when calculating vibration response estimates when using model based analysis approach. Achieving conservative estimates that have more flight like accuracy is desired. The paper may also assist analysts in determining how ground test data may relate to expected flight response levels. Empirical response estimates may also need to be adjusted if the measured response used as an input to the study came from a test article without flight like cable harnesses.

Smith, Andrew↗

Draft ASME Code Case to qualify L-PBF 316H material for Section III, Division 5 applications

This report documents the AMMT program’s development and submission of a draft ASME Code Case to qualify Laser Powder Bed Fusion (L PBF) Type 316H stainless steel for Section III, Divi-sion 5 Class A and SM high temperature nuclear applications. It summarizes the technical basis, the comprehensive high temperature mechanical test database assembled between 2023–2026, and the proposed code language and qualification framework submitted to ASME. The work was co-ordinated across multiple national laboratories and leverages prior ASME efforts to integrate additive manufacturing into the Boiler & Pressure Vessel Code. The body of the report describes the experimental database and analysis supporting the Code Case: tensile, creep, fatigue, creep fatigue, and thermal aging tests collected from multiple additive manufacturing sites, machine types, and powder lots, with material processed by a solution anneal heat treatment. The dataset — including both full size and subsized specimens and tests oriented parallel and perpendicular to build direction — shows limited tensile anisotropy, tensile properties comparable to wrought 316H, creep strength within the scatter of wrought material, but markedly reduced creep ductility above about 650 °C associated with rapid σ phase formation in L PBF microstructures. The draft Code Case itself prescribes a staged qualification model (manufacturing process qualification, component qualification, and per build witness testing), treats L PBF components as equivalent to Type 316 weld metal for design and inspection, and requires mechanical, chemical, and metallographic controls tied to ASTM/ISO 52946. Key acceptance criteria include tensile tests within a 90% prediction interval of the AMMT dataset, a creep fatigue screening test adapted from ASME Section III, Division 5, Subsection HB, HBB 2800 but with the cycle acceptance reduced to 100 for L PBF material, and double volumetric inspection of production components. The report concludes that the present data support treating L PBF 316H as analogous to conventional fusion weld metal for Division 5 design and inspection, while highlighting important caveats: the σ phase driven loss of creep ductility above ~650 °C, preliminary indications of enhanced creep fatigue sensitivity in some lots, and remaining gaps in long term aging and additional cyclic testing. Recommended next actions include completing outstanding cyclic and long duration creep/aging tests on the solution annealed condition, supporting inclusion of the 316H chemistry and heat treatment in ASTM/ISO 52946, and continuing engagement with ASME and NRC during balloting and review to enable industry adoption.

Messner, Mark C. (ORCID:0000000200404385)↗

FY21 Progress Report: SRNL Analysis of ICCWR LCM and WAMS data for Corrosion and Cracking

The development of algorithms for machine learning and data analysis for the 3013 Surveillance Program is a collaborative effort by the Savannah River National Laboratory (SRNL) and the University of South Carolina (USC). For corrosion detection, Laser Confocal Microscope (LCM) or Wide Area 3D Measurement System (WAMS) data is extracted from large binary files, with software written to convert the data to physical attributes (e.g., height, color and grayscale values; all as functions of a location in a plane projection). A user-friendly Matlab Graphical User Interface (GUI) that reads data from either LCM or WAMS files was developed to integrate input data with software developed for processing and evaluation. The GUI can selectively download binary data, interrogate data attributes, label data, flag significant features, execute Machine Learning (ML) algorithms, output parameters for trained ML algorithms, report ML model accuracy with respect to labeled data, and generate graphical representations for various analyses. Features can be called out by user-specified thresholds, manual labeling or machine learning algorithms when they have been completed. The ability to rapidly label data is important because of the volume of data required for training machine learning algorithms. The GUI has the flexibility to allow addition of improved ML algorithms, methods for data visualization, and statistical computations. Statistical analyses via the GUI include areas of pits within a defined range of pit depths, correlations between Red-Green-Blue (RGB) or grayscale intensity and relative surface height, covariances between values associated with features, and feature histograms. The development of supervised machine learning algorithms, however, has been hindered by a lack of training data. The machine learning algorithms for crack identification are being refined but require improvements to the true positive rate for crack detection. This shortcoming is an artifact of the limited training data currently available, perhaps more so than the structure of the neural networks. At present, the best results are had from a consensus over an ensemble of randomly generated Deep Neural Network (DNN) or Convolutional Neural Network (CNN) algorithms. Although the consensus accuracy method has yielded optimum true positive and true negative rates in excess of 80%, additional validation testing is necessary. In addition to the suite of LCM data that was initially used, and which represents the majority of the work presented in this report, WAMS image data was also reviewed at a preliminary level. The review included a comparison between image resolution and dynamic range for each method. WAMS (ZON file) image data was found to have a pixel pitch of 3.69μm compared to 1 μm for the LCM (vk4 file) data, which implies a lower resolution for the WAMS images. Conversely, the ratio of dynamic range of the WAMS data to the LCM data was approximately 41:20 for height data, suggesting that information from WAMS should more accurately determine the depth of pits. At present, the significance of the greater dynamic range of the WAMS data relative to the LCM data has not yet been evaluated.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

GRC1.5 Project: Joint Industry Megawatt Scale Gearbox Field Tests (Final Report)

A new DOE/NREL industry collaboration called the Gearbox Reliability Collaborative (GRC) 1.5 will undertake field testing on current commercial multi-megawatt wind turbine gearboxes to collect loading data from installed turbines to thoroughly characterize gearbox input loads and responses during actual in-field conditions. A chief outcome is to provide operational loading data relative to the most common failure modes. This will provide a greater understanding of steady-state, transient, and fault response for both the input and output of the gearbox, thus facilitating improvements in the gearbox, power converter or turbine controller.

