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At least 271 records · Page 15

Fabrication and Characterization of Diffusion Bonds for Silicon Carbide

Diffusion bonds of silicon carbide (SiC) were fabricated using several different types of titanium (Ti) based interlayers between the SiC substrates. The interlayers were an alloyed Ti foil, a pure Ti foil, and a physically vapor deposited (PVD) Ti coating. Microscopy was conducted to evaluate the cross-sections of the resulting bonds. Microprobe analysis identified reaction formed phases in the diffusion bonded region. Uniform and well adhered bonds were formed between the SiC substrates. In the case where the alloyed Ti foil or a thick Ti coating (i.e. 20 micron) was used as the interlayer, microcracks and several phases were present in the diffusion bonds. When a thinner interlayer was used (i.e. 10 micron PVD Ti), no microcracks were observed and only two reaction formed phases were present. The two phases were preferred and fully reacted phases that did not introduce thermal stresses or microcracks during the cool-down stage after processing. Diffusion bonded samples were evaluated with the non-destructive evaluation (NDE) methods of pulsed thermography and immersion ultrasonic testing. Joined SiC substrates that were fully bonded and that had simulated bond flaws in the interlayer were also evaluated using immersion ultrasound. Pull testing was conducted on the bonds to determine the tensile strength. To demonstrate the joining approach for a complex multilayered component for a low NOx injector application, the diffusion bonding approach was used to join three 4" diameter SiC discs that contained complex fuel and air flow channels.

Halbig, Michael↗

Spacecraft Station-Keeping Trajectory and Mission Design Tools

Two tools were developed for designing station-keeping trajectories and estimating delta-v requirements for designing missions to a small body such as a comet or asteroid. This innovation uses NPOPT, a non-sparse, general-purpose sequential quadratic programming (SQP) optimizer and the Two-Level Differential Corrector (T-LDC) in LTool (Libration point mission design Tool) to design three kinds of station-keeping scripts: vertical hovering, horizontal hovering, and orbiting. The T-LDC is used to differentially correct several trajectory legs that join hovering points. In a vertical hovering, the maximum and minimum range points must be connected smoothly while maintaining the spacecrafts range from a small body, all within the law of gravity and the solar radiation pressure. The same is true for a horizontal hover. A PatchPoint is an LTool class that denotes a space-time event with some extra information for differential correction, including a set of constraints to be satisfied by T-LDC. Given a set of PatchPoints, each with its own constraint, the T-LDC differentially corrects the entire trajectory by connecting each trajectory leg joined by PatchPoints while satisfying all specified constraints at the same time. Vertical and horizontal hover both are needed to minimize delta-v spent for station keeping. A Python I/F to NPOPT has been written to be used from an LTool script. In vertical hovering, the spacecraft stays along the line joining the Sun and a small body. An instantaneous delta-v toward the anti- Sun direction is applied at the closest approach to the small body for station keeping. For example, the spacecraft hovers between the minimum range (2 km) point and the maximum range (2.5 km) point from the asteroid 1989ML. Horizontal hovering buys more time for a spacecraft to recover if, for any reason, a planned thrust fails, by returning almost to the initial position after some time later via a near elliptical orbit around the small body. The mapping or staging orbit may be similarly generated using T-LDC with a set of constraints. Some delta-v tables are generated for several different asteroid masses.

Chung, Min-Kun J.↗

Braze Development of Graphite Fiber for Use in Phase Change Material Heat Sinks

Hamilton Sundstrand (HS), together with NASA Johnson Space Center, developed methods to metallurgically join graphite fiber to aluminum. The goal of the effort was to demonstrate improved thermal conductance, tensile strength and manufacturability compared to existing epoxy bonded techniques. These improvements have the potential to increase the performance and robustness of phase change material heat sinks that use graphite fibers as an interstitial material. Initial work focused on evaluating joining techniques from 4 suppliers, each consisting of a metallization step followed by brazing or soldering of one inch square blocks of Fibercore graphite fiber material to aluminum end sheets. Results matched the strength and thermal conductance of the epoxy bonded control samples, so two suppliers were down-selected for a second round of braze development. The second round of braze samples had up to a 300% increase in strength and up to a 132% increase in thermal conductance over the bonded samples. However, scalability and repeatability proved to be significant hurdles with the metallization approach. An alternative approach was pursued which used nickel and active braze allows to prepare the carbon fibers for joining with aluminum. This approach was repeatable and scalable with improved strength and thermal conductance when compared with epoxy bonding.

