Members Can Post Anonymously On This Site
-
Similar Topics
-
By NASA
6 Min Read NASA Stennis Flashback: Learning About Rocket Engine Smoke for Safe Space Travel
An image shows engineers at an early version of the test stand at the Diagnostic Testbed Facility. From 1988 to the mid-1990s, NASA Stennis engineers operated the facility to conduct rocket engine plume exhaust diagnostics and learn more about the space shuttle main engine combustion process. Credits: NASA/Stennis NASA’s Stennis Space Center near Bay St. Louis, Mississippi, is widely known as the nation’s largest rocket propulsion test site. More than 35 years ago, it also served as a hands-on classroom for NASA engineers seeking to improve the efficiency of space shuttle main engines.
From 1988 to the mid-1990’s, NASA Stennis engineers operated a Diagnostic Test Facility to conduct rocket engine plume exhaust diagnostics and learn more about the space shuttle main engine combustion process. The effort also laid the groundwork for the frontline research-and-development testing conducted at the center today.
“The Diagnostic Test Facility work is just another example of the can-do, will-do attitude of the NASA Stennis team and of its willingness to support the nation’s space exploration program in all ways needed and possible,” said Joe Schuyler, director of the NASA Stennis Engineering and Test Directorate.
The Diagnostic Test Facility work is just another example of the can-do, will-do attitude of the NASA Stennis team…
joe schuyler
NASA Stennis Engineering and Test Directorate Director
Tests conducted at the Diagnostic Testbed Facility played a critical safety role for engine operations and also provided a real-time opportunity for NASA Stennis engineers to learn about exhaust diagnostics. NASA/Stennis An image shows the Diagnostic Testbed Facility test stand data acquisition trailer. NASA/Stennis The Need
Envision a rocket or space vehicle launching into the sky. A trail of bright exhaust, known as the engine plume, follows. As metals wear down in the engines from the intense heat of the combustion process, the flame glows with colors, some visible, such as orange or yellow, and others undetectable by the human eye.
The colors tell a story – about the health and operation of the engine and its components. For space shuttle main engines, which flew on multiple missions, engineers needed to understand that story, much as a doctor needs to understand the condition of a human body during checkup, to ensure future engine operation.
Where better place to study such details than the nation’s premier propulsion test site? Paging NASA Stennis.
An image shows the rocket motor and thruster at the Diagnostic Testbed Facility. NASA/Stennis An image shows the Diagnostic Testbed Facility blended team of NASA personnel and contractors. Kneeling, left to right, is Brantly Adams (NASA), Felix Bircher (Sverdrup Technology), Dennis Butts (Sverdrup Technology), and Nikki Raines (Sverdrup Technology). Standing, left to right, NASA astronaut John Young, Greg Sakala (Sverdrup Technology), Barney Nokes (Sverdrup Technology), John Laboda (Sverdrup Technology), Glenn Varner (NASA), Stan Gill (NASA), Bud Nail (NASA), Don Sundeen (Sverdrup Technology), NASA astronaut John Blaha.NASA/Stennis The Facility
NASA Stennis has long enabled and supported innovative and collaborative work to benefit both the agency and the commercial space industry. When NASA came calling in the late 1980s, site engineers went to work on a plan to study space shuttle main engine rocket exhaust.
The concept for an enabling structure about the size of a home garage was born in October 1987. Five months later, construction began on a Diagnostic Testbed Facility to provide quality research capabilities for studying rocket engine exhaust and learning more about the metals burned off during hot fire.
The completed facility featured a 1,300-square-foot control and data analysis center, as well as a rooftop observation deck. Small-scale infrastructure was located nearby for testing a 1,000-pound-thrust rocket engine that simulated the larger space shuttle main engine. The 1K engine measured about 2 feet in length and six inches in diameter. Using a small-scale engine allowed for greater flexibility and involved less cost than testing the much-larger space shuttle engine.
