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NASA NTRS2014

Development Status of Adjustable Grazing Incidence Optics for 0.5 Arcsecond X-Ray Imaging

We describe progress in the development of adjustable grazing incidence X-ray optics for 0.5 arcsec resolution cosmic X-ray imaging. To date, no optics technology is available to blend high resolution imaging like the Chandra X-ray Observatory, with square meter collecting area. Our approach to achieve these goals simultaneously is to directly deposit thin film piezoelectric actuators on the back surface of thin, lightweight Wolter-I or Wolter- Schwarschild mirror segments. The actuators are used to correct mirror figure errors due to fabrication, mounting and alignment, using calibration and a one-time figure adjustment on the ground. If necessary, it will also be possible to correct for residual gravity release and thermal effects on-orbit. In this paper we discuss our most recent results measuring influence functions of the piezoelectric actuators using a Shack-Hartmann wavefront sensor. We describe accelerated and real-time lifetime testing of the piezoelectric material, and we also discuss changes to, and recent results of, our simulations of mirror correction.

Reid, Paul B.↗
NASA NTRS2014

Using Lunar Observations to Validate Pointing Accuracy and Geolocation, Detector Sensitivity Stability and Static Point Response of the CERES Instruments

Validation of in-orbit instrument performance is a function of stability in both instrument and calibration source. This paper describes a method using lunar observations scanning near full moon by the Clouds and Earth Radiant Energy System (CERES) instruments. The Moon offers an external source whose signal variance is predictable and non-degrading. From 2006 to present, these in-orbit observations have become standardized and compiled for the Flight Models -1 and -2 aboard the Terra satellite, for Flight Models-3 and -4 aboard the Aqua satellite, and beginning 2012, for Flight Model-5 aboard Suomi-NPP. Instrument performance measurements studied are detector sensitivity stability, pointing accuracy and static detector point response function. This validation method also shows trends per CERES data channel of 0.8% per decade or less for Flight Models 1-4. Using instrument gimbal data and computed lunar position, the pointing error of each detector telescope, the accuracy and consistency of the alignment between the detectors can be determined. The maximum pointing error was 0.2 Deg. in azimuth and 0.17 Deg. in elevation which corresponds to an error in geolocation near nadir of 2.09 km. With the exception of one detector, all instruments were found to have consistent detector alignment from 2006 to present. All alignment error was within 0.1o with most detector telescopes showing a consistent alignment offset of less than 0.02 Deg.

