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296 records · Page 17

Assembly of a Full-Scale External Tank Barrel Section Using Friction Stir Welding

A full-scale pathfinder barrel section of the External Tank for the National Aeronautics and Space Administration (NASA) Space Transport System (Space Shuttle) has been assembled at Marshall Space Flight Center (MSFC) via a collaborative effort between NASA/MSFC and Lockheed Martin Michoud Space Systems. The barrel section is 27.5 feet in diameter and 15 feet in height. The barrel was assembled using Super-Light-Weight (SLWT), orthogrid, Al-Li 2195 panel sections and a single longeron panel. A vertical weld tool at MSFC was modified to accommodate FSW and used to assemble the barrel. These modifications included the addition of a FSW weld head and new controller hardware and software, the addition of a backing anvil and the replacement of the clamping system with individually actuated clamps. Weld process 4evelopment was initially conducted to optimize the process for the welds required for completing the assembly. The variable thickness welds in the longeron section were conducted via both two-sided welds and with the use of a retractable pin tool. The barrel assembly was completed in October 1998. Details of the vertical weld tool modifications and the assembly process are presented.

Jones, Chip↗

Fabrication Method for LOBSTER-Eye Optics in <110> Silicon

Soft x-ray optics can use narrow slots to direct x-rays into a desirable pattern on a focal plane. While square-pack, square-pore, slumped optics exist for this purpose, they are costly. Silicon (Si) is being examined as a possible low-cost replacement. A fabrication method was developed for narrow slots in <110> Si demonstrating the feasibility of stacked slot optics to replace micropores. Current micropore optics exist that have 20-micron-square pores on 26-micron pitch in glass with a depth of 1 mm and an extent of several square centimeters. Among several proposals to emulate the square pore optics are stacked slot chips with etched vertical slots. When the slots in the stack are positioned orthogonally to each other, the component will approach the soft x-ray focusing observed in the micropore optics. A specific improvement Si provides is that it can have narrower sidewalls between slots to permit greater throughput of x-rays through the optics. In general, Si can have more variation in slot geometry (width, length). Further, the sidewalls can be coated with high-Z materials to enhance reflection and potentially reduce the surface roughness of the reflecting surface. Narrow, close-packed deep slots in <110> Si have been produced using potassium hydroxide (KOH) etching and a patterned silicon nitride (SiN) mask. The achieved slot geometries have sufficient wall smoothness, as observed through scanning electron microscope (SEM) imaging, to enable evaluation of these slot plates as an optical element for soft x-rays. Etches of different angles to the crystal plane of Si were evaluated to identify a specific range of etch angles that will enable low undercut slots in the Si <110> material. These slots with the narrow sidewalls are demonstrated to several hundred microns in depth, and a technical path to 500-micron deep slots in a precision geometry of narrow, closepacked slots is feasible. Although intrinsic stress in ultrathin wall Si is observed, slots with walls approaching 1.5 microns can be achieved (a significant improvement over the 6-micron walls in micro - pore optics). The major advantages of this technique are the potential for higher x-ray throughout (due to narrow slot walls) and lower cost over the existing slumped micropore glass plates. KOH etching of smooth sidewalls has been demonstrated for many applications, suggesting its feasibility for implementation in x-ray optics. Si cannot be slumped like the micropore optics, so the focusing will be achieved with millimeter-scale slot plates that populate a spherical dome. The possibility for large-scale production exists for Si parts that is more difficult to achieve in micropore parts.

