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NASA NTRS2005

Spur Gear Wear Investigated in Support of Space Shuttle Return-To-Flight Efforts

As part of NASA s Return-To-Flight efforts, the Space Operations Program investigated the condition of actuators for the orbiter s rudder speed brake. The actuators control the position of the rudder panels located in the tail of the orbiter, providing both steering control and braking during reentry, approach, and landing. Inspections of flight hardware revealed fretting and wear damage to the critical working surfaces of the actuator gears. To best understand the root cause of the observed damage and to help establish an appropriate reuse and maintenance plan for these safety critical parts, researchers completed a set of gear wear experiments at the NASA Glenn Research Center.

Krantz, Timothy L.↗

NASA NTRS2007

Subclinical Reactivation and Shed of Infectious Varicella Zoster Virus in Saliva of Astronauts

We have previously detected VZV in healthy astronauts both during spaceflight and shortly after landing. Herein, we show that VZV shed in seropositive astronauts is infectious. A total of 40 saliva samples were obtained from each of the 3 astronauts. From each astronaut, 14 samples were taken 109 to 133 days before liftoff, 1 sample was taken every day during 12 days in space, and one sample was taken for 14 consecutive days beginning the second day after landing. Quantitative PCR was used to detect VZV DNA in saliva. None of 42 preflight saliva samples contained VZV DNA. VZV DNA was detected in saliva from 2 of 3 astronauts. In 1 astronaut, 6 of 12 samples obtained during space flight contained 120 to 2,500 copies of VZV DNA per ml; after landing, 1250 copies of VZV DNA were present on day 2, 45 copies on day 3, and 110 copies on day 5. All samples taken 6 to 15 days after touchdown were negative for VZV DNA. In the second astronaut, 5 of 12 samples obtained during space flight contained 18 to 650 copies of VZV DNA per ml; after landing, 560 copies of VZV DNA were present in saliva on day 2, 340 copies on day 4, 45 copies on day 5, and 23 copes on day 6. All samples taken 7 to 15 days after touchdown were negative for VZV DNA. Saliva taken 2 to 6 days after landing from all 3 astronauts was cultured on human fetal lung cells. After one subcultivation, a cytopathic effect developed in cultures inoculated with saliva from the two astronauts whose saliva contained VZV DNA. Both PCR and immunostaining identified the isolates to be VZV and not HSV-1. Importantly, the astronaut in whom no VZV was detected had a history of zoster 9 years earlier. It is possible that a boost in cell-mediated immunity to VZV which is known to develop after zoster protected him from subclinical reactivation. The genotype of the two VZV isolates was determined by VZV ORF22-based PCR/sequencing along with FRET-based PCR assays that target specific nucleotide polymorphisms. Both VZV isolates were found to be the European genotype which also contained a rare MspI restriction enodnuclease site in VZV ORF62 at position 107,252. These findings extend our previous demonstration of VZV DNA in saliva of astronauts by showing that infectious VZV is also present. Thus, like HSV-1 and HSV-2, VZV can reactivate and shed infectious virus in the absence of clinical disease.

