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NASA NTRS2014

High Current ESD Test of Advanced Triple Junction Solar Array Coupon

Testing was conducted on an Advanced Triple Junction (ATJ) coupon that was part of a risk reduction effort in the development of a high-powered solar array design by Space Systems/Loral, LLC (SSL). The ATJ coupon was a small, 4-cell, two-string configuration that has served as the basic test coupon design used in previous SSL environmental aging campaigns. The coupon has many attributes of the flight design; e.g., substrate structure with graphite face sheets, integrated by-pass diodes, cell interconnects, RTV grout, wire routing, etc. The objective of the present test was to evaluate the performance of the coupon after being subjected to induced electrostatic discharge (ESD) testing at two string voltages (100 V, 150 V) and four array currents (1.65 A, 2.0 A, 2.475 A, and 3.3 A). An ESD test circuit, unique to SSL solar array design, was built that simulates the effect of missing cells and strings in a full solar panel with special primary arc flashover circuitry. A total of 73 primary arcs were obtained that included 7 temporary sustained arcs (TSA) events. The durations of the TSAs ranged from 50 micro-seconds to 2.75 milli-seconds. All TSAs occurred at a string voltage of 150 V. Post-test Large Area Pulsed Solar Simulator (LAPSS), Dark I-V, and By-Pass Diode tests showed that no degradation occurred due to the TSA events. In addition, the post-test insulation resistance measured was > 50 G-ohms between cells and substrate. These test results indicate a robust design for application to a high-current, high-power mission.

Wright, Kenneth H., Jr.↗
NASA NTRS2014

Orion ECLSS/Suit System Intermediate Pressure Integrated Suit Test

The Intermediate Pressure Integrated Suit Test (IPIST) phase of the integrated system testing of the Orion Vehicle Atmosphere Revitalization System (ARS) technology was conducted for the Multipurpose Crew Vehicle (MPCV) Program within the National Aeronautics and Space Administration (NASA) Exploration Systems Mission Directorate. This test was performed in the eleven-foot human-rated vacuum chamber at the NASA Johnson Space Center by the Crew and Thermal Systems Division. This testing is the second phase of suit loop testing to demonstrate the viability of the Environmental Control and Life Support System (ECLSS) being developed for Orion. The IPIST configuration consisted of development hardware that included the CAMRAS, air revitalization loop fan and suit loop regulator. Two test subjects were in pressure suits at varying suit pressures. Follow-on testing, to be conducted in 2014, will utilize the same hardware with human test subjects in pressure suits at vacuum. This paper will discuss the results and findings of IPIST and will also discuss future testing.

Barido, Richard A.↗
NASA NTRS2014

Pilot Sensorimotor and Cardiovascular Results from the Joint Russian/U.S. Field Test

The primary goal of this research is to determine functional abilities associated with long-duration space flight crews beginning as soon after landing as possible (< 2 hours) with an additional two follow-up measurements sessions on the day of landing. This goal has both sensorimotor and cardiovascular elements, including evaluations of NASA's new anti-orthostatic compression garment and the Russian Kentavr garment. Functional sensorimotor measurements will include, but are not limited to, assessing hand/eye coordination, standing from a seated position (sit-to-stand), walking normally without falling, measurement of dynamic visual acuity, discriminating different forces generated with both the hands and legs, recovering from a fall (standing from a prone position), coordinated walking involving tandem heel-to-toe placement, and determining postural ataxia while standing. The cardiovascular portion of the investigation includes measuring blood pressure and heart rate during a timed stand test in conjunction with postural ataxia testing (quiet stance sway) as well as cardiovascular responses during the other functional tasks. In addition to the immediate post-landing collection of data for the full FT, postflight data is being acquired twice more within the 24 hours after landing and will continue over the subsequent weeks until functional sensorimotor and cardiovascular responses have returned to preflight normative values. The PFT represents a initial evaluation of the feasibility of testing in the field, and is comprised of a jointly agreed upon subset of tests from the full FT and relies heavily on Russia's Institute of Biomedical Problems Sensory-Motor and Countermeasures Laboratories for content and implementation. The PFT has been collected on several ISS missions. Testing on the U.S. side has included: (1) a sit-to-stand test, (2) recovery from a fall where the crewmember began in the prone position on the ground and then stood for 3 minutes while cardiovascular stability was determined and postural ataxia data were acquired, and (3) a tandem heel-to-toe walk test to determine changes in the central locomotor program. Video, cardiovascular parameters (heart rate and blood pressure), data from bodyworn inertial sensors, and severity of postflight motion sickness were collected during each test session. Our Russian investigators have added measurements associated with: (a) obstacle avoidance, (b) muscle compliance and (c) postural adjustments to perturbations (push) applied to the subject's chest area. The level of functional deficit observed in the crew tested to date is typically beyond what was expected and is clearly triggered by the acquisition of gravity loads immediately after landing when the demands for crew intervention in response to emergency operations will be greatest. Clearly measureable performance parameters such as ability to perform a seat egress, recover from a fall or the ability to see clearly when walking, and related physiologic data (orthostatic responses) are required to provide an evidence base for characterizing programmatic risks and the degree of variability among crewmembers for exploration missions where the crew will be unassisted after landing. Overall, these early functional and related physiologic measurements will allow the estimation of nonlinear sensorimotor and cardiovascular recovery trends that have not been previously captured