Quinn, Gregory↗

Braze Development of Graphite Fiber for Use in Phase Change Material Heat Sinks

Hamilton Sundstrand (HS), together with NASA Johnson Space Center, developed methods to metallurgically join graphite fiber to aluminum. The goal of the effort was to demonstrate improved thermal conductance, tensile strength and manufacturability compared to existing epoxy bonded techniques. These improvements have the potential to increase the performance and robustness of phase change material heat sinks that use graphite fibers as an interstitial material. Initial work focused on evaluating joining techniques from four suppliers, each consisting of a metallization step followed by brazing or soldering of one inch square blocks of Fibercore graphite fiber material to aluminum end sheets. Results matched the strength and thermal conductance of the epoxy bonded control samples, so two suppliers were down-selected for a second round of braze development. The second round of braze samples had up to a 300% increase in strength and up to a 132% increase in thermal conductance over the bonded samples. However, scalability and repeatability proved to be significant hurdles with the metallization approach. An alternative approach was pursued which used a nickel braze allow to prepare the carbon fibers for joining with aluminum. Initial results on sample blocks indicate that this approach should be repeatable and scalable with good strength and thermal conductance when compared with epoxy bonding.

Quinn, Gregory↗

Gas Shielding Technology for Welding and Brazing

Welding is a common method that allows two metallic materials to be joined together with high structural integrity. When joints need to be leak-tight, light-weight, or free of contaminant-trapping seams or surface asperities, welding tends to be specified. There are many welding techniques, each with its own advantages and disadvantages. Some of these techniques include Forge Welding, Gas Tungsten Arc Welding, Friction Stir Welding, and Laser Beam Welding to name a few. Whichever technique is used, the objective is a structural joint that meets the requirements of a particular component or assembly. A key practice in producing quality welds is the use of shielding gas. This article discusses various weld techniques, quality of the welds, and importance of shielding gas in each of those techniques. Metallic bonds, or joints, are produced when metals are put into intimate contact. In the solid-state "blacksmith welding" process, now called Forge Welding (FOW), the site to be joined is pounded into intimate contact. The surfaces to be joined usually need to be heated to make it easier to deform the metal. The surfaces are sprinkled with a flux to melt surface oxides and given a concave shape so that surface contamination can be squeezed out of the joint as the surfaces are pounded together; otherwise the surface contamination would be trapped in the joint and would weaken the weld. In solid-state welding processes surface oxides or other contamination are typically squeezed out of the joint in "flash."

Nunes, Arthur J.↗

Simulations of DSB Yields and Radiation-induced Chromosomal Aberrations in Human Cells Based on the Stochastic Track Structure Induced by HZE Particles

The formation of double‐strand breaks (DSBs) and chromosomal aberrations (CAs) is of great importance in radiation research and, specifically, in space applications. We are presenting a new particle track and DNA damage model, in which the particle stochastic track structure is combined with the random walk (RW) structure of chromosomes in a cell nucleus. The motivation for this effort stems from the fact that the model with the RW chromosomes, NASARTI (NASA radiation track image) previously relied on amorphous track structure, while the stochastic track structure model RITRACKS (Relativistic Ion Tracks) was focused on more microscopic targets than the entire genome. We have combined chromosomes simulated by RWs with stochastic track structure, which uses nanoscopic dose calculations performed with the Monte‐Carlo simulation by RITRACKS in a voxelized space. The new simulations produce the number of DSBs as function of dose and particle fluence for high‐energy particles, including iron, carbon and protons, using voxels of 20 nm dimension. The combined model also calculates yields of radiation‐induced CAs and unrejoined chromosome breaks in normal and repair deficient cells. The joined computational model is calibrated using the relative frequencies and distributions of chromosomal aberrations reported in the literature. The model considers fractionated deposition of energy to approximate dose rates of the space flight environment. The joined model also predicts of the yields and sizes of translocations, dicentrics, rings, and more complex‐type aberrations formed in the G0/G1 cell cycle phase during the first cell division after irradiation. We found that the main advantage of the joined model is our ability to simulate small doses: 0.05‐0.5 Gy. At such low doses, the stochastic track structure proved to be indispensable, as the action of individual delta‐rays becomes more important.