Cohrs, Randall J.↗

NASA NTRS2007

CompactPCI(Registered TradeMark) Connectors in Space Flight Applications

This report documents the current status of CompactPCI(Registered TradeMark) connectors in GSFC spaceflight applications. To the extent the information is known, this report summarizes to what component quality level each NASA contractor (referred to as OEM in this report) procured the parts, and what board level and system level testing was performed. The report also provides the current status of the reliability assessment for each GSFC project based on the results of testing and FMEA (Failure Mode Effects Analysis). This report addresses how the CompactPCI(Registered TradeMark) connectors came into existence, and how these became the connector style chosen by many designers of space flight hardware. It identifies the design philosophy and the lack of robustness which has led to several known failure modes. These failure modes include fretting of connector pins during vibration, shock and thermal cycling, exposure of underplating, and increased resistance, including brief excursions to very high resistance. Each of these are signs of aging, which becomes an increasing concern for long duration orbiting space flight applications. This report addresses the mitigation strategy to replace CompactPCI(Registered TradeMark) connectors with space qualified Hypertronics 2mm cPCI connectors. The Hypertronics 2mm cPCI connectors are pin-to-pin compatible with the CompactPCI(Registered TradeMark) connectors and meet all of the same technical requirements, except the ability to hot mate, and to mate directly with a CompactPCI of the opposite gender. A detailed comparison of the CompactPCI(Registered TradeMark) connector and the Hypertronics 2mm cPCI connector is provided to describe the ruggedness of Hypertronics connector for space flight applications. Finally, this report makes recommendations for flight hardware for the future missions where the hardware is yet to be built, as well as for the hardware which has already been built with CompactPCI(Registered TradeMark) connectors.

Williams, Richard↗

NASA NTRS2005

An Intense Terminal Epoch of Widespread Fluvial Activity on Early Mars: 2. Increased Runoff and Paleolake Development

To explain the much higher denudation rates and valley network development on early Mars (more than approximately 3.6 Gyr ago), most investigators have invoked either steady state warm/wet (Earthlike) or cold/dry (modern Mars) end-member paleoclimates. Here we discuss evidence that highland gradation was prolonged, but generally slow and possibly ephemeral during the Noachian Period, and that the immature valley networks entrenched during a brief terminal epoch of more erosive fluvial activity in the late Noachian to early Hesperian. Observational support for this interpretation includes (1) late-stage breaching of some enclosed basins that had previously been extensively modified, but only by internal erosion and deposition; (2) deposition of pristine deltas and fans during a late stage of contributing valley entrenchment; (3) a brief, erosive response to base level decline (which was imparted as fretted terrain developed by a suite of processes unrelated to surface runoff) in fluvial valleys that crosscut the highland-lowland boundary scarp; and (4) width/contributing area relationships of interior channels within valley networks, which record significant late-stage runoff production with no evidence of recovery to lower-flow conditions. This erosion appears to have ended abruptly, as depositional landforms generally were not entrenched with declining base level in crater lakes. A possible planetwide synchronicity and common cause to the late-stage fluvial activity are possible but remain uncertain. This increased activity of valley networks is offered as a possible explanation for diverse features of highland drainage basins, which were previously cited to support competing warm, wet and cold, dry paleoclimate scenarios.

Rossman III, Irwin P.↗

NASA NTRS2013

Performance and Analysis of Perfluoropolyalkyl Ether Grease Used on Space Shuttle Actuators--A Case Study

Actuators used on the United States space shuttle fleet are lubricated with unspecified amounts of Braycote 601 (Castrol Braycote) grease consisting of a perfluoropolyalkyl ether (PFPAE) base oil thickened with a polytetrafluoroethylene (PTFE) filler. Each shuttle has four body flap actuators (BFAs) (two on each wing) on a common segmented shaft and four rudder speed brake (RSB) actuators. The actuators were designed to operate for 10 years and 100 flights without periodic relubrication. Visible inspection of two partially disassembled RSB actuators in continuous use for 19 years raised concerns over possible grease degradation due to discoloration of the grease on several places on the surfaces of the gears. Inspection revealed fretting, micropitting, wear and corrosion of the bearings and gears. A small amount of oil dripped from the disassembled actuators. Whereas new grease is beige in appearance, the discolored grease consisted of both grey and reddish colors. Grease samples taken from the actuators together with representative off-the-shelf new and unused grease samples were analyzed by gravimetry for oil content; by inductively coupled plasma spectroscopy (ICP) for metals content; Fourier transform infrared (FTIR) spectroscopy for base oil decomposition; and by size exclusion chromatography (SEC) for determination of the molecular weight distributions of the grease oil. The Braycote 601 grease was stable after 19 years of continuous use in the sealed RSB actuators and was fit for its intended purpose. There were no significant chemical differences between the used grease samples and new and unused samples. Base oil separation was not significant within the sealed actuators. No corrosive effect in the form of iron fluoride was detected. The grey color of grease samples was due to metallic iron. The red color was due to oxidation of the metallic wear particles from the gears and the bearings comprising the actuators.