Daniels, Janet L.↗
NASA NTRSDate not supplied

22 N HPGP Thruster Life Testing

In the ever-changing paradigm of efficient and capable spacecraft design, scientific missions continue pushing the envelope enabling spacecraft subsystems to deliver effective solutions to meet challenging new mission/spacecraft needs. From an in-space storable liquid chemical propulsion perspective, monopropellant hydrazine has been, and continues to be, a dependable propellant with considerable flight heritage, a variety of engine thrust classes available from multiple vendors, with repeatable and reliable performance. Additionally, the space propulsion industry has learned to successfully handle hydrazine, its regulations, the safety protocols, the personnel protective equipment, and the unique training standards–all requisite for loading spacecraft propulsion systems with toxic hypergolic hydrazine. The question now arises as to “what is next for in-space chemical propulsion?” Further, with the evolution and concrete advancements in innovative in-space green propellant technologies, capable of providing realizable benefits to scientific missions, concern over the reliability and availability of this higher performing and safer to handle class of propellants is waning. As science missions move forward with the potential flight in fusion of High Performance Green Propulsion (HPGP), NASA and its industry partners are working to address any gaps in system reliability, performance, or unique operational considerations. Propellant technology that offers both higher performance and significant reduction in personnel hazards compared to hydrazine presents an attractive propulsion subsystem design opportunity. Increased propulsion subsystem performance can result in lower spacecraft launch mass, larger scientific payloads, or extended on-orbit lifetimes. Mission trades using green propulsion technologies have been documented on multiple NASA Goddard Space Flight Center (GSFC) mission classes, examining various parameters and requirements to support mission architectures in Low Earth Orbit (LEO), High Earth Orbit (HEO), geostationary, lunar, planetary, and Quasi-halo orbit around Sun-Earth Lagrange point (L2). The results of these trade studies show promising, attainable benefits. The perceived programmatic risk of flying a newer propulsion technology has, unfortunately, not outweighed the benefits to date. To take advantage of the improved performance and mitigate programmatic risk, HPGP engines must demonstrate life testing at higher propellant throughputs than have currently been demonstrated. In an effort to proactively address the challenges with technology infusion into a risk-averse community, NASA and the Swedish National Space Agency (SNSA) outlined a collaborative Implementing Arrangement (IA) for the respective agencies to pursue increased HPGP technology maturation. This initial IA effort began in 2013, fresh off the heels of the successful PRISMA HPGP technology demonstration mission. The IA targeted objective is to reduce risk to potential future HPGP missions and fully characterize the LMP-103S propellant and associated engine performance. Over the past eight years, HPGP has flown in propulsion systems on twenty-five(25) spacecraft from seven(7) different Launch Ranges around the globe and on seven (7) different Launch Vehicles. Six(6) of these launches involved multiple loading operations for multiple spacecraft. For U.S. Range operations, nine (9) HPGP systems have been processed at Vandenberg Space Force Base(VSFB):six(6) in 2017, and three (3) in 2018. Six (6) more have been processed at Cape Canaveral Air Force Station (CCAFS)in May 2020, with three (3) systems launched in June 2020 and the remaining three (3) system were left loaded and ready until their launch in August of 2020. Three (3) more systems have been processed at Wallops Flight Facility(WFF)and launched in June 2021. In addition, these propulsion subsystems employed heritage propulsion subsystem component such as valves, filters, and pressure transducers, and have further demonstrated nominal functionality in both diaphragm and Propellant Management Device (PDM) propellant tanks. Based on these successes, HPGP technology continues to be considered for NASA Science Mission Directorate missions at GSFC. The work presented herein represents many years of development and collaborative efforts to successfully align higher performance, low toxicity hydrazine alternatives into scientific missions. NASA GSFC Propulsion Engineering, in collaboration with Bradford ECAPS, has developed mission specific thruster design and testing requirements to establish GSFC’s desired test conditions and firing sequences.In2017, the first flight-like 22N HPGP thruster Engineering Qualification Model (EQM-1)was designed and built by Bradford ECAPS to prove out the thruster design, materials, build process, and test campaign with respect to NASA GSFC critical component and mission requirements. This test program was developed to comprehensively test the thruster, the technology, and ultimately increase the 22N HPGP Technology Readiness Level(TRL). EQM-1was tested to environmental qualification levels prior to hot fire performance testing to represent the relevant end-to-end environment (launch to on-orbit operation)with required margin. This thruster demonstrated steady-state and pulse mode operational capability with propellant thruster throughput up to~53kg.At this throughput level, the EQM-1 engine began to present off-nominal performance and the test campaign was halted to allow for non-destructive testing and identify the root cause for the an omalous performance. Capitalizing on the successful elements of the EQM-1 campaign, an upgraded 22N HPGP EQM-2 has been manufactured by Bradford ECAPS to meet the complete GSFC requirements. The EQM-2 thruster’s test campaign has further demonstrated the robustness of the HPGP propulsion technology and increased the Technology Readiness Level (TRL) by undergoing a full acceptance test program, then proceeding into qualification, including environmental testing (vibration and shock to qualification levels),as well as hot-fire life testing, operating at steady-state and pulse modes with increased propellant thruster throughput to~150kg. The HPGP thruster performance testing enables effective HPGP thruster readiness evaluation to meet NASA candidate mission requirements in the future.

