Electric propulsion ground testing.
Ground testing of electric propulsion devices and systems, discussing electrostatic and plasma propulsion, testing requirements and facilities
ELECTRIC PROPULSION↗
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Ground test experiment for large space structures
In recent years a new body of control theory has been developed for the design of control systems for Large Space Structures (LSS). The problems of testing this theory on LSS hardware are aggravated by the expense and risk of actual in orbit tests. Ground tests on large space structures can provide a proving ground for candidate control systems, but such tests require a unique facility for their execution. The current development of such a facility at the NASA Marshall Space Flight Center (MSFC) is the subject of this report.
Tollison, D. K.↗
Advanced manufacturing development of a composite empennage component for L-1011 aircraft. Phase 4: Full scale ground test
The ground tests conducted on the advanced composite vertical fin (ACVF) program are described. The design and fabrication of the test fixture and the transition structure, static test of Ground Test Article (GTA) No. 1, rework of GTA No. 2, and static, damage tolerance, fail-safe and residual strength tests of GTA No. 2 are described.
Jackson, A. C.↗
A Method for Calculating the Probability of Successfully Completing a Rocket Propulsion Ground Test
Propulsion ground test facilities face the daily challenges of scheduling multiple customers into limited facility space and successfully completing their propulsion test projects. Due to budgetary and schedule constraints, NASA and industry customers are pushing to test more components, for less money, in a shorter period of time. As these new rocket engine component test programs are undertaken, the lack of technology maturity in the test articles, combined with pushing the test facilities capabilities to their limits, tends to lead to an increase in facility breakdowns and unsuccessful tests. Over the last five years Stennis Space Center's propulsion test facilities have performed hundreds of tests, collected thousands of seconds of test data, and broken numerous test facility and test article parts. While various initiatives have been implemented to provide better propulsion test techniques and improve the quality, reliability, and maintainability of goods and parts used in the propulsion test facilities, unexpected failures during testing still occur quite regularly due to the harsh environment in which the propulsion test facilities operate. Previous attempts at modeling the lifecycle of a propulsion component test project have met with little success. Each of the attempts suffered form incomplete or inconsistent data on which to base the models. By focusing on the actual test phase of the tests project rather than the formulation, design or construction phases of the test project, the quality and quantity of available data increases dramatically. A logistic regression model has been developed form the data collected over the last five years, allowing the probability of successfully completing a rocket propulsion component test to be calculated. A logistic regression model is a mathematical modeling approach that can be used to describe the relationship of several independent predictor variables X(sub 1), X(sub 2),..,X(sub k) to a binary or dichotomous dependent variable Y, where Y can only be one of two possible outcomes, in this case Success or Failure. Logistic regression has primarily been used in the fields of epidemiology and biomedical research, but lends itself to many other applications. As indicated the use of logistic regression is not new, however, modeling propulsion ground test facilities using logistic regression is both a new and unique application of the statistical technique. Results from the models provide project managers with insight and confidence into the affectivity of rocket engine component ground test projects. The initial success in modeling rocket propulsion ground test projects clears the way for more complex models to be developed in this area.
Messer, Bradley P.↗
A Method for Calculating the Probability of Successfully Completing a Rocket Propulsion Ground Test
Propulsion ground test facilities face the daily challenge of scheduling multiple customers into limited facility space and successfully completing their propulsion test projects. Over the last decade NASA s propulsion test facilities have performed hundreds of tests, collected thousands of seconds of test data, and exceeded the capabilities of numerous test facility and test article components. A logistic regression mathematical modeling technique has been developed to predict the probability of successfully completing a rocket propulsion test. A logistic regression model is a mathematical modeling approach that can be used to describe the relationship of several independent predictor variables X(sub 1), X(sub 2),.., X(sub k) to a binary or dichotomous dependent variable Y, where Y can only be one of two possible outcomes, in this case Success or Failure of accomplishing a full duration test. The use of logistic regression modeling is not new; however, modeling propulsion ground test facilities using logistic regression is both a new and unique application of the statistical technique. Results from this type of model provide project managers with insight and confidence into the effectiveness of rocket propulsion ground testing.