Morales, Wilfredo↗

NASA NTRS2009

Multimodal Friction Ignition Tester

The multimodal friction ignition tester (MFIT) is a testbed for experiments on the thermal and mechanical effects of friction on material specimens in pressurized, oxygen-rich atmospheres. In simplest terms, a test involves recording sensory data while rubbing two specimens against each other at a controlled normal force, with either a random stroke or a sinusoidal stroke having controlled amplitude and frequency. The term multimodal in the full name of the apparatus refers to a capability for imposing any combination of widely ranging values of the atmospheric pressure, atmospheric oxygen content, stroke length, stroke frequency, and normal force. The MFIT was designed especially for studying the tendency toward heating and combustion of nonmetallic composite materials and the fretting of metals subjected to dynamic (vibrational) friction forces in the presence of liquid oxygen or pressurized gaseous oxygen test conditions approximating conditions expected to be encountered in proposed composite material oxygen tanks aboard aircraft and spacecraft in flight. The MFIT includes a stainless-steel pressure vessel capable of retaining the required test atmosphere. Mounted atop the vessel is a pneumatic cylinder containing a piston for exerting the specified normal force between the two specimens. Through a shaft seal, the piston shaft extends downward into the vessel. One of the specimens is mounted on a block, denoted the pressure block, at the lower end of the piston shaft. This specimen is pressed down against the other specimen, which is mounted in a recess in another block, denoted the slip block, that can be moved horizontally but not vertically. The slip block is driven in reciprocating horizontal motion by an electrodynamic vibration exciter outside the pressure vessel. The armature of the electrodynamic exciter is connected to the slip block via a horizontal shaft that extends into the pressure vessel via a second shaft seal. The reciprocating horizontal motion can be chosen to be random with a flat spectrum over the frequency range of 10 Hz to 1 kHz, or to be sinusoidal at any peak-to-peak amplitude up to 0.8 in. (.2 cm) and fixed or varying frequency up to 1 kHz. The temperatures of the specimen and of the vessel are measured by thermocouples. A digital video camera mounted outside the pressure vessel is aimed into the vessel through a sapphire window, with its focus fixed on the interface between the two specimens. A position transducer monitors the displacement of the pneumatic-cylinder shaft. The pressure in the vessel is also monitored. During a test, the output of the video camera, the temperatures, and the pneumatic-shaft displacement are monitored and recorded. The test is continued for a predetermined amount of time (typically, 10 minutes) or until either (1) the output of the position transducer shows a sudden change indicative of degradation of either or both specimens, (2) ignition or another significant reaction is observed, or (3) pressure in the vessel increases beyond a pre-set level that triggers an automatic shutdown.

Davis, Eddie↗

NASA NTRS2010

Burnishing Techniques Strengthen Hip Implants

In the late 1990s, Lambda Research Inc., of Cincinnati, Ohio, received Small Business Innovation Research (SBIR) awards from Glenn Research Center to demonstrate low plasticity burnishing (LPB) on metal engine components. By producing a thermally stable deep layer of compressive residual stress, LPB significantly strengthened turbine alloys. After Lambda patented the process, the Federal Aviation Administration accepted LPB for repair and alteration of commercial aircraft components, the U.S. Department of Energy found LPB suitable for treating nuclear waste containers at Yucca Mountain. Data from the U.S. Food and Drug Administration confirmed LPB to completely eliminate the occurrence of fretting fatigue failures in modular hip implants.

