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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

Flexible Metallic Overwrap Concept Developed for On-Orbit Repair of Space Shuttle Orbiter Leading Edges

The Columbia accident has focused attention on the critical need for on-orbit repair concepts for leading edges in the event that damage is incurred during space shuttle orbiter flight. Damage that is considered as potentially catastrophic for orbiter leading edges ranges from simple cracks to holes as large as 16 in. in diameter. NASA is particularly interested in examining potential solutions for areas of larger damage since such a problem was identified as the cause for the Columbia disaster. One possible idea for the on-orbit repair of the reinforced carbon/carbon (RCC) leading edges is an overwrap concept that would use a metallic sheet flexible enough to conform to the contours of the orbiter and robust enough to protect any problem area from catastrophic failure during reentry. The simplified view of the application of a refractory metal sheet over a mockup of shuttle orbiter panel 9, which experiences the highest temperatures on the shuttle during reentry is shown. The metallic overwrap concept is attractive because of its versatility as well as the ease with which it can be included in an onboard repair kit. Reentry of the orbiter into Earth's atmosphere imposes extreme requirements on repair materials. Temperatures can exceed 1650 C for up to 15 min in the presence of an extremely oxidizing plasma environment. Several other factors are critical, including catalysity, emissivity, and vibrational and aerodynamic loads. Materials chosen for this application will need to be evaluated with respect to high-temperature capability, resistance to oxidation, strength, coefficient of thermal expansion, and thermal conductivity. The temperature profile across panel 9 during reentry as well as a schematic of the overwrap concept itself is shown.

Ritzert, Frank J.↗
NASA NTRS2006

In Situ Fabrication and Repair (ISFR) Technologies; New Challenges for Exploration

NASA's human exploration initiative poses great opportunity and great risk for manned missions to the Moon and Mars. Engineers and Scientists at the Marshall Space Flight Center (MSFC) are continuing to evaluate current technologies for in situ resource-based exploration fabrication and repair applications. Several technologies to be addressed in this paper have technology readiness levels (TRLs) that are currently mature enough to pursue for exploration purposes. However, while many technologies offer promising applications, these technologies must be pulled along by the demands and applications of this great initiative. The In Situ Fabrication and Repair (ISFR) Element will supply and push state of the art technologies for applications such as habitat structure development, in situ resource utilization for tool and part fabrication, and repair and non-destructive evaluation W E ) of common life support elements. As an overview of the ISFR Element, this paper will address rapid prototyping technologies, their applications, challenges, and near term advancements. This paper will also discuss the anticipated need to utilize in situ resources to produce replacement parts and fabricate repairs to vehicles, habitats, life support and quality of life elements. Overcoming the challenges of ISFR development will provide the Exploration initiative with state of the art technologies that reduce risk, and enhance supportability.

Bassler, Julie A.↗
NASA NTRS2005

Orbiter Repair Maneuver Contingency Separation Methods and Analysis

Repairing damaged thermal protection system tile requires the Space Shuttle to be oriented such that repair platform access from the International Space Station (ISS) is possible. To do this, the Space Shuttle uses the Orbiter Repair Maneuver (ORM), which utilizes the Shuttle Remote Manipulator System (SRMS) to rotate the Space Shuttle in relation to the ISS, for extended periods of time. These positions cause difficulties and challenges to performing a safe separation (no collision or thruster plume damage to sensitive ISS structures) should an inadvertent release occur or a contingency procedure require it. To help protect for an SRMS failure or other failures, a method for separating without collision and the ability to redock to ISS from the ORM configuration was needed. The contingency ORM separation solution elegantly takes advantage of orbital mechanics between ISS and the separating Space Shuttle. By pitching the ISS down approximately 45 degrees, in a majority of the ORM repair positions, the altitude difference between the ISS and Space Shuttle center of gravity is maximized. This altitude difference results in different orbital energies (orbital periods) causing objects to separate from each other without requiring translational firings. Using this method, a safe contingency ORM separation is made possible in many odd positions even though some separation positions point high powered thrusters directly at fragile ISS and Soyuz solar arrays. Documented in this paper are the development simulations and procedures of the contingency ORM separation and the challenges encountered with large constraints to work around. Lastly, a method of returning to redock with the ISS to pick up the stranded crew members (or transfer the final crew members) is explained as well as the thruster and ISS loads analysis.