Ponomarev, Artem↗

Simulations of DSB Yields and Radiation-induced Chromosomal Aberrations in Human Cells Based on the Stochastic Track Structure iIduced by HZE Particles

The formation of double‐strand breaks (DSBs) and chromosomal aberrations (CAs) is of great importance in radiation research and, specifically, in space applications. We are presenting a new particle track and DNA damage model, in which the particle stochastic track structure is combined with the random walk (RW) structure of chromosomes in a cell nucleus. The motivation for this effort stems from the fact that the model with the RW chromosomes, NASARTI (NASA radiation track image) previously relied on amorphous track structure, while the stochastic track structure model RITRACKS (Relativistic Ion Tracks) was focused on more microscopic targets than the entire genome. We have combined chromosomes simulated by RWs with stochastic track structure, which uses nanoscopic dose calculations performed with the Monte‐Carlo simulation by RITRACKS in a voxelized space. The new simulations produce the number of DSBs as function of dose and particle fluence for high‐energy particles, including iron, carbon and protons, using voxels of 20 nm dimension. The combined model also calculates yields of radiation‐induced CAs and unrejoined chromosome breaks in normal and repair deficient cells. The joined computational model is calibrated using the relative frequencies and distributions of chromosomal aberrations reported in the literature. The model considers fractionated deposition of energy to approximate dose rates of the space flight environment. The joined model also predicts of the yields and sizes of translocations, dicentrics, rings, and more complex‐type aberrations formed in the G0/G1 cell cycle phase during the first cell division after irradiation. We found that the main advantage of the joined model is our ability to simulate small doses: 0.05‐0.5 Gy. At such low doses, the stochastic track structure proved to be indispensable, as the action of individual delta‐rays becomes more important.

Ponomarev, Artem↗

Reliable Bonding of Composite Laminates Using Reflowable Epoxy Resins

Epoxy matrix composites assembled with adhesives maximize the performance of aerospace structures, but the possibility of forming weak bonds requires the installation of redundant fasteners, which add weight and manufacturing cost. Co-cured joints (e.g. unitized composite structures) are immune to weak bonds because the uncured resin undergoes diffusion and mixing through the joint. A means of co-curing complex structures may reduce the need for redundant fasteners in bondlines. To this end, NASA started the AERoBOND project to develop novel joining materials to enable a “secondary-co-cure” assembly process. Aerospace epoxy resin systems reformulated with offset stoichiometry prevented the resin from advancing beyond the gel point during a conventional autoclave cure cycle up to 180 °C. The offset resins were applied to the joining surfaces of laminate preforms as prepreg. Two surfaces with complimentary offset resins were joined using conventional secondary bonding techniques. Preliminary efforts have indicated that the resulting joint has no discernable interface and appears as a conventional co-cured laminate under optical magnification. This report will discuss the initial work performed regarding formulation of the epoxy resin system using calorimetry, rheology, and mechanical testing.

Palmieri, Frank L.↗

Test Results for Autonomous Assembly of Modular Space Structures

This paper presents test results for autonomous assembly of a modular space structure. A Universal Robots UR10e manipulator with a custom end-effector, known as the Grapple Tool, was used to join TriTruss structural modules. The TriTrusses and their assembly configuration were developed for an in-space assembled telescope conceptual design. The tests presented here were performed with a 1:2.8 dimensionally scaled version of the Tri-Trusses. Robot trajectories were generated autonomously using a sample-based motion planner and an a-priori worksite model. The test results verify the assembly concept of operations as well as the software requirements for the Grapple Tool. While the Grapple Tool used in the tests was designed for the 1:2.8 scale Tri-Trusses, it has the same actuators, software, and computation architecture as the version designed for the full scale structure. The test operations consist of picking up two TriTrusses from their stowed locations and joining them to a third TriTruss mounted on a test stand and joining them to each other. This constitutes the first three modules of the in-space assembled telescope conceptual design. The paper presents the robot behavioral architecture, the generated trajectories commanded, the actual trajectories of the robot, and actuator performance of the Grapple Tool.