Source record↗

NASA NTRS2003

High-Temperature Switched-Reluctance Electric Motor

An eight-pole radial magnetic bearing has been modified into a switched-reluctance electric motor capable of operating at a speed as high as 8,000 rpm at a temperature as high as 1,000 F (=540 C). The motor (see figure) is an experimental prototype of starter-motor/generator units that have been proposed to be incorporated into advanced gas turbine engines and that could operate without need for lubrication or active cooling. The unique features of this motor are its electromagnet coils and, to some extent, its control software. Heretofore, there has been no commercial-off-the-shelf wire capable of satisfying all of the requirements for fabrication of electromagnet coils capable of operation at temperatures up to 1,000 F (=540 C). The issues addressed in the development of these electromagnet coils included thermal expansion, oxidation, pliability to small bend radii, micro-fretting, dielectric breakdown, tensile strength, potting compound, thermal conduction, and packing factor. For a test, the motor was supported, along with a rotor of 18 lb (.8-kg) mass, 3-in. (.7.6-cm) diameter, 21-in. (.53-cm) length, on bearings packed with high-temperature grease. The motor was located at the mid span of the rotor and wrapped with heaters. The motor stator was instrumented with thermocouples. At the time of reporting the information for this article, the motor had undergone 14 thermal cycles between room temperature and 1,000 F (.540 C) and had accumulated operating time >27.5 hours at 1,000 F (=540 C). The motor-controller hardware includes a personal computer equipped with analog-to-digital input and digital-to-analog output cards. The controller software is a C-language code that implements a switched-reluctance motor-control principle: that is, it causes the coils to be energized in a sequence timed to generate a rotating magnetic flux that creates a torque on a scalloped rotor. The controller can operate in an open- or closed-loop mode. In addition, the software has been modified to enable the simultaneous operation of the prototype motor or another, similar apparatus as both a motor and a magnetic bearing. Combined bearing/motor operation has been demonstrated at room temperature but had not yet been demonstrated at high temperature at the time of reporting the information for this article.

Montague, Gerald↗

NASA NTRS2012

Discovery of a Plains Caldera Complex and Extinct Lava Lake in Arabia Terra, Mars: Implications for the Discovery of Additional Highland Volcanic Source Regions

Several irregularly shaped topographic depressions occur near the dichotomy boundary in northern Arabia Terra, Mars. The geomorphology of these features suggests that they formed by collapse, opposed to meteor impact. At least one depression (approx.55 by 85 km) displays geologic features indicating a complex, multi-stage collapse history. Features within and around the collapse structure indicate volcanic processes. The complex occurs within Hesperian ridged plains of likely volcanic origin and displays no crater rim or evidence for ejecta. Instead the depression consists of a series of circumferential graben and down-dropped blocks which also display upper surfaces similar to ridged plain lavas. Large blocks within the depression are tilted towards the crater center, and display graben that appear to have originally been linked with circumferential graben outside of the complex related to earlier collapse events. A nearly 700 m high mound exists along a graben within the complex that might be a vent. The deepest depression displays two sets of nearly continuous terraces, which we interpret as high-stands of a drained lava lake. These features appear similar to the black ledge described during the Kilauea Iki eruption in 1959. A lacustrine origin for the terraces seems unlikely because of the paucity of channels found in or around the depression that could be linked to aqueous surface processes. In addition, there is no obvious evidence for lacustrine sediments within the basin. Together with the presence of significant faulting that is indicative of collapse we conclude that this crater complex represents a large caldera formed in the Late Noachian to Early Hesperian. Other linear and irregular depressions in the region also might be linked to ancient volcanism. If that hypothesis is correct, it suggests that northern Arabia Terra could contain a large, previously unrecognized highland igneous province. Evacuation of magma via explosive and effusive activity produced localized collapse, might have contributed to nearby ridged plains, and pyroclastic materials erupted from these vents might have supplied sediments in fretted terrain and other deposits. The recognition of volcanoes within Arabia Terra expands the known extent of Noachian-Hesperian volcanism to cover much of the preserved martian highland crust.