Machula, Michael↗
NASA NTRS2007

NASA Shuttle Orbiter Reinforced Carbon Carbon (RCC) Crack Repair Arc-Jet Testing

This NASA study demonstrates the capability for testing NOAX-repaired RCC crack models in high temperature environments representative of Shuttle Orbiter during reentry. Analysis methods have provided correlation of test data with flight predictions. NOAX repair material for RCC is flown on every STS flight in the event such a repair is needed. Two final test reports are being generated on arc-jet results (both calibration model runs and repaired models runs).

Clark, ShawnDella↗
NASA NTRS1999

Friction stir welding process to repair voids in aluminum alloys

The present invention provides an in-process method to repair voids in an aluminum alloy, particularly a friction stir weld in an aluminum alloy. For repairing a circular void or an in-process exit hole in a weld, the method includes the steps of fabricating filler material of the same composition or compatible with the parent material into a plug form to be fitted into the void, positioning the plug in the void, and friction stir welding over and through the plug. For repairing a longitudinal void (30), the method includes machining the void area to provide a trough (34) that subsumes the void, fabricating filler metal into a strip form (36) to be fitted into the trough, positioning the strip in the trough, and rewelding the void area by traversing a friction stir welding tool longitudinally through the strip. The method is also applicable for repairing welds made by a fusing welding process or voids in aluminum alloy workpieces themselves.

Rosen, Charles D.↗
NASA NTRS2006

Space Shuttle Thermal Protection System Repair Flight Experiment Induced Contamination Impacts

NASA s activities to prepare for Flight LF1 (STS-114) included development of a method to repair the Thermal Protection System (TPS) of the Orbiter s leading edge should it be damaged during ascent by impacts from foam, ice, etc . Reinforced Carbon-Carbon (RCC) is used for the leading edge TPS. The repair material that was developed is named Non- Oxide Adhesive eXperimental (NOAX). NOAX is an uncured adhesive material that acts as an ablative repair material. NOAX completes curing during the Orbiter s descent. The Thermal Protection System (TPS) Detailed Test Objective 848 (DTO 848) performed on Flight LF1 (STS-114) characterized the working life, porosity void size in a micro-gravity environment, and the on-orbit performance of the repairs to pre-damaged samples. DTO 848 is also scheduled for Flight ULF1.1 (STS-121) for further characterization of NOAX on-orbit performance. Due to the high material outgassing rates of the NOAX material and concerns with contamination impacts to optically sensitive surfaces, ASTM E 1559 outgassing tests were performed to determine NOAX condensable outgassing rates as a function of time and temperature. Sensitive surfaces of concern include the Extravehicular Mobility Unit (EMU) visor, cameras, and other sensors in proximity to the experiment during the initial time after application. This paper discusses NOAX outgassing characteristics, how the amount of deposition on optically sensitive surfaces while the NOAX is being manipulated on the pre-damaged RCC samples was determined by analysis, and how flight rules were developed to protect those optically sensitive surfaces from excessive contamination where necessary.

Smith, Kendall A.↗
NASA NTRS2008

Friction Stir Weld Restart+Reweld Repair Allowables

A friction stir weld (FSW) repair method has been developed and successfully implemented on Al 2195 plate material for the Space Shuttle External Fuel Tank (ET). The method includes restarting the friction stir weld in the termination hole of the original weld followed by two reweld passes. Room temperature and cryogenic temperature mechanical properties exceeded minimum FSW design strength and compared well with the development data. Simulated service test results also compared closely to historical data for initial FSW, confirming no change to the critical flaw size or inspection requirements for the repaired weld. Testing of VPPA fusion/FSW intersection weld specimens exhibited acceptable strength and exceeded the minimum design value. Porosity, when present at the intersection was on the root side toe of the fusion weld, the "worst case" being 0.7 inch long. While such porosity may be removed by sanding, this "worst case" porosity condition was tested "as is" and demonstrated that porosity did not negatively affect the strength of the intersection weld. Large, 15-inch "wide panels" FSW repair welds were tested to demonstrate strength and evaluate residual stresses using photo stress analysis. All results exceeded design minimums, and photo stress analysis showed no significant stress gradients due to the presence of the restart and multi-pass FSW repair weld.

