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A means of eliminating the subsynchronous rotor whirl encountered during the development testing of the high-pressure oxygen turbopump of the Space Shuttle Main Engine is proposed. The rotor response is improved by reducing the pump end bearing loads and adding damping between the rotor and housing. In the present method, the impeller annular seals are converted into damping seals and the second rotor critical speed is increased due to the added stiffness of the seal conversion and the stiffening of the rotor shaft.

The cause, or causes, for the Space Shuttle Main Engine ball wear were unknown, however, several mechanisms were suspected. Two testers were designed and built for operation in liquid oxygen to empirically gain insight into the problems and iterate solutions in a timely and cost efficient manner independent of engine testing. Schedules and test plans were developed that defined a test matrix consisting of parametric variations of loading, cooling or vapor margin, cage lubrication, material, and geometry studies. Initial test results indicated that the low pressure pump thrust bearing surface distress is a function of high axial load. Initial high pressure turbopump bearing tests produced the wear phenomenon observed in the turbopump and identified an inadequate vapor margin problem and a coolant flowrate sensitivity issue. These tests provided calibration data of analytical model predictions to give high confidence in the positive impact of future turbopump design modification for flight. Various modifications will be evaluated in these testers, since similar turbopump conditions can be produced and the benefit of the modification will be quantified in measured wear life comparisons.

The SP-100 Project was established to develop and demonstrate feasibility of a space reactor power system (SRPS) at power levels of 10's of kilowatts to a megawatt. To help determine systems requirements for the SRPS, a mission and spacecraft were examined which utilize this power system for a space-based radar to observe moving objects. Aspects of the mission and spacecraft bearing on the power system were the primary objectives of this study; performance of the radar itself was not within the scope. The study was carried out by the Systems Design Audit Team of the SP-100 Project.

Various system aspects of a 300-kW nuclear reactor power system for spacecraft have been investigated. Special attention is given to the cases of a reusable OTV and a space-based radar. It is demonstrated that the stowed length of the power system is important to mission design, and that orbital storage for months to years may be needed for missions involving orbital assembly.

To help determine the systems requirements for a 300-kWe space nuclear reactor power system, a mission and spacecraft have been examined which utilize electric propulsion and this nuclear reactor power for multiple transfers of cargo between low earth orbit (LEO) and geosynchronous earth orbit (GEO). A propulsion system employing ion thrusters and xenon propellant was selected. Propellant and thrusters are replaced after each sortie to GEO. The mass of the Orbital Transfer Vehicle (OTV), empty and dry, is 11,000 kg; nominal propellant load is 5000 kg. The OTV operates between a circular orbit at 925 km altitude, 28.5 deg inclination, and GEO. Cargo is brought to the OTV by Shuttle and an Orbital Maneuvering Vehicle (OMV); the OTV then takes it to GEO. The OTV can also bring cargo back from GEO, for transfer by OMV to the Shuttle. OTV propellant is resupplied and the ion thrusters are replaced by the OMV before each trip to GEO. At the end of mission life, the OTV's electric propulsion is used to place it in a heliocentric orbit so that the reactor will not return to earth. The nominal cargo capability to GEO is 6000 kg with a transit time of 120 days; 1350 kg can be transferred in 90 days, and 14,300 kg in 240 days. These capabilities can be considerably increased by using separate Shuttle launches to bring up propellant and cargo, or by changing to mercury propellant.

The high pressure turbomachinery of the Space Shuttle Main Engine has the highest power-to-weight ratio of any operational machine known. Subsynchronous rotor whirl of the high pressure oxygen turbopump occurred in development testing at full-power level (109 percent thrust). The means by which the turbopump was successfully uprated is presented herein. The subsynchronous motion was determined to be driven by impeller destabilizing forces in combination with low net damping and bearing degradation. The degradation resulted from ball wear due primarily to an excessive loading condition of operating too near the lightly damped rotor second critical speed while under a large static load and, secondarily, from reverse bearing loading or loss of internal clearance and coolant during simulated flight conditions. The rotor response was reduced by stiffening the shaft and supports, optimizing the stiffness and damping of annular seals, and increasing the bearing deadband. The uprated oxygen turbopump configuration was verified by converting the pump and bearing support into a load cell for the purpose of systematically quantifying the load reduction benefits relative to baseline turbopumps. The damped second critical speed margin and the load sharing have been substantially improved which has resulted in reduced bearing loads for improved service life of the machine at full-power level.

Transient unbalance shifts were determined not to excite a rotor instability in the high pressure turbomachinery of the Space Shuttle Main Engine using the current rotor dynamic models. Sudden unbalance changes of relatively small magnitudes during fast-speed ramps showed stable nonsynchronous motion depending on the resultant unbalance distribution at subsequent high speed dwells. Transient moment unbalance may initiate a limit cycle subsynchronous response that shortly decays, but a persistent subsynchronous with large amplitudes was never achieved. These limit cycle subsynchronous amplitudes appear to be minimized with lower unbalance magnitudes, which indicates improved rotor balancing would sustain synchronous motion only. The transient unbalance phenomenon was determined to be an explanation for synchronous response shifts often observed during engine tests.