Reschke, M. F.↗
NASA NTRS2014

Development and Testing of Functionally Operative and Visually Appealing Remote Firing Room Displays and Applications

This internship provided an opportunity for an intern to work with NASA's Ground Support Equipment (GSE) for the Spaceport Command and Control System (SCCS) at Kennedy Space Center as a remote display developer, under NASA technical mentor Kurt Leucht. The main focus was on creating remote displays and applications for the hypergolic and high pressure helium subsystem team to help control the filling of the respective tanks. As a remote display and application developer for the GSE hypergolic and high pressure helium subsystem team the intern was responsible for creating and testing graphical remote displays and applications to be used in the Launch Control Center (LCC) on the Firing Room's computers. To become more familiar with the subsystem, the individual attended multiple project meetings and acquired their specific requirements regarding what needed to be included in the software. After receiving the requirements for the displays, the next step was to create displays that had both visual appeal and logical order using the Display Editor, on the Virtual Machine (VM). In doing so, all Compact Unique Identifiers (CUI), which are associated with specific components within the subsystem, were need to be included in each respective display for the system to run properly. Then, once the display was created it was to be tested to ensure that the display runs as intended by using the Test Driver, also found on the VM. This Test Driver is a specific application that checks to make sure all the CUIs in the display are running properly and returning the correct form of information. After creating and locally testing the display it needed to go through further testing and evaluation before deemed suitable for actual use. For the remote applications the intern was responsible for creating a project that focused on channelizing each component included in each display. The core of the application code was created by setting up spreadsheets and having an auto test generator, generate the complete code structure. This application code was then loaded and ran on a testing environment set to ensure the code runs as anticipated. By the end of the semester-long experience at NASA's Kennedy Space Center, the individual should have gained great knowledge and experience in various areas of both display and application development and testing. They were able to demonstrate this new knowledge obtained by creating multiple successful remote displays that will one day be used by the hypergolic and high pressure helium subsystem team in the LCC's firing rooms to service the new Orion spacecraft. The completed display channelization application will be used to receive verification from NASA quality engineers.

Display Devices↗
NASA NTRS2015

NASA's Functional Task Test: Providing Information for an Integrated Countermeasure System