Bleacher, Jacob↗

NASA NTRS2013

NASA Tech Briefs, September 2013

Topics include: ISS Ammonia Leak Detection Through X-Ray Fluorescence; A System for Measuring the Sway of the Vehicle Assembly Building; Fast, High-Precision Readout Circuit for Detector Arrays; Victim Simulator for Victim Detection Radar; Hydrometeor Size Distribution Measurements by Imaging the Attenuation of a Laser Spot; Quasi-Linear Circuit; High-Speed, High-Resolution Time-to-Digital Conversion; Li-Ion Battery and Supercapacitor Hybrid Design for Long Extravehicular Activities; Ultrasonic Low-Friction Containment Plate for Thermal and Ultrasonic Stir Weld Processes; High-Powered, Ultrasonically Assisted Thermal Stir Welding; Next-Generation MKIII Lightweight HUT/Hatch Assembly; Centrifugal Sieve for Gravity-Level-Independent Size; Segregation of Granular Materials; Ion Exchange Technology Development in Support of the Urine Processor Assembly; Nickel-Graphite Composite Compliant Interface and/or Hot Shoe Material; UltraSail CubeSat Solar Sail Flight Experiment; Mechanism for Deploying a Long, Thin-Film Antenna From a Rover; Counterflow Regolith Heat Exchanger; Acquisition and Retaining Granular Samples via a Rotating Coring Bit; Very-Low-Cost, Rugged Vacuum System; Medicine Delivery Device With Integrated Sterilization and Detection; FRET-Aptamer Assays for Bone Marker Assessment, C-Telopeptide, Creatinine, and Vitamin D; Multimode Directional Coupler for Utilization of Harmonic Frequencies from TWTAs; Dual-Polarization, Multi-Frequency Antenna Array for use with Hurricane Imaging Radiometer; Complementary Barrier Infrared Detector (CBIRD) Contact Methods; Autonomous Control of Space Nuclear Reactors; High-Power, High-Speed Electro-Optic Pockels Cell Modulator; Covariance Analysis Tool (G-CAT) for Computing Ascent, Descent, and Landing Errors; Enigma Version 12; Micrometeoroid and Orbital Debris (MMOD) Shield Ballistic Limit Analysis Program; Spitzer Telemetry Processing System; Planetary Protection Bioburden Analysis Program; Wing Leading Edge RCC Rapid Response Damage Prediction Tool (IMPACT2); ISSM: Ice Sheet System Model; Automated Loads Analysis System (ATLAS); Integrated Main Propulsion System Performance Reconstruction Process/Models. Phoenix Telemetry Processor; Contact Graph Routing Enhancements Developed in ION for DTN; GFEChutes Lo-Fi; Advanced Strategic and Tactical Relay Request Management for the Mars Relay Operations Service; Software for Generating Troposphere Corrections for InSAR Using GPS and Weather Model Data; Ionospheric Specifications for SAR Interferometry (ISSI); Implementation of a Wavefront-Sensing Algorithm; Sally Ride EarthKAM - Automated Image Geo-Referencing Using Google Earth Web Plug-In; Trade Space Specification Tool (TSST) for Rapid Mission Architecture (Version 1.2); Acoustic Emission Analysis Applet (AEAA) Software; Memory-Efficient Onboard Rock Segmentation; Advanced Multimission Operations System (ATMO); Robot Sequencing and Visualization Program (RSVP); Automating Hyperspectral Data for Rapid Response in Volcanic Emergencies; Raster-Based Approach to Solar Pressure Modeling; Space Images for NASA JPL Android Version; Kinect Engineering with Learning (KEWL); Spacecraft 3D Augmented Reality Mobile App; MPST Software: grl_pef_check; Real-Time Multimission Event Notification System for Mars Relay; SIM_EXPLORE: Software for Directed Exploration of Complex Systems; Mobile Timekeeping Application Built on Reverse-Engineered JPL Infrastructure; Advanced Query and Data Mining Capabilities for MaROS; Jettison Engineering Trajectory Tool; MPST Software: grl_suppdoc; PredGuid+A: Orion Entry Guidance Modified for Aerocapture; Planning Coverage Campaigns for Mission Design and Analysis: CLASP for DESDynl; and Space Place Prime.