Chervenak, James↗

The Enigmatic Longevity of Granular Materials on Mars: The Case for Geologically Episodic Dune Formation

Martian sand dunes are concentrated in vast sand seas in the circumpolar belt of the planet's northern hemisphere, but they are also pervasive over the whole planet. Their occurrence is to be expected on a super-arid planetary surface subjected to boundary layer drag from a continually active atmosphere. Whilst their occurrence is to be expected, their survival is enigmatic. But the enigma only arises if the martian system is considered similar to Earth's --where sand is moved highly frequently, more or less on a seasonal basis. Experimentally it is readily demonstrated that active sand will soon wear down to small grains and eventually diminish to below the critical sand size required to sustain dune formation. According to conventional wisdom, sand moves at higher speeds on Mars than on Earth, and if it were to move as frequently as it does on Earth, then the dune-forming sand population should have long since disappeared, given the great longevity of the martian aeolian system (Sagan coined the term "kamikaze" grains to express this disappearance). No supply of sand could keep pace with this depletion, especially in light of the fact that Mars does not have very active weathering, nor significant crustal differentiation. On Earth, plate tectonics, magmatic activity, and general crustal differentiation over geological time have produced great concentrations of quartz crystals in the continental crustal masses. Not only are these quartz grains chemically and mechanically resilient, they are about the right size for being transported by either wind or water. Add to this, the geologically recent contribution of glacial grinding, and it is easy to see why there are dune field on Earth. So what are the martian dunes composed of, and how does the material survive the eons of attrition? In addition to experimental demonstrations of sand comminution in laboratory aeolian simulations, the problem can be approached from first principles. Sagan showed that by simple considerations of material strength versus mechanical work applied to the material, comminution to sub-sand size would be inevitable. Another semi-analytical approach might be taken by considering that the archetypal aeolian sand surface texture is an irregularly pitted ("frosted") surface composed of chipping hollows approximately 10 microns in diameter, 5 microns deep. Their volume = about 250 cubic microns, or about 1/25000 of the volume of a 100 micron diameter dune grain. Because a saltating grain always strikes another grain, then two surfaces are impacted. Thus each grain undergoes two impacts for every one saltation leap, when the impact statistics are considered for a closed dune system (it can be calculated that a grain can never undergo <1 impact, and never >2 per saltation leap). Hence, if we conservatively assume that there is damage to a grain each time it bounces, but with the minimum damage of only 2 microscopic craters per impact, then approximately 12,500 impacts are required to completely eliminate the grain. Of course, it would require only a fraction of this amount to reduce the grain to below sand size. A grain will make only several tens of saltation leaps on the stoss side of a dune before becoming buried on the lee slope. The dune then has to move its full length before the grain is exhumed again for abrasion. Even with this hiatus in transport, it is easy to see that terrestrial dunes need resupplying with sand in order to survive. In recent theoretical work it has been shown that martian aeolian transport may be initiated with high-speed grains, but this converts to a lower energy dynamic transport equilibrium in which a reptation population dominates grain transport (on Earth, at least half of the flux is by reptation and creep). On Mars, therefore, average grain speeds may be lower than those on Earth, or at least comparable. This would permit greater longevity for martian sands, but it would not go far enough to solve the survival problem. It may, however, explain why martian dunes are about the same size as terrestrial dunes. If martian saltation leaps were significantly longer than on Earth (as usually assumed), then a dune's lee slope would have to be correspondingly longer in order to trap the sand; this would scale up the whole dune structure. But with shorter trajectories in a reptation population, larger dunes would be unnecessary. Additional information is contained in the original.

Marshall, J.↗

TPSAS-NF1676L-26965-DND

A comprehensive understanding of the spatial and temporal distributions of clouds on a global scale can be best achieved when the vertical distributions and multi-layer occurrence frequencies obtained from active remote sensors are fully integrated with the horizontal distributions currently provided by passive sensors. The Cloud-Aerosol Lidar with Orthogonal Polarization (CALIOP) satellite lidar onboard the Cloud-Aerosol Lidar and Infrared Pathfinder Satellite Observation (CALIPSO) spacecraft was specially designed to acquire aerosol and cloud profiles with unprecedented high vertical resolution and accuracy. As a part of the A-Train satellite constellation, CALIPSO has been operating routinely for more than 10 years and continues to provide a wealth of cloud observations to describe the mean state and inter-annual variability. Recently a suite of level 3 (L3) cloud products has been under development by the CALIPSO lidar science working group at the NASA Langley Research Center. These products describe 3-dimensional (3D) cloud occurrence and 3D ice cloud extinction coefficients and ice water content. Future evolution of the products will add observations from the Imaging Infrared Radiometer onboard CALIPSO. Here we present a brief introduction and provide results from a product prototype. We will characterize the inter-annual vertical variability of zonal cloud occurrence and ice water content during the last 10 years. Suggestions and comments are welcome to help us design and provide better cloud climatology products using CALIOP observations for our cloud community.