Exposure to the microgravity conditions of spaceflight causes astronauts to experience alterations in multiple physiological systems. These physiological changes include sensorimotor disturbances, cardiovascular deconditioning, and loss of muscle mass and strength. Some or all of these changes might affect the ability of crewmembers to perform critical mission tasks immediately after landing on a planetary surface. The goals of the Functional Task Test (FTT) study were to determine the effects of spaceflight on functional tests that are representative of critical exploration mission tasks and to identify the key physiological factors that contribute to decrements in performance. The FTT was comprised of seven functional tests and a corresponding set of interdisciplinary physiological measures targeting the sensorimotor, cardiovascular and muscular changes associated with exposure to spaceflight. Both Shuttle and ISS crewmembers participated in this study. Additionally, we conducted a supporting study using the FTT protocol on subjects before and after 70 days of 6 head-down bed rest. The bed rest analog allowed us to investigate the impact of body unloading in isolation on both functional tasks and on the underlying physiological factors that lead to decrements in performance, and then to compare them with the results obtained in our spaceflight study. Spaceflight data were collected on three sessions before flight, on landing day (Shuttle only) and 1, 6 and 30 days after landing. Bed rest subjects were tested three times before bed rest and immediately after getting up from bed rest as well as 1, 6, and 12 days after reambulation. We have shown that for Shuttle, ISS and bed rest subjects, functional tasks requiring a greater demand for dynamic control of postural equilibrium (i.e. fall recovery, seat egress/obstacle avoidance during walking, object translation, jump down) showed the greatest decrement in performance. Functional tests with reduced requirements for postural stability (i.e. hatch opening, ladder climb, manual manipulation of objects and tool use) showed little reduction in performance. These changes in functional performance were paralleled by similar decrements in sensorimotor tests designed to specifically assess postural equilibrium and dynamic gait control. Bed rest subjects experienced similar deficits both in functional tests with balance challenges and in sensorimotor tests designed to evaluate postural and gait control as spaceflight subjects indicating that body support unloading experienced during spaceflight plays a central role in post-flight alteration of functional task performance. To determine how differences in body-support loading experienced during in-flight treadmill exercise affect postflight functional performance, the loading history for each subject during in-flight treadmill (T2) exercise was correlated with postflight measures of performance. ISS crewmembers who walked on the treadmill with higher pull-down loads had enhanced post-flight performance on tests requiring mobility. Taken together the spaceflight and bed rest data point to the importance of supplementing inflight exercise countermeasures with balance and sensorimotor adaptability training. These data also support the notion that inflight treadmill exercise performed with higher body loading provides sensorimotor benefits leading to improved performance on functional tasks that require dynamic postural stability and mobility.

Bloomberg, J. J.↗
NASA NTRS2014

Recent Improvements to the Acoustical Testing Laboratory at the NASA Glenn Research Center

The Acoustical Testing Laboratory (ATL) consists of a 27 by 23 by 20 ft (height) convertible hemi/anechoic chamber and separate sound-attenuating test support enclosure. Absorptive fiberglass wedges in the test chamber provide an anechoic environment down to 100 Hz. A spring-isolated floor system affords vibration isolation above 3 Hz. These specifications, along with very low design background levels, enable the acquisition of accurate and repeatable acoustical measurements on test articles that produce very low sound pressures. Removable floor wedges allow the test chamber to operate in either a hemi-anechoic or anechoic configuration, depending on the size of the test article and the specific test being conducted. The test support enclosure functions as a control room during normal operations. Recently improvements were accomplished in support of continued usage of the ATL by NASA programs including an analysis of the ultra-sonic characteristics. A 3 dimensional traverse system inside the chamber was utilized for acquiring acoustic data for these tests. The traverse system drives a linear array of 13, 1/4"-microphones spaced 3" apart (36" span). An updated data acquisition system was also incorporated into the facility.

Podboy, Devin M.↗
NASA NTRS2010

Results from Testing of Two Rotary Percussive Drilling Systems

The developmental test program for the MSL (Mars Science Laboratory) rotary percussive drill examined the e ect of various drill input parameters on the drill pene- tration rate. Some of the input parameters tested were drill angle with respect to gravity and percussive impact energy. The suite of rocks tested ranged from a high strength basalt to soft Kaolinite clay. We developed a hole start routine to reduce high sideloads from bit walk. The ongoing development test program for the IMSAH (Integrated Mars Sample Acquisition and Handling) rotary percussive corer uses many of the same rocks as the MSL suite. An additional performance parameter is core integrity. The MSL development test drill and the IMSAH test drill use similar hardware to provide rotation and percussion. However, the MSL test drill uses external stabilizers, while the IMSAH test drill does not have external stabilization. In addition the IMSAH drill is a core drill, while the MSL drill uses a solid powdering bit. Results from the testing of these two related drilling systems is examined.

Kriechbaum, Kristopher↗
NASA NTRS2015

NASA Data Acquisition System Software Development for Rocket Propulsion Test Facilities