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NASA NTRS2014

Crack Growth Behavior in the Threshold Region for High Cycle Fatigue Loading

The research results described in this paper presents a new understanding of the behavior of fatigue crack growth in the threshold region. It is believed by some crack growth experts that the ASTM load shedding test method does not produce true or valid threshold properties. The concern involves the observed fanning of threshold region da/dN data plots for some materials in which the low R-ratio data fans out or away from the high R-ratio data. This data fanning or elevation of threshold values is obviously caused by an increase in crack closure in the low R-ratio tested specimens. This increase in crack closure is assumed by some investigators to be caused by a plastic wake on the crack surfaces that was created during the load shedding test phase. This study shows that the increase in crack closure is the result of an extensive occurrence of crack bifurcation behavior in some materials, particularly in aluminum alloys, when the crack tip cyclic yield zone size becomes less than the grain size of the alloy. This behavior is related to the high stacking fault energy (SFE) property of aluminum alloys which results in easier slip characteristics. Therefore, the particular fanning behavior in aluminum alloys is a function of intrinsic dislocation property of the materials and that the fanned data represents valid material properties. However, for corrosion sensitive steel alloys used in this study the fanning was caused by a build-up of iron oxide at the crack tip from fretting corrosion.

Forman, Royce G.↗

NASA NTRS2014

Crack Growth Behavior in the Threshold Region for High Cycle Fatigue Loading

This paper describes the results of a research program conducted to improve the understanding of fatigue crack growth rate behavior in the threshold growth rate region and to answer a question on the validity of threshold region test data. The validity question relates to the view held by some experimentalists that using the ASTM load shedding test method does not produce valid threshold test results and material properties. The question involves the fanning behavior observed in threshold region of da/dN plots for some materials in which the low R-ratio data fans out from the high R-ratio data. This fanning behavior or elevation of threshold values in the low R-ratio tests is generally assumed to be caused by an increase in crack closure in the low R-ratio tests. Also, the increase in crack closure is assumed by some experimentalists to result from using the ASTM load shedding test procedure. The belief is that this procedure induces load history effects which cause remote closure from plasticity and/or roughness changes in the surface morphology. However, experimental studies performed by the authors have shown that the increase in crack closure is a result of extensive crack tip bifurcations that can occur in some materials, particularly in aluminum alloys, when the crack tip cyclic yield zone size becomes less than the grain size of the alloy. This behavior is related to the high stacking fault energy (SFE) property of aluminum alloys which results in easier slip characteristics. Therefore, the fanning behavior which occurs in aluminum alloys is a function of intrinsic dislocation property of the alloy, and therefore, the fanned data does represent the true threshold properties of the material. However, for the corrosion sensitive steel alloys tested in laboratory air, the occurrence of fanning results from fretting corrosion at the crack tips, and these results should not be considered to be representative of valid threshold properties because the fanning is eliminated when testing is performed in dry air.

Forman, R. G.↗

NASA NTRS2014

Supervolcanoes Within an Ancient Volcanic Province in Arabia Terra, Mars

Several irregularly shaped craters located within Arabia Terra, Mars represent a new type of highland volcanic construct and together constitute a previously unrecognized martian igneous province. Similar to terrestrial supervolcanoes, these low-relief paterae display a range of geomorphic features related to structural collapse, effusive volcanism, and explosive eruptions. Extruded lavas contributed to the formation of enigmatic highland ridged plains in Arabia Terra. Outgassed sulfur and erupted fine-grained pyroclastics from these calderas likely fed the formation of altered, layered sedimentary rocks and fretted terrain found throughout the equatorial region. Discovery of a new type of volcanic construct in the Arabia volcanic province fundamentally changes the picture of ancient volcanism and climate evolution on Mars. Other eroded topographic basins in the ancient Martian highlands that have been dismissed as degraded impact craters should be reconsidered as possible volcanic constructs formed in an early phase of widespread, disseminated magmatism on Mars.