Clifton, Andrew↗
NASA NTRS2009

Chromosomal Aberrations in DNA Repair Defective Cell Lines: Comparisons of Dose Rate and Radiation Quality

Chromosome aberration yields were assessed in DNA double-strand break repair (DSB) deficient cells after acute doses of gamma-rays or high-LET iron nuclei, or low dose-rate (0.018 Gy/hr) gamma-rays. We studied several cell lines including fibroblasts deficient in ATM (product of the gene that is mutated in ataxia telangiectasia patients) or NBS (product of the gene mutated in the Nijmegen breakage syndrome), and gliomablastoma cells that are proficient or lacking in DNA-dependent protein kinase, DNA-PK activity. Chromosomes were analyzed using the fluorescence in-situ hybridization (FISH) chromosome painting method in cells at the first division post-irradiation and chromosome aberrations were identified as either simple exchanges (translocations and dicentrics) or complex exchanges (involving >2 breaks in 2 or more chromosomes). Gamma radiation induced higher yields of both simple and complex exchanges in the DSB repair defective cells than in the normal cells. The quadratic dose-response terms for both chromosome exchange types were significantly higher for the ATM and NBS defective lines than for normal fibroblasts. However, the linear dose-response term was significantly higher only for simple exchanges in the NBS cells. Large increases in the quadratic dose response terms indicate the important roles of ATM and NBS in chromatin modifications that facilitate correct DSB repair and minimize aberration formation. Differences in the response of AT and NBS deficient cells at lower doses suggests important questions about the applicability of observations of radiation sensitivity at high dose to low dose exposures. For all iron nuclei irradiated cells, regression models preferred purely linear and quadratic dose responses for simple and complex exchanges, respectively. All the DNA repair defective cell lines had lower Relative biological effectiveness (RBE) values than normal cells, the lowest being for the DNA-PK-deficient cells, which was near unity. To further investigate the sensitivity differences for low and low high doses, we performed chronic low dose-rate irradiation, and have begun studies with ATM and Nibrin inhibitors and siRNA knockout of these proteins. Results support the conclusion that for the endpoint of simple chromosomal aberrations (translocation or dicentrics), the increased radiation sensitivity of AT cells found at high doses (>1 Gy) does not carry over to low doses or doserates, while NBS cells show increased sensitivity for both high and low dose exposures.

George, K. A.↗
NASA NTRS2008

New Materials for the Repair of Polyimide Electrical Wire Insulation

Two viable polyimide backbone materials have been identified that will allow the repair of polyimide electrical wire insulation found on the Space Shuttle and other aging aircraft. This identification is the outcome of ongoing efforts to assess the viability of using such polyimides and polyimide precursors (polyamic acids [PAAs]) as repair materials for aging polyimide electrical wire insulation. These repair materials were selected because they match the chemical makeup of the underlying wire insulation as closely as possible. This similarity allows for maximum compatibility, coupled with the outstanding physical properties of polyimides. The two polyimide backbone materials allow the polymer to be extremely flexible and to melt at low temperatures. A polymer chain end capping group that allows the polymer to crosslink into a nonflowable repair upon curing at around 200 C was also identified.

Source record↗
NASA NTRS2008

Systems Maintenance Automated Repair Tasks (SMART)

SMART is an interactive decision analysis and refinement software system that uses evaluation criteria for discrepant conditions to automatically provide and populate a document/procedure with predefined steps necessary to repair a discrepancy safely, effectively, and efficiently. SMART can store the tacit (corporate) knowledge merging the hardware specification requirements with the actual "how to" repair methods, sequences, and required equipment, all within a user-friendly interface. Besides helping organizations retain repair knowledge in streamlined procedures and sequences, SMART can also help them in saving processing time and expense, increasing productivity, improving quality, and adhering more closely to safety and other guidelines. Though SMART was developed for Space Shuttle applications, its interface is easily adaptable to any hardware that can be broken down by component, subcomponent, discrepancy, and repair.

Source record↗
NASA NTRS2009

Light-Curing Adhesive Repair Tapes

Adhesive tapes, the adhesive resins of which can be cured (and thereby rigidized) by exposure to ultraviolet and/or visible light, are being developed as repair patch materials. The tapes, including their resin components, consist entirely of solid, low-outgassing, nonhazardous or minimally hazardous materials. They can be used in air or in vacuum and can be cured rapidly, even at temperatures as low as -20 C. Although these tapes were originally intended for use in repairing structures in outer space, they can also be used on Earth for quickly repairing a wide variety of structures. They can be expected to be especially useful in situations in which it is necessary to rigidize tapes after wrapping them around or pressing them onto the parts to be repaired.