17 WIND ENERGY↗

Data-acquisition and control system for severe environments

Report evaluates control system by measuring accuracy and performance of system subcomponents, including interface wiring unit, power controller, and tape recorder. Test parameters establish variety of severe operation environments. Text features test program descriptions, sample readouts, and results. Summary of custom solar system simulator is included.

Source record↗

SPHERES: From Ground Development to Operations on ISS

SPHERES (Synchronized Position Hold Engage and Reorient Experimental Satellites) is an internal International Space Station (ISS) Facility that supports multiple investigations for the development of multi-spacecraft and robotic control algorithms. The SPHERES Facility on ISS is managed and operated by the SPHERES National Lab Facility at NASA Ames Research Center (ARC) at Moffett Field California. The SPHERES Facility on ISS consists of three self-contained eight-inch diameter free-floating satellites which perform the various flight algorithms and serve as a platform to support the integration of experimental hardware. To help make science a reality on the ISS, the SPHERES ARC team supports a Guest Scientist Program (GSP). This program allows anyone with new science the possibility to interface with the SPHERES team and hardware. In addition to highlighting the available SPHERES hardware on ISS and on the ground, this presentation will also highlight ground support, facilities, and resources available to guest researchers. Investigations on the ISS evolve through four main phases: Strategic, Tactical, Operations, and Post Operations. The Strategic Phase encompasses early planning beginning with initial contact by the Principle Investigator (PI) and the SPHERES program who may work with the PI to assess what assistance the PI may need. Once the basic parameters are understood, the investigation moves to the Tactical Phase which involves more detailed planning, development, and testing. Depending on the nature of the investigation, the tactical phase may be split into the Lab Tactical Phase or the ISS Tactical Phase due to the difference in requirements for the two destinations. The Operations Phase is when the actual science is performed; this can be either in the lab, or on the ISS. The Post Operations Phase encompasses data analysis and distribution, and generation of summary status and reports. The SPHERES Operations and Engineering teams at ARC is composed of experts who can guide the Payload Developer (PD) and Principle Investigator (PI) in reaching critical milestones to make their science a reality using the SPHERES platform. From performing integrated safety and verification assessments, to assisting in developing crew procedures and operations products, to organizing, planning, and executing all test sessions, to helping manage data products, the SPHERES team at ARC is available to support microgravity research with the SPEHRES Guest Scientist Program.

ISS Research↗

Shuttle Return-to-Flight IH-108 Aerothermal Test at CUBRC - Flow Field Calibration and CFD

This paper discusses one specific aspect of the Shuttle Retrun-To-Flight IH-108 Aerothermal Test at CUBRC, the test flow field calibration. It showed the versatility of the CUBRC LENS II wind tunnel for an aerothermal test with unique and demanding requirements. CFD analyses were used effectively to extend the test range at the low end of the Mach range. It demonstrated how ground test facility and CFD synergy can be utilitzed iteratively to enhance the confidence in the fedility of both tools. It addressed the lingering concerns of the aerothermal community on use of inpulse facility and CFD analysis. At the conclusion of the test program, members from the NASA Marshall (MSFC), CUBRC and USA (United Space Alliance) Consultants (The Grey Beards) were asked to independently verify the flight scaling data generated by Boeing for flight certification of the re-designed external tank (ET) components. The blind test comparison showed very good results. A more comprehensive discussion of the topics in this paper can be found in Chapter 6 of Reference [1]. The overall aspect of the test program has been discussed in an AIAA paper by Tim Wadhams [2]. The Shuttle Ascent Stack performance and related issues discussed in the Report [1] are not included in this paper. No ITAR data is included in this paper.

Lau, Kei Y.↗

FY2022 Progress on Imbibition Testing in Containment Science

Estimation of two-phase fluid flow properties is important to understand and predict water and gas movement through the vadose zone for agricultural, hydrogeological, and engineering applications, such as for vapor-phase contaminant transport and/or containment of noble gases in the subsurface. In this second progress report of FY22, we present two ongoing activities related to imbibition testing on volcanic rock samples. We present the development of a new analytical solution predicting the temperature response observed during imbibition into dry samples, as discussed in our previous first progress report for FY22. We also illustrate the use of a multi-modal capillary pressure distribution to simulate both early- and late-time imbibition data collected on tuff core that can exhibit multiple pore types. These FY22 imbibition tests were conducted for an extended period (i.e., far beyond the time required for the wetting front to reach the top of the sample), which is necessary for parameter estimation and characterization of two different pore types within the samples.

42 ENGINEERING↗