test↗

Test Results for Autonomous Assembly of Modular Space Structures

This paper presents test results for autonomous assembly of a modular space structure. A Universal Robots UR10e manipulator with a custom end-effector, known as the Grapple Tool, was used to join TriTruss structural modules. The TriTrusses and their assembly configuration were developed for an in-space assembled telescope conceptual design. The tests presented here were performed with a 1:2.8 dimensionally scaled version of the Tri-Trusses. Robot trajectories were generated autonomously using a sample-based motion planner and an a-priori worksite model. The test results verify the assembly concept of operations as well as the software requirements for the Grapple Tool. While the Grapple Tool used in the tests was designed for the 1:2.8 scale Tri-Trusses, it has the same actuators, software, and computation architecture as the version designed for the full scale structure. The test operations consist of picking up two TriTrusses from their stowed locations and joining them to a third TriTruss mounted on a test stand and joining them to each other. This constitutes the first three modules of the in-space assembled telescope conceptual design. The paper presents the robot behavioral architecture, the generated trajectories commanded, the actual trajectories of the robot, and actuator performance of the Grapple Tool.

test↗

A Combined Computational, Experimental, and Technology Development Approach to In-Space Laser Manufacturing Maturation at NASA Marshall Space Flight Center

In-space manufacturing (ISM) is emerging as a field vital to continued access and capabilities in the space environment. NASA Marshall Space Flight Center (MSFC) is advancing the frontier of in-space laser manufacturing (ISLM) techniques through work initially focused on maturing laser beam welding (LBW) and laser forming (LF) for use in space. Such techniques proffer the ability to assemble and join structures in space from sheet metal or other stock – extant satellites, in situ resource utilization of Lunar regolith, etc. – by forming to desired shapes and then joining via in-space welding (ISW). ISLM processes are useful for assembly, joining, modification, and repair of structures in free space and on the Lunar surface such as large observatories, antennas, trusses, blast/thermal/radiation shields, pressure vessels, and more. However, these techniques are not yet qualified & certified (Q&C) for regular application in space. It would be prohibitively expensive, laborious, and time-consuming to perform Q&C via traditional experimental approaches as data collection & experimentation in space is resource-intensive. As such, benchmark experiments and focused, properly instrumented technology demonstration efforts in space can collect sufficient data that – when combined with verified computational models in an integrated computational materials engineering (ICME) approach – can validate ICME tools capable of translating more readily obtained ground data to in-space, in situ, computationally informed Q&C of ISLM techniques. Several ISLM projects at MSFC are obtaining the data required to validate ICME tools through both ground and flight experiments. A parabolic flight experiment of LBW under vacuum is manifested for August 2024, including both microgravity and Lunar gravity profiles. This collaboration with the Ohio State University is investigating common aerospace alloys such as 316L stainless steel, 2219 aluminum alloy, and Ti64 titanium alloy. In situ data collection includes videography, thermography, and reference thermocouples to build a thermal model of the welds. This will elucidate the relevant physics when combined with post-flight microstructural examination and mechanical testing. MSFC is also progressing towards a suborbital flight experiment of LBW under vacuum, which could provide reams of data on ISW during sustained, high-quality reduced gravity. The effect of combined thermal (cryogenic and high-temperature) and vacuum exposure on both LBW (NASA-funded) and LF (DARPA-funded) is being investigated through ground experiments. In addition to the copious data collected during these ground experiments, ruggedization of LBW hardware will also be pursued. The datasets from these experiments will be used to validate computational models which will inform future ISLM efforts in an ICME framework. A variety of techniques across lengths scales, from CALPHAD-driven thermodynamics & kinetics to phase field modeling of solidification to kinetic Monte Carlo simulations of grain evolution at the mesoscale, will be employed to accelerate the infusion and eventual Q&C of LBW and LF for use in space. The development of data-driven surrogate models to bridge ground to flight experiments and thereby reduce the need for resource-intensive experiments in space will also be investigated. These ICME techniques, surrogate models, and datasets from ground testing can also be employed to advance manufacturing in terrestrial environments.

in-space welding↗

Tube welding and brazing

Brochures outline the tools, equipment, materials, and techniques used for joining tubes by automatic and semiautomatic welding and brazing. A few of the metals being joined are stainless steels of various diameters and thickness. Techniques have been developed for on-site or work-bench repair.