Messer, Bradley↗
Experimental Results of Thin-Film Photovoltaic Cells in a Low Density LEO Plasma Environment: Ground Tests
Plasma ground testing results, conducted at the Glenn Research Center (GRC) National Plasma Interaction (N-PI) Facility, are presented for a number of thin-film photovoltaic cells. The cells represent a mix of promising new technologies identified by the Air Force Research Laboratory (AFRL) under the CYGNUS Space Science Technology Experiment (SSTE-4) Program. The current ground tests are aimed at characterizing the performance and survivability of thin film technologies in the harsh low earth orbital space environment where they will be flown. Measurements of parasitic current loss, charging/dielectric breakdown of cover-slide coatings and arcing threshold tests are performed for each individual cell. These measurements are followed by a series of experiments designed to test for catastrophic arc failure mechanisms. A special type of power supply, called a solar array simulator (SAS) with adjustable voltage and current limits on the supply s output, is employed to bias two adjacent cells at a predetermined voltage and current. The bias voltage is incrementally ramped up until a sustained arc results. Sustained arcs are precursors to catastrophic arc failure where the arc current rises to a maximum value for long timescales often ranging between 30 to 100 sec times. Normal arcs by comparison, are short lived events with a timescale between 10 to 30 sec. Sustained arcs lead to pyrolization with extreme cell damage and have been shown to cause the loss of entire array strings in solar arrays. The collected data will be used to evaluate the suitability of thin-film photovoltaic technologies for future space operations.
Galofaro, Joel T.↗
Phase 2 program on ground test of refanned JT8D turbofan engines and nacelles for the 727 airplane. Volume 3: Ground tests
The NASA Refan Program included full-scale performance and noise ground tests of both a current production (JT8D-15) and a refanned (JT8D-115) engine. A description of the two ground tests including detailed propulsion, noise, and structural test results is presented. The primary objectives of the total test program were comparison of JT8D-15 and JT8D-115 overall propulsion system performance and noise characteristics and determination of incremental component noise levels. Other objectives of the test program included: (1) determination of acoustic treatment effectiveness; (2) measurement of internal sound pressure levels; (3) measurement of inlet and exhaust hardware performance; (4) determination of center-engine surge margin; and (5) evaluation of certain structural characteristics associated with the 727 refan center-engine inlet duct and JT8D refan engine exhaust system. The JT8D-15 and -115 tests were conducted during September 1974 and January to March 1975, respectively. Analyses of the test data indicated that the JT8D-115, as compared to the JT8D-15, demonstrates a 12.5 percent to 13.2 percent reduction in static specific fuel consumption, and a reduction of 6 to 7 PNdB in a weighted average value of static tone corrected perceived noise level. Separated into noise components, a significant reduction was shown for the inlet fan, aft fan, exhaust duct flow, turbine, and jet noises. However, core noise was increased. Photographs of test stands and test equipment are shown.
Source record↗
GTTC Future of Ground Testing Meta-Analysis of 20 Documents
National research, development, test, and evaluation ground testing capabilities in the United States are at risk. There is a lack of vision and consensus on what is and will be needed, contributing to a significant threat that ground test capabilities may not be able to meet the national security and industrial needs of the future. To support future decisions, the AIAA Ground Testing Technical Committee’s (GTTC) “Future of Ground Test” (FoGT) Working Group selected and reviewed 20 “seminal” documents related to the application and direction of ground testing. Each document was reviewed, with the content main points collected and organized into sections in the form of a gap analysis – current state, future state, major challenges/gaps, and recommendations. This paper includes key findings and selected commentary by an editing team.
Dunn, Steven C.↗
Subscale Validation of the Subsurface Active Filtration of Exhaust (SAFE) Approach to the NTP Ground Testing
Nuclear thermal propulsion (NTP) has been recognized as an enabling technology for missions to Mars and beyond. However, one of the key challenges of developing a nuclear thermal rocket is conducting verification and development tests on the ground. A number of ground test options are presented, with the Sub-surface Active Filtration of Exhaust (SAFE) method identified as a preferred path forward for the NTP program. The SAFE concept utilizes the natural soil characteristics present at the Nevada National Security Site to provide a natural filter for nuclear rocket exhaust during ground testing. A validation method of the SAFE concept is presented, utilizing a non-nuclear sub-scale hydrogen/oxygen rocket seeded with detectible radioisotopes. Additionally, some alternative ground test concepts, based upon the SAFE concept, are presented. Finally, an overview of the ongoing discussions of developing a ground test campaign are presented.