Xia Cai↗

Tropical Three-dimensional Cloud Climatology during El Niño Events with CALIPSO Level-3 Cloud Products

The El Niño–Southern Oscillation (ENSO) is a large-scale climatic phenomenon that originates in the tropical Pacific Ocean but affects global climate patterns. Its warm phase El Niño occurs irregularly every two to seven years and peaks in winter. A previous case study showed opposite cloud anomalies at high, middle and low altitude regions during a weak 2006/2007 El Niño and a moderate 2009/2010 El Niño, suggesting a non-linear response of tropical clouds to El Niño sea surface temperature (SST) forcing. To further understand the cloud response to SST, we examine the three-dimensional (3-D) cloud anomalies during all recent five El Niño events since 2006 using level-3 (L3) cloud products from the Cloud-Aerosol Lidar and Infrared Pathfinder Satellite Observation (CALIPSO) mission. During its 17+ years operation, CALIPSO delivered near-global measurements of cloud and aerosol profiles at unprecedented high resolution and sensitivity. In this work, we provide a comprehensive picture of cloud anomalies during El Niño, with a particular focus on thin cirrus clouds at high altitudes, which are challenging for passive sensor detection algorithms. Specifically, the vertical cloud anomalies are calculated with the L3 3-D Cloud Occurrence Product, the horizontal cloud anomalies are from the L3 Global Energy and Water Exchanges (GEWEX) product, and the ice cloud extinction profiles and ice water content are obtained from the L3 Ice Cloud product. These findings will improve current knowledge of ENSO from a new perspective.

El Nino↗

Towards a Marine Stratus Climatology on Drizzle Occurrence from CALIPSO

Marine stratus are a predominant feature of our planet with the annual mean coverage exceeding 20%. They strongly reflect sunlight, yet exert only a modest effect on outgoing infrared radiation, providing a significant net cooling to the Earth’s radiative balance. Their formation is coupled to boundary layer circulations that are driven, in part, by cloud top radiative cooling and evaporative cooling from precipitation in downdrafts. Understanding how these cloud systems evolve as the climate changes is a key question that requires additional information on their lifecycle and microphysical properties to accurately represent their behavior in global circulation models. From a large-scale perspective, insight into the microphysical properties of marine stratus at cloud top can be realized through estimates of the effective radius (Re) of the droplet size distributions derived from MODIS observations. Estimates on the occurrence of rain/drizzle are available from CloudSat. Together these observations indicate that precipitation frequently occurs in clouds with higher cloud top Re. This relationship is consistent with the well documented shift in cloud top droplet size distributions towards fewer, yet larger droplets prior the onset of precipitation. Here we report on a new and complementary set observations from the CALIPSO mission. The approach derives an extinction-to-backscatter ratio (Sc, also known as the cloud lidar ratio) using an established relationship that depends on observations of the lidar attenuated backscatter and volume depolarization ratio within the cloud. Because Sc is strongly and inversely related to Re, a change in the derived Sc from higher to lower values corresponds to a change in the droplet size distribution as seen by MODIS. This change in the lidar signals at cloud top clearly identifies clouds that are capable of precipitation. The presentation provides a brief overview of the approach for deriving Sc and compares CALIOP-derived Sc with observations from other techniques. CALIOP classifications of drizzling clouds, based on the retrieved values Sc, are compared to independent, collocated assessments of drizzle occurrence reported in the standard CloudSat data products. Regional and seasonal comparisons highlight the strengths and weaknesses of the two sensors. A machine learning approach that combines information from both CALIOP and CloudSat showcases possible improvements in the global identification of scenes likely to contain rain-bearing clouds.

