Engineering topics
Publications and source records attributed to Workman, Gary L..
Collection of three reports surveys emerging technology of chemical fingerprinting, which can be defined, loosely, as systematic application of modern methods of analysis to determine elemental or molecular compositions of materials, measure relative amounts of constituents of materials, and/or measure other relevant properties of materials.
Proposed optical-fiber sensor detects small changes in pressure in elastomeric O-ring or similar pressure seal, which may indicate deterioration of seal and interpreted as indications of incipient failure. According to concept, length of optical fiber embedded in seal. Light-emitting diode illuminates one end of fiber; photodetector measures intensity of light emerging from other end. Pressure-induced changes in seal bend fiber slightly, altering microbending-induced loss of light from fiber and alter intensity of light at photodetector. Change in intensity approximately proportional to change in pressure.
The control of surface contamination in the manufacture of space hardware can become a critical step in the production process. Bonded surfaces have been shown to be affected markedly by contamination. It is important to insure surface cleanliness by preventing contamination prior to bonding. In this vein techniques are needed in which the contamination which may affect bonding are easily found and removed. Likewise, if materials which are detrimental to bonding are not easily removed, then they should not be used in the manufacturing process. This study will address the development of techniques to locate and quantify contamination levels of particular contaminants. With other data becoming available from MSFC and its contractors, this study will also quantify how certain contaminants affect bondlines and how easily they are removed in manufacturing.
Fluoride glasses have great potential for optical fiber communications due to the high transmittance when no microcrystallites occur during drawing operations. This work has developed apparatus to test the occurrence of microcrystallites during recrystallization in reduced gravity on the KC-135. The apparatus allows fluoride glass fiber, such as ZBLAN, to be melted and recrystallized during both the low and high g portions the parabolic flight.
A major step in transferring technology is to disseminate information about new developments to the appropriate sector(s). A useful vehicle for transferring technology from the government sector to industry has been demonstrated with the use of periodical and journal announcements to highlight technological achievements which may meet the needs of industries other than the one who developed the innovation. To meet this end, NASA has very successfully pursued the goal of identifying technical innovations through the national circulation publication; NASA Tech Briefs. At one time the Technology Utilization Offices of the various centers coordinated the selection of appropriate technologies through a common channel. In recent years, each NASA field center has undertaken the task of evaluating submittals for Tech Brief publication independently of the others. The University of Alabama in Huntsville was selected to assist MSFC in evaluating technology developed under the various programs managed by the NASA center for publication in the NASA Tech Briefs journal. The primary motivation for the NASA Tech Briefs publication is to bring to the attention of industry the various NASA technologies which, in general, have been developed for a specific aerospace requirement, but has application in other areas. Since there are a number of applications outside of NASA that can benefit from innovative concepts developed within the MSPC programs, the ability to transfer technology to other sectors is very high. In most cases, the innovator(s) are not always knowledgeable about other industries which might potentially benefit from their innovation. The evaluation process can therefore contribute to the list of potential users through a knowledgeable evaluator.
The research activity for this first year has focussed on three distinct activities: (1) the use of an integrating sphere to improve upon the gathering of spectral data from a variety of surfaces; (2) the use of optical fiber spectrometry to determine levels of contamination from tape residues on critical bonding surfaces; and (3) an exploratory activity in the use of spectroscopic ellipsometry for the analysis of thin films of contaminants on critical surfaces has also begun.
Propellant characteristics for solid rocket motors were not completely determined for its use as a processing variable in today's production facilities. A major effort to determine propellant characteristics obtainable through ultrasonic measurement techniques was performed in this task. The information obtained was then used to determine the uniformity of manufacturing methods and/or the ability to determine non-uniformity in processes.
Hardnesses and tensile strengths greater. Welds made under right conditions in low gravity appear superior to those made under high gravity. Conclusion drawn from results of welding experiments conducted during low- and high-gravity-simulating maneuvers of KC-135 airplane. Results have implications not only for welding in outer space but also for repeated rapid welding on Earth or in airplanes under simulated low gravity to obtain unusually strong joints.
Processing and data reduction of holographic images from Spacelab presents some interesting challenges in determining the effects of microgravity on crystal growth processes. Evaluation of several processing techniques, including the Computerized Holographic Image Processing System and the Software Development Package (SDP151) will provide fundamental information for holographic and schlieren analysis of the space flight data.
Directional solidification experiments have been utilized throughout the Materials Processing in Space Program to provide an experimental platform which minimizes variables in solidification experiments. Because of the wide-spread use of this experimental technique in space-based research, it has become apparent that a better understanding of all the phenomena occurring during solidification can be better understood if direct visualization of the solidification interface were possible.
Shearography has emerged as a useful technique for nondestructible evaluation and materials characterization of aerospace materials. A suitable candidate for the technique is to determine the response of debonds on foam-metal interfaces such as the TPS system on the External Tank. The main thrust is to develop a model which allows valid interpretation of shearographic information on TPS type systems. Confirmation of the model with shearographic data will be performed.
SUPER PHACOMP developed after research into many versions of PHACOMP algorithm. Resulting program implements three of these versions, enabling comparison of results to give greater reliability to predictions. Inasmuch as certain calculations common to each, three versions woven together for efficiency. While prediction of formation of sigma phase is primary function, also performs other calculations of properties of alloys. Program benefits anyone working in design of alloys. Written in BASIC.