Nuclear Rocket Engines↗
Guidance on the Stand Down, Mothball, and Reactivation of Ground Test Facilities
The development of aerospace and aeronautics products typically requires three distinct types of testing resources across research, development, test, and evaluation: experimental ground testing, computational "testing" and development, and flight testing. Over the last twenty plus years, computational methods have replaced some physical experiments and this trend is continuing. The result is decreased utilization of ground test capabilities and, along with market forces, industry consolidation, and other factors, has resulted in the stand down and oftentimes closure of many ground test facilities. Ground test capabilities are (and very likely will continue to be for many years) required to verify computational results and to provide information for regimes where computational methods remain immature. Ground test capabilities are very costly to build and to maintain, so once constructed and operational it may be desirable to retain access to those capabilities even if not currently needed. One means of doing this while reducing ongoing sustainment costs is to stand down the facility into a "mothball" status - keeping it alive to bring it back when needed. Both NASA and the US Department of Defense have policies to accomplish the mothball of a facility, but with little detail. This paper offers a generic process to follow that can be tailored based on the needs of the owner and the applicable facility.
Volkman, Gregrey T.↗
Phase 2 program on ground test of refanned JT8D turbofan engines and nacelles for the 727 airplane. Volume 1: Summary
The propulsion performance, acoustic, structural, and systems changes to a 727-200 airplane retrofitted with a refan modification of the JT8D turbofan engine are evaluated. Model tests, design of certifiable airplane retrofit kit hardware, manufacture of test hardware, ground test of a current production JT8D engine, followed by test of the same engine modified to the refan configuration, detailed analyses of the retrofit impact on airplane airworthiness, performance, and noise, and a preliminary analysis of retrofit costs are included. Results indicate that the refan retrofit of the 727-200 would be certifiable and would result in a 6-to 8 EPNdb reduction in effective perceived noise level (EPNL) at the FAR 36 measuring points and an annoyance-weighted footprint area reduction of 68% to 83%. The installed refan engine is estimated to provide 14% greater takeoff thrust at zero velocity and 10% greater thrust at 100 kn (51.4 m/s). There would be an approximate 0.6% increase in cruise specific fuel consumption (SFC). The refan engine performance in conjunction with the increase in stalled weight results in a range reduction of approximately 15% over the unmodified airplane at the same brake release gross weight (BRGW), with a block fuel increase of 1.5% to 3%. With the particular model 727 that was studied, however, it is possible to operate the airplane (with minor structural modifications) at a higher BRGW and increase the range up to approximately 15% relative to the nonrefanned airplane (with equal or slightly increased noise levels). The JT8D refan engine also improves the limited-field range of the airplane.
Source record↗
Optimization of the 4-Bed CO2 Scrubber Performance Based on Ground Tests
Testing of ground hardware closely matching the flight design for the 4-Bed CO2Scrubber (4BCO2) has provided a wealth of information about the complex and highly coupled batch process. The 4BCO2 process is a Thermal and Vacuum Swing Adsorption (TVSA) cycle with recirculating flows. The ability to measure CO2concentration at intermediate points in this architecture is new to this ground test system and has revealed a better understanding of system performance and its dependence on system design, operational parameters, and boundary conditions. This paper will discuss a statistical analysis performed to identify significant correlations between performance factors and operational parameters. Using these new insights on the highly coupled system physics, means for improvements to system performance are proposed.
CO2 Removal↗
The voltage threshold for arcing for solar cells in LEO: Flight and ground test results
Ground and flight results of solar cell arcing in low Earth orbit (LEO) conditions are compared and interpreted. It is shown that an apparent voltage threshold for arcing may be produced by a strong power law dependence of arc rate on voltage, combined with a limited observation time. The change in this apparent threshold with plasma density is a reflection of the density dependence of the arc rate. A nearly linear dependence of arc rate on density is inferred from the data. A real voltage threshold for arcing for 2 by 2 cm solar cells may exist however, independent of plasma density, near -230 V relative to the plasma. Here, arc rates may change by more than an order of magnitude for a change of only 30 V in array potential. For 5.9 by 5.9 solar cells, the voltage dependence of the arc rate is steeper, and the data are insufficient to indicate the existence of an arcing increased by an atomic oxygen plasma, as is found in LEO, and by arcing from the backs of welded-through substrates.