Mars↗

NASA NTRS2014

Investigation of Spiral Bevel Gear Condition Indicator Validation Via AC-29-2C Using Damage Progression Tests

This report documents the results of spiral bevel gear rig tests performed under a NASA Space Act Agreement with the Federal Aviation Administration (FAA) to support validation and demonstration of rotorcraft Health and Usage Monitoring Systems (HUMS) for maintenance credits via FAA Advisory Circular (AC) 29-2C, Section MG-15, Airworthiness Approval of Rotorcraft (HUMS) (Ref. 1). The overarching goal of this work was to determine a method to validate condition indicators in the lab that better represent their response to faults in the field. Using existing in-service helicopter HUMS flight data from faulted spiral bevel gears as a "Case Study," to better understand the differences between both systems, and the availability of the NASA Glenn Spiral Bevel Gear Fatigue Rig, a plan was put in place to design, fabricate and test comparable gear sets with comparable failure modes within the constraints of the test rig. The research objectives of the rig tests were to evaluate the capability of detecting gear surface pitting fatigue and other generated failure modes on spiral bevel gear teeth using gear condition indicators currently used in fielded HUMS. Nineteen final design gear sets were tested. Tables were generated for each test, summarizing the failure modes observed on the gear teeth for each test during each inspection interval and color coded based on damage mode per inspection photos. Gear condition indicators (CI) Figure of Merit 4 (FM4), Root Mean Square (RMS), +/- 1 Sideband Index (SI1) and +/- 3 Sideband Index (SI3) were plotted along with rig operational parameters. Statistical tables of the means and standard deviations were calculated within inspection intervals for each CI. As testing progressed, it became clear that certain condition indicators were more sensitive to a specific component and failure mode. These tests were clustered together for further analysis. Maintenance actions during testing were also documented. Correlation coefficients were calculated between each CI, component, damage state and torque. Results found test rig and gear design, type of fault and data acquisition can affect CI performance. Results found FM4, SI1 and SI3 can be used to detect macro pitting on two more gear or pinion teeth as long as it is detected prior to progressing to other components or transitioning to another failure mode. The sensitivity of RMS to system and operational conditions limit its reliability for systems that are not maintained at steady state. Failure modes that occurred due to scuffing or fretting were challenging to detect with current gear diagnostic tools, since the damage is distributed across all the gear and pinion teeth, smearing the impacting signatures typically used to differentiate between a healthy and damaged tooth contact. This is one of three final reports published on the results of this project. In the second report, damage modes experienced in the field will be mapped to the failure modes created in the test rig. The helicopter CI data will then be re-processed with the same analysis techniques applied to spiral bevel rig test data. In the third report, results from the rig and helicopter data analysis will be correlated. Observations, findings and lessons learned using sub-scale rig failure progression tests to validate helicopter gear condition indicators will be presented.

gears↗

NASA NTRS2015

Relation Between Residual and Hoop Stresses and Rolling Bearing Fatigue Life

Rolling-element bearings operated at high speed or high vibration may require a tight interference fit between the bore of the bearing and shaft to prevent rotation of the bearing bore around the shaft and fretting damage at the interfaces. Previous work showed that the hoop stresses resulting from tight interference fits can reduce bearing lives by as much as 65 percent. Where tight interference fits are required, case-carburized steel such as AISI 9310 or M50 NiL is often used because the compressive residual stresses inhibit subsurface crack formation and the ductile core inhibits inner-ring fracture. The presence of compressive residual stress and its combination with hoop stress also modifies the Hertz stress-life relation. This paper analyzes the beneficial effect of residual stresses on rolling-element bearing fatigue life in the presence of high hoop stresses for three bearing steels. These additional stresses were superimposed on Hertzian principal stresses to calculate the inner-race maximum shearing stress and the resulting fatigue life of the bearing. The load-life exponent p and Hertz stress-life exponent n increase in the presence of compressive residual stress, which yields increased life, particularly at lower stress levels. The Zaretsky life equation is described and is shown to predict longer bearing lives and greater load- and stress-life exponents, which better predicts observed life of bearings made from vacuum-processed steel.