Current NASA propulsion test facilities include Stennis Space Center in Mississippi, Marshall Space Flight Center in Alabama, Plum Brook Station in Ohio, and White Sands Test Facility in New Mexico. Within and across these centers, a diverse set of data acquisition systems exist with different hardware and software platforms. The NASA Data Acquisition System (NDAS) is a software suite designed to operate and control many critical aspects of rocket engine testing. The software suite combines real-time data visualization, data recording to a variety formats, short-term and long-term acquisition system calibration capabilities, test stand configuration control, and a variety of data post-processing capabilities. Additionally, data stream conversion functions exist to translate test facility data streams to and from downstream systems, including engine customer systems. The primary design goals for NDAS are flexibility, extensibility, and modularity. Providing a common user interface for a variety of hardware platforms helps drive consistency and error reduction during testing. In addition, with an understanding that test facilities have different requirements and setups, the software is designed to be modular. One engine program may require real-time displays and data recording; others may require more complex data stream conversion, measurement filtering, or test stand configuration management. The NDAS suite allows test facilities to choose which components to use based on their specific needs. The NDAS code is primarily written in LabVIEW, a graphical, data-flow driven language. Although LabVIEW is a general-purpose programming language; large-scale software development in the language is relatively rare compared to more commonly used languages. The NDAS software suite also makes extensive use of a new, advanced development framework called the Actor Framework. The Actor Framework provides a level of code reuse and extensibility that has previously been difficult to achieve using LabVIEW. The

Herbert, Phillip W., Sr.↗
NASA NTRS2015

A Vehicle Management End-to-End Testing and Analysis Platform for Validation of Mission and Fault Management Algorithms to Reduce Risk for NASA's Space Launch System

The engineering development of the new Space Launch System (SLS) launch vehicle requires cross discipline teams with extensive knowledge of launch vehicle subsystems, information theory, and autonomous algorithms dealing with all operations from pre-launch through on orbit operations. The characteristics of these spacecraft systems must be matched with the autonomous algorithm monitoring and mitigation capabilities for accurate control and response to abnormal conditions throughout all vehicle mission flight phases, including precipitating safing actions and crew aborts. This presents a large and complex system engineering challenge, which is being addressed in part by focusing on the specific subsystems involved in the handling of off-nominal mission and fault tolerance with response management. Using traditional model based system and software engineering design principles from the Unified Modeling Language (UML) and Systems Modeling Language (SysML), the Mission and Fault Management (M&FM) algorithms for the vehicle are crafted and vetted in specialized Integrated Development Teams (IDTs) composed of multiple development disciplines such as Systems Engineering (SE), Flight Software (FSW), Safety and Mission Assurance (S&MA) and the major subsystems and vehicle elements such as Main Propulsion Systems (MPS), boosters, avionics, Guidance, Navigation, and Control (GNC), Thrust Vector Control (TVC), and liquid engines. These model based algorithms and their development lifecycle from inception through Flight Software certification are an important focus of this development effort to further insure reliable detection and response to off-nominal vehicle states during all phases of vehicle operation from pre-launch through end of flight. NASA formed a dedicated M&FM team for addressing fault management early in the development lifecycle for the SLS initiative. As part of the development of the M&FM capabilities, this team has developed a dedicated testbed that integrates specific M&FM algorithms, specialized nominal and off-nominal test cases, and vendor-supplied physics-based launch vehicle subsystem models. Additionally, the team has developed processes for implementing and validating these algorithms for concept validation and risk reduction for the SLS program. The flexibility of the Vehicle Management End-to-end Testbed (VMET) enables thorough testing of the M&FM algorithms by providing configurable suites of both nominal and off-nominal test cases to validate the developed algorithms utilizing actual subsystem models such as MPS. The intent of VMET is to validate the M&FM algorithms and substantiate them with performance baselines for each of the target vehicle subsystems in an independent platform exterior to the flight software development infrastructure and its related testing entities. In any software development process there is inherent risk in the interpretation and implementation of concepts into software through requirements and test cases into flight software compounded with potential human errors throughout the development lifecycle. Risk reduction is addressed by the M&FM analysis group working with other organizations such as S&MA, Structures and Environments, GNC, Orion, the Crew Office, Flight Operations, and Ground Operations by assessing performance of the M&FM algorithms in terms of their ability to reduce Loss of Mission and Loss of Crew probabilities. In addition, through state machine and diagnostic modeling, analysis efforts investigate a broader suite of failure effects and associated detection and responses that can be tested in VMET to ensure that failures can be detected, and confirm that responses do not create additional risks or cause undesired states through interactive dynamic effects with other algorithms and systems. VMET further contributes to risk reduction by prototyping and exercising the M&FM algorithms early in their implementation and without any inherent hindrances such as meeting FSW processor scheduling constraints due to their target platform - ARINC 653 partitioned OS, resource limitations, and other factors related to integration with other subsystems not directly involved with M&FM such as telemetry packing and processing. The baseline plan for use of VMET encompasses testing the original M&FM algorithms coded in the same C++ language and state machine architectural concepts as that used by Flight Software. This enables the development of performance standards and test cases to characterize the M&FM algorithms and sets a benchmark from which to measure the effectiveness of M&FM algorithms performance in the FSW development and test processes.