CALIPSO↗

Satellite Tracking of Shallow Cumulus during CAMP2Ex: The Aerosol and Organization Connection

Shallow moist convection is ubiquitous throughout the tropics and represents a key player in boundary layer processes. Shallow clouds come in many forms, from scattered, short-lived cumulus to organized features that include cold pool boundaries and lines reaching O(100 km) scale lasting several hours. In this study, we explore how cloud morphology and environmental aerosol affect shallow cumulus lifecycle properties. Measuring such influences requires a broad, detailed view of these cloud fields as they grow and decay. Geostationary satellites provide a means to follow the clouds with enhanced spatiotemporal sampling from space. We apply a cloud-tracking tool to study lifecycle properties of shallow cumulus sampled during the NASA Cloud, Aerosol, and Monsoon Processes Philippines Experiment (CAMP2Ex) field campaign of 2019. The mission conducted airborne and shipborne operations over the West Pacific Ocean, in tandem with Rapid Scan imagery from the Advanced Himawari Imager (AHI) on the Japan Meteorological Agency’s (JMA) Himawari-8 satellite. We segment shallow cumulus on AHI 0.5-km visible reflectance during the daylit hours of several research flights that exhibited ideal atmospheric conditions for tracking. We collect the resulting cloud tracks by regions containing airborne sampling of the cloud environments and by two specific segmentation techniques: one optimized for small, disorganized cumulus and the other for larger, organized clouds using suitable thresholds for reflectance and blurring. We present an analysis of cloud lifecycle properties using our dual segmentation approach for various sampled environments of CAMP2Ex. A total of 7 research flights (RFs) exhibited ideal conditions for generating cloud-track ensembles under similar thermodynamic and kinematic profiles but with varying aerosol load. We consider lifetime, track-achieved metrics, and ensemble-fitted growth rates to evaluate the aerosol effect. Cloud elongation, a factor in cloud morphology, is also considered for any potential influence in observed shifts in growth rates. The results suggest that aerosol affects cloud lifecycles more significantly for clouds with larger areas and independent of the elongation factor.

Cloud Tracking↗

SLI Complex Curvature Friction Stir Weld Risk Reduction Program

The Space Launch Initiative Program (SLI) in conjunction with the National Center for Advanced Manufacturing (NCAM) will demonstrate the ability to produce large-scale complex curvature hardware using the self-reacting friction stir welding process. This multi-phased risk reduction program includes friction stir welding process development and manufacture of a 22-ft diameter quarter dome using a conventional tooling approach; it culminates in a 27.5-ft diameter quarter dome demonstration performed on a 5-axis Universal Weld System. The design, fabrication, and installation of the Universal Weld System is made possible through a collaboration between the State of Louisiana, NASA, and the University of New Orleans. The Universal Weld System, manufactured by MTS Systems Corporation, will be installed at the Michoud Assembly Facility in New Orleans, Louisiana, and will be capable of manufacturing domes up to 30 ft in diameter. All welding will be accomplished using the Adaptable Adjustable Pin Tool (AdAPT) weld head and controller manufactured by MTS. Weld parameters will be developed for an aluminum alloy in gauges ranging from 0.320 to 0.400 in. thick. Weld quality will be verified through radiography, mechanical property testing at ambient and LN2 temperatures, and metallurgical analysis. The AdAPT weld head will then be mounted on a 22-ft diameter dome tool, which will be modified to include a welding track and drive system for moving the AdAPT weld head along the weld joint. This tool will then be used to manufacture a 22-ft diameter dome of an aluminum alloy, with 0.320-in. constant thickness joints, consisting of three individual gore panels. Finally, the 27.5-ft diameter quarter dome will be welded on the Universal Weld System. The quarter dome will consist of three individual gore panels with weld lands tapering from 0.320 to 0.360 in. in thickness. With the demonstration of these welds, the ability to manufacture large diameter domes using the friction stir weld process in conjunction with a universal weld system provides a low risk approach to the fabrication of aluminum tanks for future launch vehicle applications.

Hartley, Paula J.↗