Fatigue↗

NASA NTRS2016

Pluto is the new Mars!

Data from NASA's New Horizons encounter with Pluto in July 2015 revealed an astoundingly complex world. The surface seen on the encounter hemisphere ranged in age from ancient to recent. A vast craterless plain of slowly convecting solid nitrogen resides in a deep primordial impact basin, reminiscent of young enigmatic deposits in Mars' Hellas basin. Like Mars, regions of Pluto are dominated by valleys, though the Pluto valleys are thought to be carved by nitrogen glaciers. Pluto has fretted terrain and halo craters. Pluto is cut by tectonics of several different ages. Like Mars, vast tracts on Pluto are mantled by dust and volatiles. Just as on Mars, Pluto has landscapes that systematically vary with latitude due to past and present seasonal (and mega-seasonal) effects on two major volatiles. On Mars, those volatiles are H2O and CO2; on Pluto they are CH4 and N2. Like Mars, some landscapes on Pluto defy easy explanation. In the Plutonian arctic there is a region of large (approx. 40 km across) deep (approx. 3-4 km) pits that probably could not be formed by sublimation, or any other single process, alone. Equally bizarre is the Bladed terrain, which is composed of fields of often roughly aligned blade-like ridges covering the flanks and crests of broad regional swells. Topping the unexpected are two large mounds approximately150 km across, approx. 5-6 km high, with great central depressions at their summits. The central depressions are almost as deep as the mounds are tall. These mounds have many of the characteristics of volcanic mountains seen on Mars and elsewhere in the inner solar system. Hypotheses for the formation of these Plutonian mounds so far all have challenges, principally revolving around the need for H2O ice to support their relief and the difficulty imagining mechanisms that would mobilize H2O. From the perspective of one year after the encounter, our appreciation of the extent of Pluto's diversity and complexity is quite reminiscent of the perspective the science community had of Mars, with similar quality data sets, soon after the early reconnaissance of that planet in the late 1960s and early 70s. So certainly in this sense, Pluto is the new Mars.

Pluto↗

NASA NTRS2019

Bridging the Gap Between Requirements and Model Analysis: Evaluation on Cyber-Physical Challenge Problems

We present a framework for introducing high-level requirement specifications in the automated analysis of dataflow models. By integrating the FRET requirements elicitation tool with the CoCoSim analyzer, our framework enables the analysis of hierarchical Simulink models against requirements written in a restricted English language. More precisely, we support: automatic extraction of Simulink model information and association of high-level requirements with target model signals and components; translation of temporal logic formulas into synchronous dataflow CoCoSpec specifications as well as Simulink monitors; and interpretation of counterexamples produced by the analysis both at the requirement and model level. The features provided by our framework are generic and can be used to integrate other requirements elicitation and Simulink/Lustre analysis tools. We report on the lessons learned from the application of our approach to the Lockheed Martin Cyber-Physical, aerospace-inspired challenge problems. For the analysis, we used the Kind2, Zustre, and Simulink Design Verifier (SLDV) tools.

Simulink↗

NASA NTRS2020

Bridging the Gap Between Requirements and Simulink Model Analysis

Formal verification and simulation are powerful tools for the verification of requirements against complex systems. Requirements are developed in early stages of the software lifecycle and are typically expressed in natural language. There is a gap between such requirements and their software implementations.We present a framework that bridges this gap by supporting a tight integration and feedback loop between high-level requirements and their analysis against software artifacts. Our framework implements an analysis portal within the fret requirements elicitation tool, thus forming an end-to-end, open-source environment where requirements are written in an intuitive, structured natural language, and are verified automatically against Simulink models.

Mavridou, Anastasia↗