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At least 307 records · Page 17

AMCC casting development. Volume 1: Executive Summary

The Advanced Combustion Chamber Casting (AMCC) has been a technically challenging part due to its size, configuration, and alloy type. The height and weight of the wax pattern assembly necessitated the development of a hollow gating system to ensure structural integrity of the shell throughout the investment process. The complexity in the jacket area of the casting required the development of an innovative casting technology that PCC has termed 'TGC' or Thermal Gradient Control. This method, of setting up thermal gradients in the casting during solidification, represents a significant process improvement for PCC and has been successfully implemented on other programs. Metallurgical integrity of the final four castings was very good. Only the areas of the parts that utilized 'TGC Shape & Location System #2' showed any significant areas of microshrinkage when evaluated by non-destructive tests. Alumina oxides detected by FPI on the 'float' surfaces (top sid surfaces of the casting during solidification) of the part were almost entirely less than the acceptance criteria of .032 inches in diameter. Destructive chem mill of the castings was required to determine the effect of the process variables used during the processing of these last four parts (with the exception of the 'Shape & Location of TGC' variable).

Source record↗

Metallographic Analysis of Brush Bristle and Integrity Testing of Brush Seal in Shroud Ring of T-700 Engine

Post-test investigation of a T-700 engine brush seal found regions void of bristles ('yanked out'), regions of bent-over bristles near the inlet, some 'snapped' bristles near the fence, and a more uniform 'smeared' bristle interface between the first and last axial rows of bristles. Several bristles were cut from the brush seal, wax mounted, polished, and analyzed. Metallographic analysis of the bristles near the rub tip showed tungsten-rich phases uniformly distributed throughout the bristle with no apparent change within 1 to 2 micron of the interface except for possibly a small amount of titanium, which would represent a transfer from the rotor. Analysis of the bristle wear face showed nonuniform tungsten, which is indicative of material resolidification. The cut end contained oxides and internal fractures; the worn end was covered with oxide scale. Material losses due to wear and elastoplastic deformation within the shear zone and third-body lubrication effects in the contact zone are discussed.

Hendricks, Robert C.↗

MobileSat (R): A characteristically Australian MSS

Optus launched its mobile satellite telephone service MobileSat in August 1994. This provided Australia and its neighboring waters with nation-wide mobile telephone coverage and still is the world's only domestic mobile satellite telephone system. This paper provides details of Optus' experience in developing and launching the MobileSat service, including (1) a retrospective of the issues that have waxed and waned in importance during the development and implementation phases, and (2) the strategy for future activities based on the experience gained in the development phase.

Wagg, Michael↗

Preliminary work toward the development of a dimensional tolerance standard for rapid prototyping

Rapid prototyping is a new technology for building parts quickly from CAD models. It works by slicing a CAD model into layers, then by building a model of the part one layer at a time. Since most parts can be sliced, most parts can be modeled using rapid prototyping. The layers themselves are created in a number of different ways - by using a laser to cure a layer of an epoxy or a resin, by depositing a layer of plastic or wax upon a surface, by using a laser to sinter a layer of powder, or by using a laser to cut a layer of paper. Rapid prototyping (RP) is new, and a standard part for use in comparing dimensional tolerances has not yet been chosen and accepted by ASTM (the American Society for Testing Materials). Such a part is needed when RP is used to build parts for investment casting or for direct use. The objective of this project was to start the development of a standard part by using statistical techniques to choose the features of the part which show curl - the vertical deviation of a part from its intended horizontal plane.

Kennedy, W. J.↗

Preferentially Etched Epitaxial Liftoff of InP Material

The present invention is directed toward a method of removing epitaxial substrates from host substrates. A sacrificial release layer of ternary material is placed on the substrate. A layer of InP is then placed on the ternary material. Afterward a layer of wax is applied to the InP layer to apply compressive force and an etchant material is used to remove the sacrificial release layer.

Bailey, Sheila G.↗

Mars Secular Obliquity Change Due to Water Ice Caps

Mars may have substantially changed its average axial tilt over geologic time due to the waxing and waning of water ice caps. Depending upon Mars' climate and internal structure, the average obliquity could have increased or decreased through climate friction by tens of degrees. A decrease could account for the apparent youthfulness of the polar layered terrain. Alternatively, Mars' average obliquity may have changed until it became "stuck" at its present value of 24.4 deg.