Preliminary rotordynamic evaluations are performed with a housing stiffness assumption that is typically determined only after the hardware is built. In addressing rotor stability, a rigid housing assumption was shown to predict an instability at a lower spin speed than a comparable flexible housing analysis. This rigid housing assumption therefore provides a conservative estimate of the stability threshold speed. A flexible housing appears to act as an energy absorber and dissipated some of the destabilizing force. The fact that a flexible housing is usually asymmetric and considerably heavier than the rotor was related to this apparent increase in rotor stability. Rigid housing analysis is proposed as a valuable screening criteria and may save time and money in construction of elaborate housing finite element models for linear stability analyses.

Runout on shaft such as on pump shaft in liquid oxygen environment measured by device employing pair of pistons placed 90 degrees apart and in contact with shaft.

It is pointed out that the energy needs of spacecraft over the last 25 years have been met by photovoltaic arrays with batteries, primary fuel cells, and radioisotope thermoelectric generators (RTG). However, it might be difficult to satisfy energy requirements for the next generation of space missions with the currently used energy sources. Applications studies have emphasized the need for a lighter, cheaper, and more compact high-energy source than the scaling up of current technologies would permit. These requirements could be satisfied by a nuclear reactor power system. The joint NASA/DOD/DOE SP-100 program is to explore and evaluate this option. Critical elements of the technology are also to be developed, taking into account space reactor systems of the 100 kW class. The present paper is concerned with some of the civil mission categories and concepts which are enabled or significantly enhanced by the performance characteristics of a nuclear reactor energy system.

Instability in rotating machinery reduced. Ring of ribs fastened to existing stator in turbopump pressure-seal inlet. Ribs suppress swirl in flow entering seal. Rib concept offers relatively inexpensive solution to some lateral-instability problems in many other systems with rotating pressure seals.

Computer program available from COSMIC provides quick, efficient, and accurate results in support of preliminary and proposed rotating-machinery designs. Advanced rotating-machinery design is iterative process in early stages of development. New program provides timely, critical-speed calculations to support preliminary rotating-machinery designs.

The dynamic radial stiffness characteristics of rolling element bearings are currently determined by analytical methods that have not been experimentally verified. These bearing data are vital to rotating machinery design integrity because accurate critical speeds and rotor stability predictions are highly dependent on the bearing stiffness. A tester was designed capable of controlling the bearing axial preload, speed, and rotor unbalance. The rotor and support structures were constructed to permit critical speeds that are predominantly determined by a 57 mm test bearing. A curve of calculated critical speed versus stiffness was used to determine the actual bearing stiffness from the empirical data. The results of extensive testing are used to verify analytical predictions, increase confidence in existing bearing computer programs, and to serve as a data base for efforts to correct these programs.

The problem is considered of the effect of reflections from discontinuities at each end of a transmission line on the group delay at microwave frequencies. Previous work is briefly reviewed and a general analysis is made. Graphical data are presented based upon the formulas developed. Experimental results are given which confirm the theory.

Delay-line standards have been tested by three independent laboratories using six different methods. Results are published in report showing delay values obtained from 15-, 30-, and 60-ns cables by different laboratories. Study of potential error sources indicates that reflection errors due to discontinuities at ends of cables are usually small.

Theoretical equations are derived for calculating the effects of local VSWR and reflection coefficient phase angle drifts on hydrogen maser frequency stability. Sample calculations made for a typical JPL maser show that under special load conditions, a VSWR drift of 0.000075/h or phase angle drive of 0.01 deg/h can produce a frequency drift of (10 to the -14th power f sub 0) Hz/h where f sub 0 is the maser frequency of approximately 1.42 x 10 to the 9th power Hz.

Calculation method can be applied to transmission lines operating in TEM mode or to single-mode propagation in waveguides. Derived data are useful for estimating limits on variation of group delay with frequency or in determining how much discontinuity reduction is necessary to achieve given accuracy in predicting group delay.

A set of cable assemblies serving as group delay standards having nominal delays of 15, 30, and 60 nsec are described. Various types of measurements were performed on the cable standards, including impedance, microwave phase shift, RF pulse burst delay, modulation pulsed delay, and envelope phase shift measurements. The results of these tests are given, and various sources of error are discussed, in particular, dispersion and internal reflections.

Metallization-related failure mechanisms were shown to be a major cause of integrated circuit failures under accelerated stress conditions, as well as in actual use under field operation. The integrated circuit industry is aware of the problem and is attempting to solve it in one of two ways: (1) better understanding of the aluminum system, which is the most widely used metallization material for silicon integrated circuits both as a single level and multilevel metallization, or (2) evaluating alternative metal systems. Aluminum metallization offers many advantages, but also has limitations particularly at elevated temperatures and high current densities. As an alternative, multilayer systems of the general form, silicon device-metal-inorganic insulator-metal, are being considered to produce large scale integrated arrays. The merits and restrictions of metallization systems in current usage and systems under development are defined.

Metallization systems for integrated circuits

Metallurgical methods for detection and analysis of failure mechanisms in microelectronic devices

Thermal and electrical conductivity of a weakly ionized cesium plasma, using onsager phenomenological coefficients