Allred, Ronald↗
NASA NTRS2010

RCC Plug Repair Thermal Tools for Shuttle Mission Support

A thermal math model for the Space Shuttle Reinforced Carbon-Carbon (RCC) Plug Repair was developed to increase the confidence in the repair entry performance and provide a real-time mission support tool. The thermal response of the plug cover plate, local RCC, and metallic attach hardware can be assessed with this model for any location on the wing leading edge. The geometry and spatial location of the thermal mesh also matches the structural mesh which allows for the direct mapping of temperature loads and computation of the thermoelastic stresses. The thermal model was correlated to a full scale plug repair radiant test. To utilize the thermal model for flight analyses, accurate predictions of protuberance heating were required. Wind tunnel testing was performed at CUBRC to characterize the heat flux in both the radial and angular directions. Due to the complexity of the implementation of the protuberance heating, an intermediate program was developed to output the heating per nodal location for all OML surfaces in SINDA format. Three Design Reference Cases (DRC) were evaluated with the correlated plug thermal math model to bound the environments which the plug repair would potentially be used.

Rodriguez, Alvaro C.↗
NASA NTRS2011

Component-Level Electronic-Assembly Repair (CLEAR) Spacecraft Circuit Diagnostics by Analog and Complex Signature Analysis

The Component-Level Electronic-Assembly Repair (CLEAR) project at the NASA Glenn Research Center is aimed at developing technologies that will enable space-flight crews to perform in situ component-level repair of electronics on Moon and Mars outposts, where there is no existing infrastructure for logistics spares. These technologies must provide effective repair capabilities yet meet the payload and operational constraints of space facilities. Effective repair depends on a diagnostic capability that is versatile but easy to use by crew members that have limited training in electronics. CLEAR studied two techniques that involve extensive precharacterization of "known good" circuits to produce graphical signatures that provide an easy-to-use comparison method to quickly identify faulty components. Analog Signature Analysis (ASA) allows relatively rapid diagnostics of complex electronics by technicians with limited experience. Because of frequency limits and the growing dependence on broadband technologies, ASA must be augmented with other capabilities. To meet this challenge while preserving ease of use, CLEAR proposed an alternative called Complex Signature Analysis (CSA). Tests of ASA and CSA were used to compare capabilities and to determine if the techniques provided an overlapping or complementary capability. The results showed that the methods are complementary.

Oeftering, Richard C.↗
NASA NTRS2018

Repair of Sandwich Structure in Support of the Payload Adapter Fitting

As part of a program examining a composite payload adaptor fitting (PAF) for NASA’s Space Launch System (SLS), a repair study of impact damage and misdrilled holes was undertaken. At the beginning of this repair study, the PAF was baselined as a honeycomb sandwich structure with eight-ply quasi-isotropic, carbon-fiber-reinforced epoxy facesheets. Although the baseline configuration could change, the repair program presented herein is generic enough in nature such that it will apply to most sandwich configurations. The vast majority of loads experienced by this structure will be in-plane compression; thus, this repair study concentrates on the in-plane compression strength of representative sandwich structure specimens. The PAF is a truncated cone with a minimum diameter of about 170 inches at the top and a maximum diameter of about 335 inches at the bottom. While the launch vehicle hardware should be protected throughout its life on the ground, rogue events (or misdrilled holes) are still a possibility. This study is not meant to address large scale damage or damage to the part other than in the acreage (the uniform portion of the structure that does not consist of joints or other detailed areas), but address the most probable type of damages (small impacts and misdrilled holes) in the vast majority of the structure (the acreage).

Nettles, A. T.↗
NASA NTRS2017

Predicting Cell Death and Mutation Frequency for a Wide Spectrum of LET by Assuming DNA Break Clustering Inside Repair Domains

The high relative biological effectiveness (RBE) of high charged and energy (HZE) particles for cell death, DNA mutations and cancer remain based on experimental data. In this work, we propose that the existence of DNA repair domains is sufficient to predict both cell death and mutation frequencies for any LET by only taking into account experimental data from low-LET, offering one mechanism for RBE across LET. We hypothesize that whenever multiple DNA double-strand breaks (DSBs) are generated within the same DNA repair domain, DSBs are actively regrouped for more efficient repair [1]. This hypothesis has been supported by the low-LET sublinear dose response observed at doses greater than ~1Gy for 53BP1 radiation-induced foci (RIF) reflecting increasing DSB/RIF with dose [2]. Previously, we modeled radiation-induced cell death of human breast cells by first inferring the size of these domains from the dose dependence of low-LET RIF, and by associating a lethality factor to the number of pairs of DSBs in each RIF [1]. In this work, we first integrate the new NASA computer models RITCARD (Relativistic Ion Tracks, Chromosome Aberrations, Repair, and Damage) [3] and BDSTracks (Biological Damage by Stochastic Tracks) for a more accurate microdosimetry and a better model of the nuclear organization to predict the location of DSBs. A large array of particles and energy are simulated, covering more than three orders of magnitude for LET (~1-1000 keV/µm). Next, we extend our previous model to predict mutation frequencies by assuming that clustered DSBs increase mutation probability, which is formalized by the mutation frequency being linearly dependent on both the number of DSBs and the number of pairs of DSBs inside individual RIF. Linear coefficients are estimated so that simulations predict accurately mutation frequencies observed in Chinese hamster cells exposed to low-LET. Keeping these coefficients unchanged, we then predict mutation frequencies induced by HZE by simulating DSBs and obtain RBEs for mutations and cell death following the expected experimental bell shape for LET dependence. We also observe an orientation effect that needs to be confirmed, showing different RBE depending on the angle of the HZE beam hitting the main axis of the cell.