An image shows Sverdrup Technology’s Robert Norfleet as he preps the dopant injection system for testing at the Diagnostic Testbed Facility. The goal of the facility was to inject known metals and materials in a chemical form and then look at what emissions were given off. During one test, generally a six or 12 second test, operators would inject three known dopants, or substances, and then run distilled water between each test to clean out the system.NASA/Stennis An image shows engineers Stan Gill, Robert Norfleet, and Elizabeth Valenti in the Diagnostic Testbed Facility test control center. NASA/Stennis The Process
Engineers could quickly conduct multiple short-duration hot fires using the smaller engine. A six-second test provided ample time to collect data from engine exhaust that reached as high as 3,900 degrees Fahrenheit.
Chemical solutions simulating engine materials were injected into the engine combustion chamber for each hot fire. The exhaust plume then was analyzed using a remote camera, spectrometer, and microcomputers to determine what colors certain metals and elements emit when burning.
Each material produced a unique profile. By matching the profiles to the exhaust of space shuttle main engine tests conducted at NASA Stennis, determinations could be made about which engine components were undergoing wear and what maintenance was needed.
We learned about purging, ignition, handling propellants, high-pressure gases, and all the components you had to have to make it work…It was a very good learning experience.
Glenn Varner
NASA Stennis Engineer
The Benefits
The Diagnostic Testbed Facility played a critical safety role for engine operations and also provided a real-time opportunity for NASA Stennis engineers to learn about exhaust diagnostics.
Multiple tests were conducted. The average turnaround time between hot fires was 18 to 20 minutes with the best turnaround from one test to another taking just 12 minutes. By January 1991, the facility had recorded a total of 588 firings for a cumulative 3,452 seconds.
As testing progressed, the facility team evolved into a collection of experts in plume diagnostics. Longtime NASA Stennis engineer Glenn Varner serves as the mechanical operations engineer at the Thad Cochran Test Stand, where he contributed to the successful testing of the first SLS (Space Launch System) core stage onsite.
However, much of Varner’s hands-on experience came at the Diagnostic Test Facility. “We learned about purging, ignition, handling propellants, high-pressure gases, and all the components you had to have to make it work,” he said. “It was a very good learning experience.”
An image shows the Diagnostic Testbed Facility team working in the test control center. Seated, left to right, is Steve Nunez, Glenn Varner, Joey Kirkpatrick. Standing, back row left to right, is Scott Dracon and Fritz Policelli. Vince Pachel is pictured standing wearing the headset. NASA/Stennis The physical remnants of the Diagnostic Testbed Facility are barely recognizable now, but that spirit and approach embodied by that effort and its teams continues in force at the center.
joe schuyler
NASA Stennis Engineering and Test Directorate Director
The Impact
The Diagnostic Testbed Facility impacted more than just those engineers involved in the testing. Following the initial research effort, the facility underwent modifications in January 1993. Two months later, facility operators completed a successful series of tests on a small-scale liquid hydrogen turbopump for a California-based aerospace company.
The project marked an early collaboration between the center and a commercial company and helped pave the way for the continued success of the NASA Stennis E Test Complex. Building on Diagnostic Testbed Facility knowledge and equipment, the NASA Stennis complex now supports multiple commercial aerospace projects with its versatile infrastructure and team of propulsion test experts.
“The physical remnants of the Diagnostic Testbed Facility are barely recognizable now,” Schuyler said. “But that spirit and approach embodied by that effort and its teams continues in force at the center.”
Additional Information
NASA Stennis has leveraged hardware and expertise from the Diagnostic Testbed Facility to provide benefit to NASA and industry for two decades and counting.
The facility’s thruster, run tanks, valves, regulators and instrumentation were used in developing the versatile four-stand E Test Complex at NASA Stennis that includes 12 active test cell positions capable of various component, engine, and stage test activities.
“The Diagnostic Testbed Facility was the precursor to that,” said NASA engineer Glenn Varner. “Everything but the structure still in the grass moved to the E-1 Test Stand, Cell 3. Plume diagnostics was part of the first testing there.”
When plume diagnostic testing concluded at E-1, equipment moved to the E-3 Test Stand, where the same rocket engine used for the Diagnostic Testbed Facility has since performed many test projects.