Ferguson, D. C.↗
The voltage threshold for arcing for solar cells in Leo - Flight and ground test results
Ground and flight results of solar cell arcing in low earth orbit (LEO) conditions are compared and interpreted. It is shown that an apparent voltage threshold for arcing may be produced by a storage power law dependence of arc rate on voltage, combined with a limited observation time. The change in this apparent threshold with plasma density is a reflection of the density dependence of the arc rate. A nearly linear dependence of arc rate on density is inferred from the data. A real voltage threshold for arcing for 2 by 2 cm solar cells may exist however, independent of plasma density, near -230 V relative to the plasma. Here, arc rates may change by more than an order of magnitude for a change of only 30 V in array potential. For 5.9 by 5.9 solar cells, the voltage dependence of the arc rate is steeper, and the data are insufficient to indicate the existence of an arcing increased by an atomic oxygen plasma, as is found in LEO, and by arcing from the backs of welded-through substrates.
Ferguson, Dale C.↗
Analytical and experimental studies to develop ion engine ground testing techniques
Ion engine ground testing techniques
GROUND TEST↗
Orbital Express Advanced Video Guidance Sensor: Ground Testing, Flight Results and Comparisons
Orbital Express (OE) was a successful mission demonstrating automated rendezvous and docking. The 2007 mission consisted of two spacecraft, the Autonomous Space Transport Robotic Operations (ASTRO) and the Next Generation Serviceable Satellite (NEXTSat) that were designed to work together and test a variety of service operations in orbit. The Advanced Video Guidance Sensor, AVGS, was included as one of the primary proximity navigation sensors on board the ASTRO. The AVGS was one of four sensors that provided relative position and attitude between the two vehicles. Marshall Space Flight Center was responsible for the AVGS software and testing (especially the extensive ground testing), flight operations support, and analyzing the flight data. This paper briefly describes the historical mission, the data taken on-orbit, the ground testing that occurred, and finally comparisons between flight data and ground test data for two different flight regimes.
Pinson, Robin M.↗
DC-10 composite vertical stabilizer ground test program
A review of the structural configuration and ground test program is presented. Particular emphasis is placed on the testing of a full-scale stub box test subcomponent and full span ground test unit. The stub box subcomponent was tested in an environmental chamber under ambient, cold/wet, and hot/wet conditions. The test program included design limit static loads, fatigue spectrum loading to approximately two service lifetimes (with and without damage), design limit damage tolerance tests, and a final residual strength test to a structural failure. The first full-scale ground test unit was tested under ambient conditions. The test unit was to have undergone static, fatigue, and damage tolerance tests but a premature structural failure occurred at design limit load during the third limit load test. A failure theory was developed which explains the similarity in types of failure and the large load discrepancy at failure between the two test articles. The theory attributes both failures to high stress concentrations at the edge of the lower rear spar access opening. A second full-scale ground test unit has been modified to incorporate the various changes resulting from the premature failure. The article has been assembled and is active in the test program.
Palmer, J. M., Jr.↗
Propulsion Ground Testing with High Test Peroxide: Lessons Learned
Propulsion Ground Testing with High Test Peroxide (85 to 98% concentration) began at the NASA John C. Stennis Space Center in calendar year 1998, when the E3 Test Facility was modified to accomodate hydrogen peroxide (H2O2) in order to suport the research and development testing of the USAF Upper Stage Flight Experiment rocket engine. Since that time, efforts have continued to provide actual and planned test services to various customers, both U.S. Government and Commercial, in the ground test of many test articles, ranging from gas generators, to catalyst beds, to turbomachinery, to main injectors, to combustion chambers, to integrated rocket engines, to integrated stages. Along this path, and over the past 4 years, there has been both the rediscovery of previously learned lessons, through literature search, archive review, and personal interviews, as well as the learning of many new lessons as new areas are explored and new endeavors are tried. This paper will summarize those lessons learned in an effort to broaden the knowledge base as High Test Peroxide is considered more widely for use in rocket propulsion applications.
Bruce, Robert↗