Trevino, Luis↗
NASA NTRS2015

Integrated Test Approach

This paper describes a testing methodology undertaken on the Facilities Development and Operations Contract (FDOC) by Lockheed Martin. The methodology was defined with the intent of reducing project schedule time to enable NASA's Johnson Space Center (JSC) to be able to deliver the Mission Control Center (MCC) 21 project as quickly as possible. 21 represents the 21st century where NASA JSC is updating its control center with new technology and operational concepts in order to support NASA customers wanting to use control center assets to support space vehicle operations. In collaboration with the NASA customer, a new test concept was conceived early during MCC21 project planning with the goal of reducing project delivery time. One enabler that could help reduce delivery time was testing. Within the project, testing was performed by two entities, software development responsible for subsystem testing and system test responsible for system integration testing. The MCC21 project took a deliberate review of testing to determine how it could be performed differently to realize an overall reduction in test time to support the goal of a more rapid project delivery.

Cotton, Will↗
NASA NTRS2015

Jet-Surface Interaction: High Aspect Ratio Nozzle Test, Nozzle Design and Preliminary Data

The Jet-Surface Interaction High Aspect Ratio (JSI-HAR) nozzle test is part of an ongoing effort to measure and predict the noise created when an aircraft engine exhausts close to an airframe surface. The JSI-HAR test is focused on parameters derived from the Turbo-electric Distributed Propulsion (TeDP) concept aircraft which include a high-aspect ratio mailslot exhaust nozzle, internal septa, and an aft deck. The size and mass flow rate limits of the test rig also limited the test nozzle to a 16:1 aspect ratio, half the approximately 32:1 on the TeDP concept. Also, unlike the aircraft, the test nozzle must transition from a single round duct on the High Flow Jet Exit Rig, located in the AeroAcoustic Propulsion Laboratory at the NASA Glenn Research Center, to the rectangular shape at the nozzle exit. A parametric nozzle design method was developed to design three low noise round-to-rectangular transitions, with 8:1, 12:1, and 16: aspect ratios, that minimizes flow separations and shocks while providing a flat flow profile at the nozzle exit. These designs validated using the WIND-US CFD code. A preliminary analysis of the test data shows that the actual flow profile is close to that predicted and that the noise results appear consistent with data from previous, smaller scale, tests. The JSI-HAR test is ongoing through October 2015. The results shown in the presentation are intended to provide an overview of the test and a first look at the preliminary results.

Aeroacoustics↗
NASA NTRS2015

High Current ESD Test of Advanced Triple Junction Solar Array Coupon

A test was conducted on an Advanced Triple Junction (ATJ) coupon that was part of a risk reduction effort in the development of a high-powered solar array design by SSL. The ATJ coupon was a small, 4-cell, two-string configuration that has served as the basic test coupon design used in previous SSL environmental aging campaigns. The coupon has many attributes of the flight design; e.g., substrate structure with graphite face sheets, integrated by-pass diodes, cell interconnects, RTV grout, wire routing, etc. The objective of the present test was to evaluate the performance of the coupon after being subjected to induced electrostatic discharge testing at two string voltages (100 V, 150 V) and four array current (1.65 A, 2.0 A, 2.475 A, and 3.3 A). An ESD test circuit, unique to SSL solar array design, was built that simulates the effect of missing cells and strings in a full solar panel with special primary arc flashover circuitry. A total of 73 primary arcs were obtained that included 7 temporary sustained arcs (TSA) events. The durations of the TSAs ranged from 50 micros to 2.9 ms. All TSAs occurred at a string voltage of 150 V. Post-test Large Area Pulsed Solar Simulator (LAPSS), Dark I-V, and By-Pass Diode tests showed that no degradation occurred due to the TSA events. In addition, the post-test insulation resistance measured was > 50 G-ohms between cells and substrate. These test results indicate a robust design for application to a high-current, high-power mission application.