Spacecraft structures and surface materials exposed to the space environment for extended periods, up to thirty years, have increased potential for damage from long term exposure to the combined space environment including solar ultraviolet radiation, electrons, and protons and orbiting space debris. The space environment in which the Space Station Freedom and other space platforms will orbit is truly a hostile environment. For example, the currently estimated integral fluence for electrons above 1 Mev at 2000 nautical miles is above 2 x 10(exp 10) electrons/cm(sup 2)/day and the proton integral fluence is above 1 x 10(exp 9) protons/cm(sup 2)/day. At the 200 - 400 nautical miles, which is more representative of the altitude which will provide the environment for the Space Station, each of these fluences will be proportionately less; however, the data indicates that the radiation environment will obviously have an effect on structural materials exposed to the environment for long durations. The effects of ultraviolet radiation, particularly in the vacuum ultraviolet (less than 200 nm wavelength) is more difficult to characterize at this time. Very little data is available in the literature which can be used for determining the life cycle of a material placed in space for extended durations of time. In order to obtain critical data for planning and designing of spacecraft systems, use of a small vacuum system at the Environmental Effects Facility at MSFC, which can be used for these purposes was used. A special effort was made to build up this capability during the course of this research effort and perform a variety of experiments on materials proposed for the Space Station. A description of the apparatus and the procedure devised to process potential spacecraft materials is included.
Containerless processing of materials provides an excellent opportunity to study nucleation phenomena and produce unique materials, primarily through the formation of metastable phases and deep undercoolings. Deep undercoolings can be readily achieved in falling drops of molten material. Extended solute solubilities and greatly refined microstructures can also be obtained in containerless processing experiments. The Drop Tube Facility at Marshall Space Flight Center has played an important role in enhancing that area of research. Previous experiments performed in the Drop Tube with refractory metals has shown very interesting microstructural changes associated with deep undercoolings. It is apparent also that the microstructure of the deep undercooled species may be changing due to the release of the latent heat of fusion during recalescence. For scientific purposes, it is important to be able to differentiate between the microstructures of the two types of metallic species. A review of the literature shows that although significant advances have been made with respect to the engineering aspects of rapid solidification phenomena, there is still much to be learned in terms of understanding the basic phenomena. The two major ways in which rapid solidification processing provides improved structures and hence improved properties are: (1) production of refined structures such as fine dendrites and eutectics, and (2) production of new alloy compositions, microstructures, and phases through extended solid solubility, new phase reaction sequences, and the formation of metallic-glass microstructures. The objective of this work has been to determine the optimal methodology required to extract this excess energy without affecting the thermo-physical parameters of the under-cooled melt. In normal containerless processing experiments recalescence occurs as the melt returns toward the melting point in order to solidify. A new type of experiment is sought in which the resultant microstructure of the undercooled species is frozen in without going through the melting point regime and subsequent near equilibrium solidification of the remaining liquid. This experimental approach entails the design of an appropriate melt spinning system which is compatible with Drop Tube operations and processing constraints. That work is the goal of this study.
This report covers the activities performed in the Drop Tube Study which The University of Alabama in Huntsville designed, fabricated and performed various low gravity experiments in materials processing from November 1, 1991 through October 30, 1992. During the performance of this contract the utilization of these ground-based containerless processing facilities has been instrumental in providing the opportunity to determine the feasibility of performing a number of solidification experiments in a simulated space environment, without the expense of a space-based experiment. A number of periodic reports have been given to the TCOR during the course of this contract hence this final report is meant only to summarize the many activities performed and not redundantly cover materials already submitted.
A reduced gravity fiber pulling apparatus (FPA) was constructed in order to study the effects of gravity on glass fiber formation. The apparatus was specifically designed and built for use on NASA's KC-135 aircraft. Four flights have been completed to date during which E-glass fiber was successfully produced in simulated zero, high, and lunar gravity environments. In addition simulated lunar soil samples were tested for their fiber producing properties using the FPA.
The original research objective was to demonstrate the ability of optical fiber spectrometry to determine contamination levels on solid rocket motor cases in order to identify surface conditions which may result in poor bonds during production. The capability of using the spectral features to identify contaminants with other sensors which might only indicate a potential contamination level provides a real enhancement to current inspection systems such as Optical Stimulated Electron Emission (OSEE). The optical fiber probe can easily fit into the same scanning fixtures as the OSEE. The initial data obtained using the Guided Wave Model 260 spectrophotometer was primarily focused on determining spectra of potential contaminants such as HD2 grease, silicones, etc. However, once we began taking data and applying multivariate analysis techniques, using a program that can handle very large data sets, i.e., Unscrambler 2, it became apparent that the techniques also might provide a nice scientific tool for determining oxidation and chemisorption rates under controlled conditions. As the ultimate power of the technique became recognized, considering that the chemical system which was most frequently studied in this work is water + D6AC steel, we became very interested in trying the spectroscopic techniques to solve a broad range of problems. The complexity of the observed spectra for the D6AC + water system is due to overlaps between the water peaks, the resulting chemisorbed species, and products of reaction which also contain OH stretching bands. Unscrambling these spectral features, without knowledge of the specific species involved, has proven to be a formidable task.
The use of holographic and schlieren optical techniques for studying the concentration gradients in solidification processes has been used by several investigators over the years. The HGS facility at MSFC has been primary resource in researching this capability. Consequently, scientific personnel have been able to utilize these techniques in both ground based research and in space experiments. An important event in the scientific utilization of the HGS facilities was the TGS Crystal Growth and the casting and solidification technology (CAST) experiments that were flown on the International Microgravity Laboratory (IML) mission in March of this year. The preparation and processing of these space observations are the primary experiments reported in this work. This project provides some ground-based studies to optimize on the holographic techniques used to acquire information about the crystal growth processes flown on IML. Since the ground-based studies will be compared with the space-based experimental results, it is necessary to conduct sufficient ground based studies to best determine how the experiment worked in space. The current capabilities in computer based systems for image processing and numerical computation have certainly assisted in those efforts. As anticipated, this study has certainly shown that these advanced computing capabilities are helpful in the data analysis of such experiments.