Acoustic Test Characterization of Melamine Foam for Usage in NASA's Payload Fairing Acoustic Attenuation Systems

The external acoustic liftoff levels predicted for NASA's future heavy lift launch vehicles are expected to be significantly higher than the environment created by today's commercial launch vehicles. This creates a need to develop an improved acoustic attenuation system for future NASA payload fairings. NASA Glenn Research Center initiated an acoustic test series to characterize the acoustic performance of melamine foam, with and without various acoustic enhancements. This testing was denoted as NEMFAT, which stands for NESC Enhanced Melamine Foam Acoustic Test, and is the subject of this paper. Both absorption and transmission loss testing of numerous foam configurations were performed at the Riverbank Acoustical Laboratory in July 2013. The NEMFAT test data provides an initial acoustic characterization and database of melamine foam for NASA. Because of its acoustic performance and lighter mass relative to fiberglass blankets, melamine foam is being strongly considered for use in the acoustic attenuation systems of NASA's future launch vehicles

NASA Engineering and Safety Center (NESC) Enhanced Melamine (ML) Foam Acoustic Test (NEMFAT)

The NASA Engineering and Safety Center (NESC) funded a proposal to achieve initial basic acoustic characterization of ML (melamine) foam, which could serve as a starting point for a future, more comprehensive acoustic test program for ML foam. A project plan was developed and implemented to obtain acoustic test data for both normal and enhanced ML foam. This project became known as the NESC Enhanced Melamine Foam Acoustic Test (NEMFAT). This document contains the outcome of the NEMFAT project

Acoustic Test Characterization of Melamine Foam for Usage in NASA's Payload Fairing Acoustic Attenuation Systems

The external acoustic liftoff levels predicted for NASA's future heavy lift launch vehicles are expected to be significantly higher than the environment created by today's commercial launch vehicles. This creates a need to develop an improved acoustic attenuation system for future NASA payload fairings. NASA Glenn Research Center initiated an acoustic test series to characterize the acoustic performance of melamine foam, with and without various acoustic enhancements. This testing was denoted as NEMFAT, which stands for NESC Enhanced Melamine Foam Acoustic Test, and is the subject of this paper. Both absorption and transmission loss testing of numerous foam configurations were performed at the Riverbank Acoustical Laboratory in July 2013. The NEMFAT test data provides an initial acoustic characterization and database of melamine foam for NASA. Because of its acoustic performance and lighter mass relative to fiberglass blankets, melamine foam is being strongly considered for use in the acoustic attenuation systems of NASA's future launch vehicles

Statistical Analysis of a Large Sample Size Pyroshock Test Data Set Including Post Flight Data Assessment

The Earth Observing System (EOS) Terra spacecraft was launched on an Atlas IIAS launch vehicle on its mission to observe planet Earth in late 1999. Prior to launch, the new design of the spacecraft's pyroshock separation system was characterized by a series of 13 separation ground tests. The analysis methods used to evaluate this unusually large amount of shock data will be discussed in this paper, with particular emphasis on population distributions and finding statistically significant families of data, leading to an overall shock separation interface level. The wealth of ground test data also allowed a derivation of a Mission Assurance level for the flight. All of the flight shock measurements were below the EOS Terra Mission Assurance level thus contributing to the overall success of the EOS Terra mission. The effectiveness of the statistical methodology for characterizing the shock interface level and for developing a flight Mission Assurance level from a large sample size of shock data is demonstrated in this paper

Effect of Coversheet Materials on the Acoustic Performance of Melamine Foam

Melamine foam is a highly absorptive material that is often used inside the payload fairing walls of a launch vehicle. This foam reduces the acoustic excitation environment that the spacecraft experiences during launch. Often, the melamine foam is enclosed by thin coversheet materials for contamination protection, thermal protection, and electrostatic discharge control. Previous limited acoustic testing by NASA Glenn Research Center has shown that the presence of a coversheet material on the melamine foam can have a significant impact on the absorption coefficient and the transmission loss. As a result of this preliminary finding a more extensive acoustic test program using several different coversheet materials on melamine foam was performed. Those test results are summarized in this paper. Additionally, a method is provided to use the acoustic absorption and transmission loss data obtained from panel level testing to predict their combined effect for the noise reduction of a launch vehicle payload fairing