Wright, Kenneth H., Jr.↗
NASA NTRS2015

Hexavalent Chrome Free Coatings for Electronics Electromagnetic Interference (EMI) Shielding Effectiveness (SE) Interim Test Report

Test specimen configuration was provided by Parker Chomerics. The EMI gasket used in this project was Cho-Seal 6503E. Black oxide alloy steel socket head bolts were used to hold the plates together. Non-conductive spacers were used to control the amount of compression on the gaskets. The following test fixture specifications were provided by Parker Chomerics. The CHO‐TP09 test plate sets selected for this project consist of two aluminum plates manufactured to the specifications detailed in CHO­‐TP09. The first plate, referred to as the test frame, is illustrated in Figure 1. The test frame is designed with a cutout in the center and two alternating bolt patterns. One pattern is used to bolt the test frame to the corresponding test cover plate (Figure 2), forming a test plate set. The second pattern accepts the hardware used to mount the fully assembled test plate set to the main adapter plate (Figure 3).

trivalent chromium↗
NASA NTRS2016

Large Payload Ground Transportation and Test Considerations

During test and verification planning for the Altair lunar lander project, a National Aeronautics and Space Administration (NASA) study team identified several ground transportation and test issues related to the large payload diameter. Although the entire Constellation Program-including Altair-has since been canceled, issues identified by the Altair project serve as important lessons learned for payloads greater than 7 m diameter being considered for NASA's new Space Launch System (SLS). A transportation feasibility study found that Altair's 8.97 m diameter Descent Module would not fit inside available aircraft. Although the Ascent Module cabin was only 2.35 m diameter, the long reaction control system booms extended nearly to the Descent Module diameter, making it equally unsuitable for air transportation without removing the booms and invalidating assembly workmanship screens or acceptance testing that had already been performed. Ground transportation of very large payloads over extended distances is not generally permitted by most states, so overland transportation alone would not be an option. Limited ground transportation to the nearest waterway may be possible, but water transportation could take as long as 66 days per production unit, depending on point of origin and acceptance test facility; transportation from the western United States would require transit through the Panama Canal to access the Kennedy Space Center launch site. Large payloads also pose acceptance test and ground processing challenges. Although propulsion, mechanical vibration, and reverberant acoustic test facilities at NASA's Plum Brook Station have been designed to accommodate large spacecraft, special handling and test work-arounds may be necessary, which could increase cost, schedule, and technical risk. Once at the launch site, there are no facilities currently capable of accommodating the combination of large payload size and hazardous processing such as hypergolic fuels, pyrotechnic devices, and high pressure gasses. Ironically, the limiting factor to a national heavy lift strategy may not be the rocket technology needed to throw a heavy payload, but rather the terrestrial infrastructure-roads, bridges, airframes, and buildings-necessary to transport, acceptance test, and process large spacecraft. Failure to carefully consider where and how large spacecraft are manufactured, tested, and launched could result in unforeseen cost to modify existing (or develop new) infrastructure, or incur additional risk due to increased handling operations or eliminating key verifications.

Rucker, Michelle A.↗
NASA NTRS2016

Experimental Photogrammetric Techniques Used on Five Full-Scale Aircraft Crash Tests

Between 2013 and 2015, full-scale crash tests were conducted on five aircraft at the Landing and Impact Research Facility (LandIR) at NASA Langley Research Center (LaRC). Two tests were conducted on CH-46E airframes as part of the Transport Rotorcraft Airframe Crash Testbed (TRACT) project, and three tests were conduced on Cessna 172 aircraft as part of the Emergency Locator Transmitter Survivability and Reliability (ELTSAR) project. Each test served to evaluate a variety of crashworthy systems including: seats, occupants, restraints, composite energy absorbing structures, and Emergency Locator Transmitters. As part of each test, the aircraft were outfitted with a variety of internal and external cameras that were focused on unique aspects of the crash event. A subset of three camera was solely used in the acquisition of photogrammetric test data. Examples of this data range from simple two-dimensional marker tracking for the determination of aircraft impact conditions to entire full-scale airframe deformation to markerless tracking of Anthropomorphic Test Devices (ATDs, a.k.a. crash test dummies) during the crash event. This report describes and discusses the techniques used and implications resulting from the photogrammetric data acquired from each of the five tests.