Rubincam, David P.↗

Materials Selection and Their Characteristics as Used in Rapid Prototyping

NASA's Marshall Space Flight Center (MSFC) conducted a program to evaluate six technologies used in Rapid Prototyping (RP) to produce investment casting patterns. In this paper, RP refers to the collective additive fabrication technologies known as Solid Free-Form Fabrication. Such technologies are being used with increasing frequency in manufacturing applications, due in part to their rapidly expanding capabilities to fabricate models from many types of materials. This study used ABS plastic, polycarbonate, TrueForm PM6, epoxy resin, paper, starch, and wax. The baseline model was a semi-complex prototype fuel pump housing, intended for use in the X-33 reusable launch vehicle. All models were shelled in a production- grade colloidal silica ceramic. Primary coats were zircon-base flour with zircon backup, while secondary coats were silica grains with a tabular alumina backup. Each model was shelled in an identical manner, using the same atmospheric conditions and drying times, as well as the same number of layers. Bake-outs and firing cycles were consistent with the leach ability of each material. Preheat and bath temperatures were also kept consistent. All molds were cast in vacuum using a hydrogen-resistant superalloy (NASA- 23) that was developed in-house. The final technical evaluation included detailed measurements of the model and the final casting, in order to determine any dimensional changes caused by different pattern materials, as well as documentation of all defects and any obvious refractory/model reactions. Prototype production costs were estimated for each method and taken into consideration during trade-off analysis.

Cooper, K.↗

Application of Rapid Prototyping and Wire Arc Spray to the Fabrication of Injection Mold Tools (MSFC Center Director's Discretionary Fund)

Rapid prototyping (RP) is a layer-by-layer-based additive manufacturing process for constructing three-dimensional representations of a computer design from a wax, plastic, or similar material. Wire arc spray (WAS) is a metal spray forming technique, which deposits thin layers of metal onto a substrate or pattern. Marshall Space Flight Center currently has both capabilities in-house, and this project proposed merging the two processes into an innovative manufacturing technique, in which intermediate injection molding tool halves were to be fabricated with RP and WAS metal forming.

Cooper, K. G.↗

Mars Secular Obliquity Decrease and the Layered Terrain

Mars may have substantially decreased its average axial tilt over geologic time due to the waxing and waning of water ice caps through the phenomenon of climate friction (also called obliquity-oblateness feedback). Depending upon Mars' climate and internal structure, water caps of the order of 10(exp 17) - 10(exp 18) kg cycling with the obliquity oscillations could have either increased or decreased the average obliquity by possibly tens of degrees over the age of the solar system. Gravity and topography observations by the Mars Global Surveyor indicate that the south polar cap is mostly uncompensated, so that Mars may be largely rigid on the obliquity timescale. Further, Mars may be a water-rich planet, so that there is a large phase angle between insolation forcing and the size of the obliquity-driven water caps. A stiff, water-rich planet implies an obliquity decrease over the eons. Such a decrease might account for the apparent youthfulness of the polar layered terrain. The idea is that fewer volatiles were available to be cycled into and out of the terrain at high mean obliquity, because of the eveness of insolation between equator and pole, and because of small insolation variations as the obliquity oscillated; so that the movement of volatiles and dust produced thin layers or perhaps no layers at all. As the average obliquity decreased, the insolation contrast between high and low latitudes increased, plus the insolation variations over the obliquity cycle grew somewhat bigger, so that more volatiles and dust might have shuttled into and out of the polar regions, forming the observed thick layers late in Mars' history. It may also be that the average tilt has decreased to the point where the climate friction mechanism is starving itself: more and more water has gotten locked up in the polar regions, making less available for cycling with the oscillations. And the layer-forming mechanism may be starving too: not only less water, but also at low average obliquity the atmospheric pressure is lower, so that dust storms become rarer, making less dust available to be deposited in the layers. The rate of water ice sublimation and the atmospheric pressure are both expected to drop sharply for obliquities only slightly lower than the present one. Hence there are qualitative reasons for believing that (a) the mean obliquity may be about as low as it can get, and (b) the mechanism for making the layers may turn off at low average obliquity, so that the layered terrain is a transient phenomenon. Thus the formation of the layered terrain may be intimately connected to a change in the mean axial tilt.