Plante, Ianik↗
NASA NTRS2020

Predicting Cell Death and Mutation Frequency for a Wide Spectrum of LET by Assuming DNA Break Clustering Inside Repair Domains

Cosmic radiation, which is composed of high charged and energy (HZE) particles, is responsible for cell death and mutation, which may be involved in cancer induction. Mutations are consequences of mis-repaired DNA breaks – especially double-strand breaks (DSBs) – that induce inter- and intra-chromosomal rearrangements (translocations, deletions, inversion). In this study, a computer simulation model is used to investigate the clustering of DSBs in repair domains, previously evidenced by our group in human breast cells [1]. This model is calibrated with experimental data measuring persistent 53BP1 radiation-induced foci (RIF) and is used to explain the high relative biological effectiveness (RBE) of HZE for both cell death and DNA mutation frequencies. We first validate our DSB cluster model using a new track structure model deployed on a simple geometrical configuration for repair domains in the nucleus; then we extend the scope from cell death to mutation induction. This work suggests that mechanism based on DSB repair process can explain several biological effects induced by HZE particles on different type of living cells

Plante, Ianik↗
NASA NTRSDate not supplied

Predicting cell death and mutation frequency for a wide spectrum of LET and across cell lines from DNA break clustering inside repair domains

Cosmic radiation, which is composed of high charged and energy (HZE) particles, is responsible for cell death and mutation, which may be involved in cancer induction. Mutations are consequences of mis-repaired DNA breaks – especially double-strand breaks (DSBs) – that induce inter- and intra-chromosomal rearrangements (translocations, deletions, inversion). In this study, a computer simulation model is used to investigate the clustering of DSBs in repair domains, previously evidenced by our group in human breast cells. This model is calibrated with experimental data measuring persistent 53BP1 radiation-induced foci (RIF) and is used to explain the high relative biological effectiveness (RBE) of HZE for both cell death and DNA mutation frequencies. We first validate our DSB cluster model using a new track structure model deployed on a simple geometrical configuration for repair domains in the nucleus; then we extend the scope from cell death to mutation induction. This work suggests that mechanism based on DSB repair process can explain several biological effects induced by HZE particles on different type of living cells.

Ianik Plante↗
DOE OSTI2019

Tailorable Adhesives for Multi-material Joining, Facile Repair and Re-assembly

Joining of materials and components is inevitable as it allows versatility in assembly and repair along with reduction in time and cost of manufacturing. This work uses ‘active adhesives’ that inherit all the benefits of bonded joints, such as lightweight, eliminate holes and associated stress-concentrations, and overcomes the shortcomings of disassembly and repair. Thermoplastic adhesives modified by the incorporation of electrically conductive graphene nanoplatelets at a concentration above the percolation point provide a unique synergy of mechanical, thermal and electrical properties. While the choice of the thermoplastic is governed by the desired application the addition of the graphene nanoplatelets allows energy to be deposited primarily in the adhesive. The percolated network of graphene particles in the adhesive at less than 2% can quickly couple to high frequency radiation (microwave, or MW) via non-contact methods and increase the adhesive temperature to above the required processing temperatures. The adhesive melts and flows over the adherends and upon cooling forms a structural adhesive bond. Furthermore, the process can be used to disassemble the adhesive joint if repair or reworking is required. In this work, the concept of aforementioned active adhesives was studied using varying graphene contents in nylon-6 adhesive. Activation and re-assembly was studied on in-plane (lap-shear) joints. Structural behavior of re-assembled joints was found to be similar to thermally bonded joints. Overall, active adhesives such as the ones attempted in this work have a great potential in a wide range of applications wherein in-situ repair, re-assembly and recyclability are essential.

36 MATERIALS SCIENCE↗