Acoustic Test Results of Melamine Foam with Application to Payload Fairing Acoustic Attenuation Systems

A spacecraft at launch is subjected to a harsh acoustic and vibration environment resulting from the passage of acoustic energy, created during the liftoff of a launch vehicle, through the vehicle's payload fairing. In order to ensure the mission success of the spacecraft it is often necessary to reduce the resulting internal acoustic sound pressure levels through the usage of acoustic attenuation systems. Melamine foam, lining the interior walls of the payload fairing, is often utilized as the main component of such a system. In order to better understand the acoustic properties of melamine foam, with the goal of developing improved acoustic attenuation systems, NASA has recently performed panel level testing on numerous configurations of melamine foam acoustic treatments at the Riverbank Acoustical Laboratory. Parameters assessed included the foam's thickness and density, as well as the effects of a top outer cover sheet material and mass barriers embedded within the foam. This testing followed the ASTM C423 standard for absorption and the ASTM E90 standard for transmission loss. The acoustic test data obtained and subsequent conclusions are the subjects of this paper

Statistical Treatment of Earth Observing System Pyroshock Separation Test Data

The Earth Observing System (EOS) AM-1 spacecraft for NASA's Mission to Planet Earth is scheduled to be launched on an Atlas IIAS vehicle in June of 1998. One concern is that the instruments on the EOS spacecraft are sensitive to the shock-induced vibration produced when the spacecraft separates from the launch vehicle. By employing unique statistical analysis to the available ground test shock data, the NASA Lewis Research Center found that shock-induced vibrations would not be as great as the previously specified levels of Lockheed Martin. The EOS pyroshock separation testing, which was completed in 1997, produced a large quantity of accelerometer data to characterize the shock response levels at the launch vehicle/spacecraft interface. Thirteen pyroshock separation firings of the EOS and payload adapter configuration yielded 78 total measurements at the interface. The multiple firings were necessary to qualify the newly developed Lockheed Martin six-hardpoint separation system. Because of the unusually large amount of data acquired, Lewis developed a statistical methodology to predict the maximum expected shock levels at the interface between the EOS spacecraft and the launch vehicle. Then, this methodology, which is based on six shear plate accelerometer measurements per test firing at the spacecraft/launch vehicle interface, was used to determine the shock endurance specification for EOS. Each pyroshock separation test of the EOS spacecraft simulator produced its own set of interface accelerometer data. Probability distributions, histograms, the median, and higher order moments (skew and kurtosis) were analyzed. The data were found to be lognormally distributed, which is consistent with NASA pyroshock standards. Each set of lognormally transformed test data produced was analyzed to determine if the data should be combined statistically. Statistical testing of the data's standard deviations and means (F and t testing, respectively) determined if data sets were significantly different at a 95-percent confidence level. If two data sets were found to be significantly different, these families of data were not combined for statistical purposes. This methodology produced three separate statistical data families of shear plate data. For each population, a P99.1/50 (probability/confidence) per-separation-nut firing level was calculated. By using the binomial distribution, Lewis researchers determined that this pernut firing level was equivalent to a P95/50 per-flight confidence level. The overall envelope of the per-flight P95/50 levels led to Lewis' recommended EOS interface shock endurance specification. A similar methodology was used to develop Lewis' recommended EOS mission assurance levels. The available test data for the EOS mission are significantly larger than for a normal mission, thus increasing the confidence level in the calculated expected shock environment. Lewis significantly affected the EOS mission by properly employing statistical analysis to the data. This analysis prevented a costly requalification of the spacecraft's instruments, which otherwise would have been exposed to significantly higher test levels