Rubincam, D. P.↗

The Dynamics of a Semi-Arid Region in Response to Climate and Water - Use Policy

The objectives of this project were to determine the response of semi-arid ecosystems to the combined forcings of climate variability and anthropogenic stress. Arid and semi-arid systems encompass close to 40% of the worlds land surface. The ecology of these regions are principally limited by water, and as the water resources wax and wane, so should the health and vigor of the ecosystems. Water, however, is a necessary and critical resource for humans living in these same regions. Thus for many and and semi-arid regions the natural systems and human systems are in direct competition for a limited resource. Increasing competition through development of and and semi-arid regions, export of water resources, as well as potential persistent changes in weather patterns are likely to lead to fundamental changes in carrying capacity, resilience, and ecology of these regions. A detailed understanding of these systems respond to forcing on a regional and local scale is required in order to better prepare for and manage future changes in the availability of water. In the Owens Valley CA, decadal changes in rainfall and increased use of groundwater resources by Los Angles (which derives 60-70% of its water from this region) have resulted in a large-scale experiment on the impacts of these changes in semi-arid ecosystems. This project works directly with the Inyo County Water Department (local water authority) and the Los Angles Department of Water and Power (regional demand on water resources) to understand changes, their causes, and impacts. Very detailed records have been kept for a number of selected sites in the valley which provide essential ground truth. These results are then scaled up through remote sensed data to regions scale to assess large scale patterns and link them to the fundamental decisions regarding the water resources of this region. A fundamental goal is to understand how resilient the native ecosystems are to large changes in water resources. Are they are on a spring (remove and return resources, do the systems return to the original state) or a vector (when water returns have the systems fundamentally changed).

Mustard, John F.↗

Process for Making Ceramic Mold

An improved process for slip casting molds that can be more economically automated and that also exhibits greater dimensional stability is disclosed. The process involves subjecting an investment pattern, preferably made from wax, to successive cycles of wet-dipping in a slurry of colloidal, silica-based binder and dry powder-coating, or stuccoing with plaster of Paris or calcium sulfate mixtures to produce a multi-layer shell over the pattern. The invention as claimed entails applying a primary and a secondary coating to the investment pattern. At least two wet-dipping on in a primary slurry and dry-stuccoing cycles provide the primary coating, and an additional two wet-dippings and dry-stuccoing cycles provide the secondary, or back-up, coating. The primary and secondary coatings produce a multi-layered shell pattern. The multi-layered shell pattern is placed in a furnace first to cure and harden, and then to vaporize the investment pattern, leaving a detailed, high precision shell mold.

Buck, Gregory M.↗

Internally Cooled Monolithic Silicon Nitride Aerospace Components

A set of rapid prototyping (RP) processes have been combined with gelcasting to make ceramic aerospace components that contain internal cooling geometry. A mold and core combination is made using a MM6Pro (Sanders Prototyping, Inc.) and SLA-250/40 (3Dsystems, Inc.). The MM6Pro produces cores from ProtoBuild (trademarked) wax that are dissolved in room temperature ethanol following gelcasting. The SLA-250/40 yields epoxy/acrylate reusable molds. Parts produced by this method include two types of specimens containing a high density of thin long cooling channels, thin-walled cylinders and plates, as well as a model hollow airfoil shape that can be used for burner rig evaluation of coatings. Both uncoated and mullite-coated hollow airfoils has been tested in a Mach 0.3 burner rig with cooling air demonstrating internal cooling and confirming the effectiveness of mullite coatings.

Best, Jonathan E.↗

Candle Flames in Microgravity

The goal of this work is to study both experimentally and numerically the behavior of a candle flame burning in a microgravity environment. Two space experiments (Shuttle and Mir) have shown the candle flame in microgravity to be small (approximately 1.5 cm diameter), dim blue, and hemispherical. Near steady flames with very long flame lifetimes (up to 45 minutes in some tests) existed for many of the tests. Most of the flames spontaneously oscillated with a period of approximately 1 Hz just prior to extinction). In a previous model of candle flame in microgravity, a porous sphere wetted with liquid fuel simulated the evaporating wick. The sphere, with a temperature equal to the boiling temperature of the fuel, was at the end of an inert cone that had a prescribed temperature. This inert cone produces the quenching effect of the candle wax in the real configuration. Although the computed flame shape resembled that observed in the microgravity experiment, the model was not able to differentiate the effect of wick geometry, e.g., a long vs. a short wick. This paper presents recent developments in the numerical model of the candle flame. The primary focus has been to more realistically account for the actual shape of the candle.

