Engineering topics

Munafo, Paul M.

Publications and source records attributed to Munafo, Paul M..

At least 19 records

NASA NTRS2002

JANNAF Rocket Nozzle Technology Subcommittee Executive Committee Report

This viewgraph presentation provides information on the structure and activities of the panels of the Joint Army Navy NASA Air Force (JANNAF) Rocket Nozzle Technology Subcommittee. The panels profiled are the Processing Science and Materials Panel, the Nozzle Design, Test, and Evaluation Panel, the Nozzle Analysis and Modeling Panel, and the Nozzle Control Systems Panel. The presentation also lists meetings, workshops, and publications in which the subcommittee participated during the reporting period.

Lawrence, Timothy W.↗

NASA NTRS2002

Flow Patterns During Friction Stir Welding

Friction Stir Welding is a relatively new technique for welding that uses a cylindrical pin or nib inserted along the weld seam. The nib (usually threaded) and the shoulder in which it is mounted are rapidly rotated and advanced along the seam. Extreme deformation takes place leaving a fine equiaxed structure in the weld region., The flow of metal during Friction Stir Welding is investigated using a faying surface tracer and a nib frozen in place during welding. It is shown that material is transported by two processes. The first is a wiping of material from the advancing front side of the nib onto a zone of material that rotates and advances with the nib. The material undergoes a helical motion within the rotational zone that both rotates and advances and descends in the wash of the threads on the nib and rises on the outer part of the rotational zone. After one or more rotations, this material is sloughed off in its wake of the nib, primarily on the advancing side. The second process is an entrainment of material from the front retreating side of the nib that fills in between the sloughed off pieces from the advancing side.

Guerra, M.↗

NASA NTRS2002

Thermal Stir Welding: A New Solid State Welding Process

Thermal Stir Shielding is a revolutionary new welding process developed at NASA's Marshall Space Flight Center in Huntsville, AL. Thermal stir welding is similar to friction stir welding in that it joins similar or dissimilar materials without melting the parent material. However, unlike friction stir welding, the heating and stirring functions are independent allowing more degrees of freedom for greater process control. This paper introduces the mechanics of the thermal stir welding process. In addition, weld mechanical property data is presented for selected alloys as well as metallurgical analysis.

Ding, R. Jeffery↗

NASA NTRS2002

Development of a Launch Vehicle Manufacturing Process

One of the goals of this chapter is to provide sufficient information so that you can develop a manufacturing process for a potential launch vehicle. With the variety of manufacturing options available, you might ask how this can possibly be done in the span of a single chapter. Actually, it will be quite simple because a basic manufacturing process is nothing more than a set of logical steps that are iterated until they produce a desired product. Although these statements seem simple and logical, don't let this simplicity fool you. Manufacturing problems with launch vehicles and their subassemblies have been the primary cause of project failures because the vehicle concept delivered to the manufacturing floor could not be built as designed.

Vickers, John↗

NASA NTRS2002

Effect of Pin Tool Shape on Metal Flow During Friction Stir Welding

It has been shown that metal moves behind the rotating Friction Stir Pin Tool in two separate currents or streams. One current, mostly on the advancing side, enters a zone of material that rotates with the pin tool for one or more revolutions and eventually is abandoned behind the pin tool in crescent-shaped pieces. The other current, largely on the retreating side of the pin tool is moved by a wiping process to the back of the pin tool and fills in between the pieces of the rotational zone that have been shed by the rotational zone. This process was studied by using a faying surface copper trace to clarify the metal flow. Welds were made with pin tools having various thread pitches. Decreasing the thread pitch causes the large scale top-to-bottorn flow to break up into multiple vortices along the pin and an unthreaded pin tool provides insufficient vertical motion for there to be a stable rotational zone and flow of material via the rotational zone is not possible leading to porosity on the advancing side of the weld.

McClure, J. C.↗

NASA NTRS2002

Demonstration of Advanced C/SiC Cooled Ramp

Under a NASA contract, SPS is evaluating its C/SiC to metal brazing technique for the development of light, composite, actively cooled panels. The program first consisted of defining a system applicable to the X-33 nozzle ramp. SPS then performed evaluation tests for tube, composite, and braze material selection, and for the adaptation of braze process parameters to the parts geometry. SPS is presently manufacturing a 250x60 millimeter squared specimen, including 10 metallic tubes, which will be cycled in the NASA/GRC-CELL-22 test bed under engine representative conditions.

Bouquet, Clement↗

NASA NTRS2002

Composite Tanks and Pressure Vessel Development

Pressure vessels and tanks are vital to NASA missions. Tanks need to be lightweight and perform under the operational environments. Design and material limitations make it difficult to contain the fuels and oxidizers. Recent interest in 90% Hydrogen Peroxide adds to the challenge of containment. The majority of current tank technologies are not easily adaptable to conformal shapes. The cost of tooling-up for large tanks are magnified by sudden design changes. New launch vehicle concepts may require tanks and pressure vessels of a non-standard configuration. Scaled versions of new tanks have been fabricated and testing has begun. Second and third generation launch vehicles decisions will effect the path of research and development.