Littell, Justin D.↗
NASA NTRS2013

HESTIA Commodities Exchange Pallet and Sounding Rocket Test Stand

During my Spring 2016 internship, my two major contributions were the design of the Commodities Exchange Pallet and the design of a test stand for a 100 pounds-thrust sounding rocket. The Commodities Exchange Pallet is a prototype developed for the Human Exploration Spacecraft Testbed for Integration and Advancement (HESTIA) program. Under the HESTIA initiative the Commodities Exchange Pallet was developed as a method for demonstrating multi-system integration thru the transportation of In-Situ Resource Utilization produced oxygen and water to a human habitat. Ultimately, this prototype's performance will allow for future evaluation of integration, which may lead to the development of a flight capable pallet for future deep-space exploration missions. For HESTIA, my main task was to design the Commodities Exchange Pallet system to be used for completing an integration demonstration. Under the guidance of my mentor, I designed, both, the structural frame and fluid delivery system for the commodities pallet. The fluid delivery system includes a liquid-oxygen to gaseous-oxygen system, a water delivery system, and a carbon-dioxide compressors system. The structural frame is designed to meet safety and transportation requirements, as well as the ability to interface with the ER division's Portable Utility Pallet. The commodities pallet structure also includes independent instrumentation oxygen/water panels for operation and system monitoring. My major accomplishments for the commodities exchange pallet were the completion of the fluid delivery systems and the structural frame designs. In addition, parts selection was completed in order to expedite construction of the prototype, scheduled to begin in May of 2016. Once the commodities pallet is assembled and tested it is expected to complete a fully integrated transfer demonstration with the ISRU unit and the Environmental Control and Life Support System test chamber in September of 2016. In addition to the development of the Commodities Exchange Pallet, I also assisted in preparation for testing the upper stage of a sounding rocket developed as a Center Innovation Fund project. The main objective of this project is to demonstrate the integration between a propulsion system and a solid oxide fuel cell (SOFC). The upper stage and SOFC are scheduled to complete an integrated test in August of 2016. As part of preparation for scheduled testing, I was responsible for designing the upper stage's test stand/support structure and main engine plume deflector to be used during hot-fire testing (fig. 3). The structural components of the test stand need to meet safety requirements for operation of the propulsion system, which consist of a 100 pounds-thrust main engine and two 15 pounds-thrust reaction control thrusters. My main accomplishment for this project was the completion of the design and the parts selection for construction of the structure, scheduled to begin late April of 2016.

Chaparro, Javier↗
NASA NTRS2015

Case Studies for the Statistical Design of Experiments Applied to Powered Rotor Wind Tunnel Tests

The application of statistical Design of Experiments (DOE) to helicopter wind tunnel testing was explored during two powered rotor wind tunnel entries during the summers of 2012 and 2013. These tests were performed jointly by the U.S. Army Aviation Development Directorate Joint Research Program Office and NASA Rotary Wing Project Office, currently the Revolutionary Vertical Lift Project, at NASA Langley Research Center located in Hampton, Virginia. Both entries were conducted in the 14- by 22-Foot Subsonic Tunnel with a small portion of the overall tests devoted to developing case studies of the DOE approach as it applies to powered rotor testing. A 16-47 times reduction in the number of data points required was estimated by comparing the DOE approach to conventional testing methods. The average error for the DOE surface response model for the OH-58F test was 0.95 percent and 4.06 percent for drag and download, respectively. The DOE surface response model of the Active Flow Control test captured the drag within 4.1 percent of measured data. The operational differences between the two testing approaches are identified, but did not prevent the safe operation of the powered rotor model throughout the DOE test matrices.

Overmeyer, Austin D.↗
NASA NTRS2016

Extended Life Testing of Duplex Ball Bearings

Sierra Nevada Corporation’s Space Systems performed bearing life testing for the Scan Mirror Motor/Encoder Assembly (SMMA), part of the Scan Mirror Assembly on-board the Aerosol Polarimetry Sensor (APS) on the NASA Glory Spacecraft. The baseline bearing life test duration extended beyond the launch date for the Glory Spacecraft; a risk that the program was willing to undertake with the understanding that if any anomalies or failures occurred before the required life was achieved, then the mission objectives or operating profile could be modified on orbit to take those results into account. Even though the Glory Spacecraft failed to reach orbit during its launch in March of 2011, the bearing life testing was continued through a mutual understanding of value between Sierra Nevada Corporation and our customer; with a revised goal of testing to failure rather than completing a required number of life cycles. Life testing thus far has not only exceeded the original mission required life, but has also exceeded the published test data for Cumulative Degradation Factor (CDF) from NASA/CR-2009-215681. Many lessons were learned along the way regarding long life testing. The bearing life test has been temporarily suspended due to test support equipment issues.

Mobley, Jeffrey↗