Dietrich, D. L.↗

Assessment of Psychophysiological Responses During Motion Sickness Testing

The purpose of this investigation is to evaluate a methodology designed to accurately trace the temporal progression of motion sickness and space motion sickness symptoms. With this method, subjects continuously monitor their own motion sickness symptoms during exposure to a provocative stimulus as symptoms occur, in contrast to previous methods during which subjects report symptoms verbally at discrete time intervals. This method not only is comparable to previous methods in the type of symptoms that subjects report, but subjects report symptoms more frequently. Frequent reporting of motion sickness symptoms allows researchers to detail the waxing and waning of motion sickness symptoms for each individual. Previous research has shown that physiological responses to motion sickness stimuli are characterized by unique individual differences in response patterns. By improving our assessment of motion sickness symptoms with continuous monitoring of symptoms, the relationship between specific physiological responses and sickness levels can be more accurately determined for each individual. Results from this study show significant positive relationships between skin conductance levels and symptom levels for ten individuals; a significant positive relationship between temperature and symptom levels for 5 of 10 individuals; and both positive and negative relationships between respiration, heart rate, blood volume pulse and symptom levels. Continuous monitoring of motion sickness symptoms can be used to more accurately assess motion sickness to aid in the evaluation of countermeasures. In addition, recognition of the onset of symptoms that are strongly related to specific physiological responses could be used as cues to initiate procedures (e.g., Autogenic Feedback Training) to prevent the development of severe motion sickness symptoms.

Stoud, Cynthia S.↗

Hypersaline Microbial Mat Lipid Biomarkers

Lipid biomarkers and compound specific isotopic abundances are powerful tools for studies of contemporary microbial ecosystems. Knowledge of the relationship of biomarkers to microbial physiology and community structure creates important links for understanding the nature of early organisms and paleoenvironments. Our recent work has focused on the hypersaline microbial mats in evaporation ponds at Guerrero Negro, Baja California Sur, Mexico. Specific biomarkers for diatoms, cyanobacteria, archaea, green nonsulfur (GNS), sulfate reducing, sulfur oxidizing and methanotrophic bacteria have been identified. Analyses of the ester-bound fatty acids indicate a highly diverse microbial community, dominated by photosynthetic organisms at the surface. The delta C-13 of cyanobacterial biomarkers such as the monomethylalkanes and hopanoids are consistent with the delta C-13 measured for bulk mat (-10%o), while a GNS biomarker, wax esters (WXE), suggests a more depleted delta C-13 for GNS biomass (-16%o). This isotopic relationship is different than that observed in mats at Octopus Spring, Yellowstone National Park (YSNP) where GNS appear to grow photoheterotrophic ally. WXE abundance, while relatively low, is most pronounced in an anaerobic zone just below the cyanobacterial layer. The WXE isotope composition at GN suggests that these bacteria utilize photoautotrophy incorporating dissolved inorganic carbon (DIC) via the 3-hydroxypropionate pathway using H2S or H2.

Jahnke, Linda L.↗

Processing of IN-718 Lattice Block Castings

Recently a low cost casting method known as lattice block casting has been developed by JAM Corporation, Wilmington, Massachusetts for engineering materials such as aluminum and stainless steels that has shown to provide very high stiffness and strength with only a fraction of density of the alloy. NASA Glenn Research Center has initiated research to investigate lattice block castings of high temperature Ni-base superalloys such as the model system Inconel-718 (IN-718) for lightweight nozzle applications. Although difficulties were encountered throughout the manufacturing process , a successful investment casting procedure was eventually developed. Wax formulation and pattern assembly, shell mold processing, and counter gravity casting techniques were developed. Ten IN-718 lattice block castings (each measuring 15-cm wide by 30-cm long by 1.2-cm thick) have been successfully produced by Hitchiner Gas Turbine Division, Milford, New Hampshire, using their patented counter gravity casting techniques. Details of the processing and resulting microstructures are discussed in this paper. Post casting processing and evaluation of system specific mechanical properties of these specimens are in progress.