DeLay, Thomas K.↗

NASA NTRS2002

Thermophysical ESEM Characterization of Carbon Fibers

Coefficients of thermal expansion (CTE) of carbon fibers create residual stresses in aggressive manufacturing and service environments. In this effort, environmental scanning electron microscope (ESEM) is used for in situ observations of a carbon fiber cross-section up to 1000 C in order to evaluate the much neglected transverse CTE. The perimeter of fiber cross-section is calculated with the Scion image processing program from images that were taken at every 100 C increments. CTE values are calculated by linear regression of the strain data based on the perimeter changes. Furthermore, through SEM, WDS and TEM observations, we are in the process of bringing an interactive rationale between CTE, crystallinity and surface roughness of carbon fibers.

Sue, Jiwoong↗

NASA NTRS2002

Low Cost Manufacturing of Composite Cryotanks

This viewgraph presentation reviews research and development of cryotank manufacturing conducted by Northrup Grumman. The objectives of the research and development included the development and validation of manufacturing processes and technology for fabrication of large scale cryogenic tanks, the establishment of a scale-up and facilitization plan for full scale cryotanks, the development of non-autoclave composite manufacturing processes, the fabrication of subscale tank joints for element tests, the performance of manufacturing risk reduction trials for the subscale tank, and the development of full-scale tank manufacturing concepts.

Meredith, Brent↗

NASA NTRS2002

Development of the Ultra-Light Stretched Lens Array

At the last IEEE (Institute of Electrical and Electronics Engineers) PVSC (Photovoltaic Specialists Conference), the new stretched lens array (SLA) concept was introduced. Since that conference, the SLA team has made significant advances in the SLA technology, including component level improvements, array level optimization, space environment exposure testing, and prototype hardware fabrication and evaluation. This paper will describe the evolved version of the SLA, highlighting the improvements in the lens, solar cell, rigid panel structure, and complete solar array wing. The near term SLA will provide outstanding wing level performance: greater than 180 W/kg specific power, greater than 300 W/sq m power density, greater than 300 V operational voltage, and excellent durability in the space environment.

O'Neill, M. J.↗

NASA NTRS2002

NASA's National Center for Advanced Manufacturing

An investment in the future, NASA has designated a new initiative where government, industry, and academia collaborate to meet the manufacturing needs of future space systems. The Marshall Space Flight Center in Huntsville, Alabama has the principal responsibility for implementation of the National Center for Advanced Manufacturing (NCAM). The mission of the NCAM is to build partnerships that will jointly conduct program planning and develop strategies to perform manufacturing research and technology development for critical national missions.

Vickers, John H.↗

NASA NTRS2002

Characterization of Space Environmental Effects on Candidate Solar Sail Material

The National Aeronautics and Space Administration's (NASA) Marshall Space Flight Center (MSFC) is concentrating research into the utilization of photonic materials for spacecraft propulsion. Spacecraft propulsion, using photonic materials, will be achieved using a solar sail. A solar sail operates on the principle that photons, originating from the sun, impart pressure to the sail and therefore provide a source for spacecraft propulsion. The pressure imparted to a solar sail can be increased, up to a factor of two if the sunfacing surface is perfectly reflective. Therefore, these solar sails are generally composed of a highly reflective metallic sun-facing layer, a thin polymeric substrate and occasionally a highly emissive back surface. The Space Environmental Effects Team, at MSFC, is actively characterizing candidate solar sail material to evaluate the thermo-optical and mechanical properties after exposure to radiation environments simulating orbital environments. This paper describes the results of three candidate materials after exposure to a simulated Geosynchronous Transfer Orbit (GTO). This is the first known characterization of solar sail material exposed to space simulated radiation environments. The technique of radiation dose versus material depth profiling was used to determine the orbital equivalent exposure doses. The solar sail exposure procedures and results of the material characterization will be discussed.

Edwards, David↗

NASA NTRS2002

Thermal Stir Welding: A New Solid State Welding Process

Thermal stir welding is a new welding process developed at NASA's Marshall Space Flight Center in Huntsville, AL. Thermal stir welding is similar to friction stir welding in that it joins similar or dissimilar materials without melting the parent material. However, unlike friction stir welding, the heating, stirring and forging elements of the process are all independent of each other and are separately controlled. Furthermore, the heating element of the process can be either a solid-state process (such as a thermal blanket, induction type process, etc), or, a fusion process (YG laser, plasma torch, etc.) The separation of the heating, stirring, forging elements of the process allows more degrees of freedom for greater process control. This paper introduces the mechanics of the thermal stir welding process. In addition, weld mechanical property data is presented for selected alloys as well as metallurgical analysis.