Poorman, R. M.↗

Explosive bonded TZM-wire-reinforced C129Y columbium composites

Technique consists of positioning layers of TZM metal filaments between thin C129Y columbium sheets and joining multiple sheet stacks by single explosive joining operation. Metallurgical bonds are excellent, external heat is not required, process is relatively inexpensive, and resulting composites are considerably stronger than base alloy.

Reece, O. Y.↗

Manufacture, assembly, and delivery of beryllium test panels

Details of the fabrication and assembly of two 99 cm by 99 cm (39 in. by 39 in.) beryllium heat shield test panels are presented. Each panel consists of two hat-stiffened, formed skins which overlap a transverse slip joint at the center of the panel; clips join the two skins at the slip joint, and continuous standoffs are provided at the ends of the panel. The hat-stiffeners are joined to the skin by furnace-brazing, using the braze alloy BAg 18. The parts are generally 0.051 cm (0.020 in.) thick. Tools used to form the detail parts are shown, together with the results of preliminary forming and brazing trials to verify processing techniques. Problems encountered in the manufacture of the panels are discussed.

Source record↗

Photographic and photometric enhancement of Lunar Orbiter products, projects A, B and C

A detailed discussion is presented of the framelet joining, photometric data improvement, and statistical error analysis. The Lunar Orbiter film handling system, readout system, and the digitization are described, along with the technique of joining adjacent framelets by a using a digital computer. Time and cost estimates are given. The problems and techniques involved in improving the digitized data are discussed. It was found that spectacular improvements are possible. Program documentations are included.

Source record↗

Development of gas-pressure bonding process for air-cooled turbine blades

An investigation was conducted on the application of gas-pressure bonding to the joining of components for convectively cooled turbine blades and vanes. A processing procedure was established for joining the fins of Udimet 700 and TD NiCr sheet metal airfoil shells to cast B1900 struts without the use of internal support tooling. Alternative methods employing support tooling were investigated. Testing procedures were developed and employed to determine shear strengths and internal burst pressures of flat and cylindrical bonded finned shell configurations at room temperature and 1750 F. Strength values were determined parallel and transverse to the cooling fin direction. The effect of thermal cycles from 1750 F to room temperature on strength was also investigated.

Meiners, K. E.↗

Energy pulse bonding

To eliminate many of the present termination problems a technique called energy pulse bonding (EPB) was developed. The process demonstrated the capability of: (1) joining conductors without prior removal of insulations, (2) joining conductors without danger of brittle intermetallics, (3) increased joint temperature capability, (4) simultaneous formation of several bonds, (5) capability of higher joint density, and (6) a production oriented process. The following metals were successfully bonded in the solid state: copper, beryllium copper, phosphor bronze, aluminum, brass, and Kovar.

Smith, G. C.↗

Cyclic debonding of adhesive joints

Bonded lap joints were manufactured and tested under static and fatigue loading. Specimens were designed to fail in the bondline, and all fatigue tests included monitoring the crack growth to failure. Test specimens included aluminum details joined by two different adhesives. Specimens also included titanium and boron-epoxy details joined by an epoxy laminating resin. Additonal program variables included bondline thickness, adherend and spice plate thickness, specimen width, and specimen fabrication procedure. Adhesive aging was found to be generally detrimental to the lives of most of the specimens bonded with one adhesive system. Adhesive material was found to have a major influence on debond rate. Co-cured titanium/boron-epoxy specimens were found to resist debonding better than specimens fabricated with a sequential cure. Splice plate thickness and test section width were found to have little effect on debond rate. The data also suggested the existence of an optimum bondline thickness.

Hoffman, D. J.↗