Hebsur, Mohan G.↗

Lipid Biomarkers for Methanogens in Hypersaline Cyanobacterial Mats for Guerrero Negro, Baja California Sur

Analyses of sediments from the vicinity of active methane seeps have uncovered a particular suite of lipid biomarker patterns that characterize methane consuming archaea and their syntrophic, sulfate reducing partners. These isoprenoid biomarkers, largely identified by their anomalously light carbon isotopic signatures, have been a topic of intense research activity and are recorded in numerous methane-rich environments from Holocene to Cenozoic. This phenomenon has implications for depleted kerogens at 2.7 Ga on early Earth (Hinrichs 2002). In contrast, the lipid biosignatures of methane producing archaea are not readily identified through distinct isotopic labels and have received comparably little attention in analyses of archaea in environmental samples. Indeed, environmental analyses generally detect only free archaeal lipids, not the intact, polar molecules found in the membrane of living organisms. As part of the Ames NAI, the 'Early Microbial Ecosystem Research Group' (EMERG) is working to understand microbial processes in the hypersaline cyanobacterial mats growing in the salt evaporation ponds of the Exportadora de Sal at Guerrero Negro, Baja California Sur, Mexico. The aim of this study was to develop methods by which we could identify the organisms responsible for methane generation in this environment. While the ester-bound fatty acids, hopanoids and wax esters provide a means to identify most of the bacterial components of these mats, the archaea which Ere evidently present through genomic assays and the fact of intense methane production (Hoehler et al. 200l), have not been identified through their corresponding lipid signatures. Archaeal core lipids present a number of analytical challenges. The core lipids of methanogens comprise C20, C40 and sometimes C25 isoprenoid chains, linked through ether bonds to glycerol. As well as archaeal (C20), sn-2- and sn-3-hydroxyarchaeol are associated particularly with methylotrophic methanogens. Recently, we have also identified a dihydroxyarchaeol in a hyperthermophilic methanogen (Summons et al. 2002). Additional structural diversity is encoded into the polar head groups that are attached to the glycerol ether cores. The C20 core lipids are readily analyzed by GC-MS as their volatile trimethylsilyl derivatives while compounds with intact polar head groups can only be detected using LC-MS approaches. Our approach was to utilize the alternative of an ether cleavage reagent (BBr3 vs. HI) and a hydride reducing agent to convert all ether lipids to hydrocarbon in order to provide a vertical profile of quantitative information that might be matched to methane fluxes. We have found that while conventional acid hydrolysis and HI treatment will destroy hydroxyarchaeols, molecular information remains intact through use of BBr3 for ether cleavage. This method revealed the presence of traces of biphytane and various ether alkyls associated with some sulfate reducing bacteria within the mat structure. An interesting, and potentially valuable, byproduct of the method utilizing HI was the identification of abundant homohopanoids after superhydride reduction. Evidently present as sulfur-bound diagenetic products these hopanoids are likely cyanobacterial biomarkers in the early stages of diagenetic preservation.

Jahnke, Linda L.↗

Seasonal Variation of Martian Polar Caps: 1999 and 2001 MOC Data

The seasonal Martian polar caps wax and wane in response to condensation and sublimation of carbon dioxide resulting from seasonal insolation changes on Mars. Numerous data exist on observations of the recession or sublimation phases in the visible portion of the spectrum for the last two centuries. William Herschel published the first quantitative observations of the seasonal recession of the Martian polar caps in 1784. During the next 180 years, ground based observers used a variety of techniques to observe recessions; Slipher summarized these observations in 1962, on the eve of the first space exploration of Mars. Portions of the seasonal cycles of the surface caps that were observed by Mariners 7 and 9 and by Viking as well as ground based studies from 1971-1988 by the International Planetary Patrol were summarized in a review article following the Fourth International Conference on Mars in 1989. Hubble Space Telescope observed points in the seasonal recessions of the south and north caps during the 1990 s. Differences between different Martian regressions have been reported in the past; but, because many of the relevant data sets are localized in longitude, at least some of these results could be an artifact introduced by the considerable longitudinal asymmetry that observed during recessions.

P B James↗