Ding, R. Jeffrey↗

NASA NTRS2002

Effects of Space Environments: Techniques and Lessons from Selected Flight Experiments

Data describing long-term materials performance under exposure to space environments has accumulated gradually over the past four decades. The authors present here selected results from several previous flight experiments and operational spacecraft, and a few examples from a current flight experiment. As examples of environmental effects on materials, analysis of Gortex samples from the Passive Optical Sample Assembly II (POSA II) experiment on the MIR-Shuttle docking module will be described. Results from a previous evaluation of radiation on silverized Teflon from over ten individual satellites will be summarized. Several examples of contamination effects on materials properties will be presented. These include outgassing of solar arrays onto nearby surfaces of the POSA I experiment and contamination of certain surfaces of the Long Duration Exposure Facility (LDEF). Results from experiments with silicone contamination on satellites in geosynchronous orbit will be compared with measurements on the Solar Maximum satellite and the LDEF. A number of techniques are being attempted to extend the range of exposure conditions present on selected experiments. Use of focusing concentrators on the Effect of Space Environments on Materials (ESEM), POSA, and Materials International Space Station Experiment (MISSE) will be described. A technique for obtaining time-resolved data from a passive materials experiment will be described. The status of an on-going materials flight experiment, MISSE, will be reported. Finally, the authors will draw some conclusions about the current state of knowledge relating to materials chosen for spacecraft applications. Understanding of degradation mechanisms, state of predictive models, and the need to strengthen model inputs will be discussed.

Golden, J. L.↗

NASA NTRS2002

Survey of Beamed Energy Propulsion Concepts by the MSFC Space Environmental Effects Team

This will be a survey paper of work that was performed by the Space Environmental Effects Team at NASA's Marshall Space Flight Center in the area of laser energy propulsion concepts. Two types of laser energy propulsion techniques were investigated. The first was ablative propulsion, which used a pulsed ruby laser impacting on single layer coatings and films. The purpose of this investigation was to determine the laser power density that produced an optimum coupling coefficient for each type of material tested. A commercial off-the-shelf multi-layer film was also investigated for possible applications in ablative micro-thrusters, and its optimum coupling coefficient was determined. The second type of study measured the purely photonic force provided by a 300W CW YAG laser. In initial studies, the photon force resulting from the momentum of incident photons was measured directly using a vacuum compatible microbalance and these results were compared to theory. Follow-on work used the same CW laser to excite a stable optical cavity for the purpose of amplifying the available force from incident photons.

Gray, P. A.↗

NASA NTRS2002

DMA Modulus as a Screening Parameter for Compatibility of Polymeric Containment Materials with Various Solutions for use in Space Shuttle Microgravity Protein Crystal Growth (PCG) Experiments

Protein crystals are grown in microgravity experiments inside the Space Shuttle during orbit. Such crystals are basically grown in a five-component system containing a salt, buffer, polymer, organic and water. During these experiments, a number of different polymeric containment materials must be compatible with up to hundreds of different PCG solutions in various concentrations for durations up to 180 days. When such compatibility experiments are performed at NASA/MSFC (Marshall Space Flight Center) simultaneously on containment material samples immersed in various solutions in vials, the samples are rather small out of necessity. DMA4 modulus was often used as the primary screening parameter for such small samples as a pass/fail criterion for incompatibility issues. In particular, the TA Instruments DMA 2980 film tension clamp was used to test rubber O-rings as small in I.D. as 0.091 in. by cutting through the cross-section at one place, then clamping the stretched linear cord stock at each end. The film tension clamp was also used to successfully test short length samples of medical/surgical grade tubing with an O.D. of 0.125 in.

Wingard, Charles Doug↗

NASA NTRS2002

NASA Principal Center for Review of Clean Air Act Regulations

The Clean Air Act (CAA) regulations have greatly impacted materials and processes utilized in the manufacture of aerospace hardware. Code JE/ NASA's Environmental Management Division at NASA Headquarters recognized the need for a formal, Agency-wide review process of CAA regulations. Marshall Space Flight Center (MSFC) was selected as the 'Principal Center for Review of Clean Air Act Regulations'. This presentation describes the centralized support provided by MSFC for the management and leadership of NASA's CAA regulation review process.

Clark-Ingram, Marceia↗

NASA NTRS2002

Micro-Raman Analysis of Irradiated Diamond Films

Owing to its unique and robust physical properties, diamond is a much sought after material for use in advanced technologies such as Microelectromechanical Systems (MEMS). The volume and weight savings promised by MEMS-based devices are of particular interest to spaceflight applications. However, much basic materials science research remains to be completed in this field. Results of micro-Raman analysis of proton (1015 - 1017 H+/cm2 doses) irradiated chemical vapor deposited (CVD) diamond reveals that the microstructure is retained even after high radiation exposure.

Newton, R. L.↗