The Testing Behind the Test Facility: the Acoustic Design of the NASA Glenn Research Center's World-Class Reverberant Acoustic Test Facility

The National Aeronautics and Space Administration (NASA) Glenn Research Center (GRC) is leading the design and build of the new world-class vibroacoustic test capabilities at the NASA GRC s Plum Brook Station in Sandusky, Ohio, U.S.A. Benham Companies, LLC is currently constructing modal, base-shake sine and reverberant acoustic test facilities to support the future testing needs of NASA s space exploration program. The large Reverberant Acoustic Test Facility (RATF) will be approximately 101,000 ft3 in volume and capable of achieving an empty chamber acoustic overall sound pressure level (OASPL) of 163 dB. This combination of size and acoustic power is unprecedented amongst the world s known active reverberant acoustic test facilities. The key to achieving the expected acoustic test spectra for a range of many NASA space flight environments in the RATF is the knowledge gained from a series of ground acoustic tests. Data was obtained from several NASA-sponsored test programs, including testing performed at the National Research Council of Canada s acoustic test facility in Ottawa, Ontario, Canada, and at the Redstone Technical Test Center acoustic test facility in Huntsville, Alabama, U.S.A. The majority of these tests were performed to characterize the acoustic performance of the modulators (noise generators) and representative horns that would be required to meet the desired spectra, as well as to evaluate possible supplemental gas jet noise sources. The knowledge obtained in each of these test programs enabled the design of the RATF sound generation system to confidently advance to its final acoustic design and subsequent ongoing construction

Acoustic Testing of the Cassini Spacecraft and Titan 4 Payload Fairing

NASA Lewis Research Center recently led a multi-organizational acoustic test program. This testing consisted of acoustically exciting a Cassini spacecraft simulator in a full scale 60 foot high Titan 4 payload fairing with various acoustic blanket designs and configurations in a large reverberant acoustic chamber. The primary purpose of this test program was to measure the fairing's internal acoustics and spacecraft vibration, especially the Radioisotope Thermoelectric Generators (RTG) vibration, and to quantify the mitigation efforts in reducing these levels. Key to this reduction effort was the utilization of new acoustic blanket designs. This paper will provide the background and rationale for performing this test program, state the test program's primary and secondary objectives and describe the test matrix, hardware and instrumentation. A second part companion paper will provide the test results and data analysis

The Development of the Acoustic Design of NASA Glenn Research Center's New Reverberant Acoustic Test Facility

The National Aeronautics and Space Administration (NASA) Glenn Research Center (GRC) is leading the design and build of the new world-class vibroacoustic test capabilities at the NASA GRC s Plum Brook Station in Sandusky, Ohio. Benham Companies, LLC is currently constructing modal, base-shake sine and reverberant acoustic test facilities to support the future testing needs of NASA s space exploration program. The large Reverberant Acoustic Test Facility (RATF) will be approximately 101,000 ft3 in volume and capable of achieving an empty chamber acoustic overall sound pressure level (OASPL) of 163 dB. This combination of size and acoustic power is unprecedented amongst the world s known active reverberant acoustic test facilities. The key to achieving the expected acoustic test spectra for a range of many NASA space flight environments in the RATF is the knowledge gained from a series of ground acoustic tests. Data was obtained from several NASA-sponsored test programs, including testing performed at the National Research Council of Canada s acoustic test facility in Ottawa, Ontario, Canada, and at the Redstone Technical Test Center acoustic test facility in Huntsville, Alabama. The majority of these tests were performed to characterize the acoustic performance of the modulators (noise generators) and representative horns that would be required to meet the desired spectra, as well as to evaluate possible supplemental gas jet noise sources. The knowledge obtained in each of these test programs enabled the design of the RATF sound generation system to confidently advance to its final acoustic design and subsequent on-going construction