The Diagnostic Testbed Facility thruster also has been used for various projects at E-3, most recently in a project for the exploration upper stage being built for use on future Artemis missions.
In addition to hardware, engineers who worked at the Diagnostic Testbed Facility also moved on to support E Test Complex projects. There, they helped new NASA engineers learn how to handle gaseous hydrogen and liquid hydrogen propellants. Engineers learned about purging, ignition, and handling propellants and all the components needed for a successful test.
“From an engineering perspective, the more knowledge you have of the processes and procedures to make propulsion work, the better off you are,” Varner said. “It applied then and still applies today. The Diagnostic Testbed Facility contributed to the future development of NASA Stennis infrastructure and expertise.”
Share
Details
Last Updated Feb 25, 2025 EditorNASA Stennis CommunicationsContactC. Lacy Thompsoncalvin.l.thompson@nasa.gov / (228) 688-3333LocationStennis Space Center Related Terms
Stennis Space Center Explore More
4 min read NASA Stennis Flashback: Shuttle Team Achieves Unprecedented Milestone
Article 7 months ago 4 min read Stennis Flashback: NASA Test Series Leads to Bold Space Shuttle Flight
It may have been small, but the white puff of smoke exiting the B-2 Test…
Article 2 years ago Keep Exploring Discover More Topics From NASA Stennis
NASA’s Stennis Space Center History
NASA Stennis Images
NASA Stennis Fact Sheets
NASA Stennis Front Door
View the full article
-
-
By NASA
2 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
NASA marked a key milestone Feb. 18 with installation of RS-25 engine No. E20001, the first new production engine to help power the SLS (Space Launch System) rocket on future Artemis missions to the Moon.
The engine, built by lead SLS engines contractor L3Harris (formerly Aerojet Rocketdyne), was installed on the Fred Haise Test Stand in preparation for acceptance testing next month. It represents the first of 24 new flight engines being built for missions, beginning with Artemis V.
Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin The NASA Stennis test team will conduct a full-duration, 500-second hot fire, providing critical performance data to certify the engine for use on a future mission. During missions to the Moon, RS-25 engines fire for about 500 seconds and up to the 111% power level to help launch SLS, with the Orion spacecraft, into orbit.
The engine arrived at the test stand from the L3Harris Engine Assembly Facility on the engine transport trailer before being lifted onto the vertical engine installer (VEI) on the west side deck. After rolling the engine into the stand, the team used the VEI to raise and secure it in place.
The upcoming acceptance test follows two certification test series that helped verify the new engine production process and components meet all performance requirements. Four RS-25 engines help launch SLS, producing up to 2 million pounds of combined thrust.
All RS-25 engines for Artemis missions are tested and proven flightworthy at NASA Stennis prior to use. RS-25 tests are conducted by a team of operators from NASA, L3Harris, and Syncom Space Services, prime contractor for site facilities and operations.
Explore More NASA Stennis Images View the full article
-
By NASA
3 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
NASA’s X-59 lights up the night sky with its unique Mach diamonds, also known as shock diamonds, during maximum afterburner testing at Lockheed Martin Skunk Works in Palmdale, California. The test demonstrated the engine’s ability to generate the thrust required for supersonic flight, advancing NASA’s Quesst mission.Credit: Lockheed Martin/Gary Tice NASA’s X-59 quiet supersonic research aircraft took another successful step toward flight with the conclusion of a series of engine performance tests.
In preparation for the X-59’s planned first flight this year, NASA and Lockheed Martin successfully completed the aircraft’s engine run tests in January. The engine, a modified F414-GE-100 that powers the aircraft’s flight and integrated subsystems, performed to expectations during three increasingly complicated tests that ran from October through January at contractor Lockheed Martin’s Skunk Works facility in Palmdale, California.
“We have successfully progressed through our engine ground tests as we planned,” said Raymond Castner, X-59 propulsion lead at NASA’s Glenn Research Center in Cleveland. “We had no major showstoppers. We were getting smooth and steady airflow as predicted from wind tunnel testing. We didn’t have any structural or excessive vibration issues. And parts of the engine and aircraft that needed cooling were getting it.”
The tests began with seeing how the aircraft’s hydraulics, electrical, and environmental control systems performed when the engine was powered up but idling. The team then performed throttle checks, bringing the aircraft up to full power and firing its afterburner – an engine component that generates additional thrust – to maximum.
In preparation for the X-59’s planned first flight this year, NASA and Lockheed Martin successfully completed the aircraft’s engine run tests in January. Testing included electrical, hydraulics, and environmental control systems.
Credit: NASA/Lillianne Hammel A third test, throttle snaps, involved moving the throttle swiftly back and forth to validate that the engine responds instantly. The engine produces as much as 22,000 pounds of thrust to achieve a desired cruising speed of Mach 1.4 (925 miles per hour) at an altitude of approximately 55,000 feet.
The X-59’s engine, similar to those aboard the U.S. Navy’s F-18 Super Hornet, is mounted on top of the aircraft to reduce the level of noise reaching the ground. Many features of the X-59, including its 38-foot-long nose, are designed to lower the noise of a sonic boom to that of a mere “thump,” similar to the sound of a car door slamming nearby.
Next steps before first flight will include evaluating the X-59 for potential electromagnetic interference effects, as well as “aluminum bird” testing, during which data will be fed to the aircraft under both normal and failure conditions. A series of taxi tests and other preparations will also take place before the first flight.
The X-59 is the centerpiece of NASA’s Quesst mission, which seeks to solve one of the major barriers to commercial supersonic flight over land by making sonic booms quieter.
Explore More
3 min read NASA Supports GoAERO University Awardees for Emergency Aircraft Prototyping
Article 6 hours ago 2 min read Wind Over Its Wing: NASA’s X-66 Model Tests Airflow
Article 6 days ago 9 min read Combustor Facilities
Article 1 week ago
View the full article
-
By NASA
1 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
NASA’s X-59 quiet supersonic research aircraft completed its first maximum afterburner test at Lockheed Martin’s Skunk Works facility in Palmdale, California. This full-power test, during which the engine generates additional thrust, validates the additional power needed for meeting the testing conditions of the aircraft. The X-59 is the centerpiece of NASA’s Quesst mission, which aims to overcome a major barrier to supersonic flight over land by reducing the noise of sonic booms.Lockheed Martin Corporation/Garry Tice NASA completed the first maximum afterburner engine run test on its X-59 quiet supersonic research aircraft on Dec. 12. The ground test, conducted at Lockheed Martin’s Skunk Works facility in Palmdale, California, marks a significant milestone as the X-59 team progresses toward flight.
An afterburner is a component of some jet engines that generates additional thrust. Running the engine, an F414-GE-100, with afterburner will allow the X-59 to meet its supersonic speed requirements. The test demonstrated the engine’s ability to operate within temperature limits and with adequate airflow for flight. It also showed the engine’s ability to operate in sync with the aircraft’s other subsystems.
The X-59 is the centerpiece of NASA’s Quesst mission, which seeks to solve one of the major barriers to supersonic flight over land by making sonic booms quieter. The X-59’s first flight is expected to occur in 2025.
Share
Details
Last Updated Dec 20, 2024 EditorDede DiniusContactMatt Kamletmatthew.r.kamlet@nasa.gov Related Terms
Aeronautics Aeronautics Research Mission Directorate Armstrong Flight Research Center Commercial Supersonic Technology Integrated Aviation Systems Program Low Boom Flight Demonstrator Quesst (X-59) Supersonic Flight Explore More
2 min read NASA, Notre Dame Connect Students to Inspire STEM Careers
Article 4 hours ago 2 min read NASA Flight Rerouting Tool Curbs Delays, Emissions
Article 4 hours ago 3 min read Atmospheric Probe Shows Promise in Test Flight
Article 1 week ago Keep Exploring Discover More Topics From NASA
Armstrong Flight Research Center
Aeronautics
Supersonic Flight
Quesst: The Vehicle
View the full article
-
-
Check out these Videos
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.