High↗
NASA NTRSDate not supplied

Geopolymer Lunar Concrete under Reduced-Pressure Curing and Vacuum Exposure

Geopolymer concrete has emerged as a promising material for constructing habitats, roads, landing pads, and other necessary infrastructure on the lunar surface. Proper in-situ resource utilization (ISRU) is an important aspect of any candidate lunar construction material. Geopolymer concrete is effective at ISRU, as the lunar regolith can be used in the “as found” condition and mixed with an alkaline solution, such as sodium silicate and sodium hydroxide, which could also be mostly produced in-situ. It is envisioned that any concrete material on the lunar surface would be deposited with additive manufacturing techniques and would require a temporary environmental enclosure to mitigate the harsh lunar environment during construction and curing, such as pressure and temperature. Data are needed to set a benchmark for the conditions to be achieved within the deployable environmental enclosure during printing, as well as the resultant material properties after the enclosure is removed. This novel study investigated the influence of reduced atmospheric pressures during the initial curing period on the compressive strength of geopolymer lunar concrete created with two types of lunar regolith simulant. The simulants used in the study represent the regolith for the lunar mare (OPRL2N) and lunar highlands (OPRH2N) regions. Results show a noticeable decline in strength with a reduction in pressure and visible degradation. After the deployable environmental enclosure is removed from the printed segment of infrastructure on the lunar surface, it would then be exposed to the harsh vacuum environment. To understand the importance of curing time required within the deployable enclosure before it is removed, samples were cast and cured for different lengths of time and then exposed to a vacuum chamber capable of achieving 100 mTorr. Control samples were also cast at the same time but left in a standard laboratory environment after curing. The weight change and compressive strength as a function of time in the vacuum chamber were monitored for up to 56 days. The results showed that exposure to the vacuum limits further reaction and strength gain in comparison to control samples left in the laboratory environment. This research is in strong alignment with the 2020 NASA Technology Taxonomy materials area (12.1) and the in-situ resource utilization area (7.1), as it provides necessary data on the geopolymer lunar concrete material to support safe and sustainable options for maintaining a human presence on the Moon.

Moon to Mars Planetary Autonomous Construction Tec↗
NASA NTRS2003

Common 5S rRNA variants are likely to be accepted in many sequence contexts

Over evolutionary time RNA sequences which are successfully fixed in a population are selected from among those that satisfy the structural and chemical requirements imposed by the function of the RNA. These sequences together comprise the structure space of the RNA. In principle, a comprehensive understanding of RNA structure and function would make it possible to enumerate which specific RNA sequences belong to a particular structure space and which do not. We are using bacterial 5S rRNA as a model system to attempt to identify principles that can be used to predict which sequences do or do not belong to the 5S rRNA structure space. One promising idea is the very intuitive notion that frequently seen sequence changes in an aligned data set of naturally occurring 5S rRNAs would be widely accepted in many other 5S rRNA sequence contexts. To test this hypothesis, we first developed well-defined operational definitions for a Vibrio region of the 5S rRNA structure space and what is meant by a highly variable position. Fourteen sequence variants (10 point changes and 4 base-pair changes) were identified in this way, which, by the hypothesis, would be expected to incorporate successfully in any of the known sequences in the Vibrio region. All 14 of these changes were constructed and separately introduced into the Vibrio proteolyticus 5S rRNA sequence where they are not normally found. Each variant was evaluated for its ability to function as a valid 5S rRNA in an E. coli cellular context. It was found that 93% (13/14) of the variants tested are likely valid 5S rRNAs in this context. In addition, seven variants were constructed that, although present in the Vibrio region, did not meet the stringent criteria for a highly variable position. In this case, 86% (6/7) are likely valid. As a control we also examined seven variants that are seldom or never seen in the Vibrio region of 5S rRNA sequence space. In this case only two of seven were found to be potentially valid. The results demonstrate that changes that occur multiple times in a local region of RNA sequence space in fact usually will be accepted in any sequence context in that same local region.

NASA Discipline Exobiology↗
NASA NTRS1978

Origins of prokaryotes, eukaryotes, mitochondria, and chloroplasts

A computer branching model is used to analyze cellular evolution. Attention is given to certain key amino acids and nucleotide residues (ferredoxin, 5s ribosomal RNA, and c-type cytochromes) because of their commonality over a wide variety of cell types. Each amino acid or nucleotide residue is a sequence in an inherited biological trait; and the branching method is employed to align sequences so that changes reflect substitution of one residue for another. Based on the computer analysis, the symbiotic theory of cellular evolution is considered the most probable. This theory holds that organelles, e.g., mitochondria and chloroplasts invaded larger bodies, e.g., bacteria, and combined functions to form eucaryotic cells.

Schwartz, R. M.↗
NASA NTRS1980

Ion temperature troughs induced by a meridional neutral air wind in the night-time equatorial topside ionosphere

A mathematical model was constructed to calculate O(+) and H(+) concentrations, field-aligned velocities, and electron temperatures in the night-time equatorial topside ionosphere. The model is used to establish the ability of F-region neutral air winds to produce observed ion temperature distributions, and to study the properties of ion temperature troughs as functions of altitude, latitude, and ionospheric composition. The O(+) - H (+) transition height represents an altitude limit above which the ion cooling from adiabatic expansion of the plasma is very small; the northern and southern edges of the ion temperature troughs are restricted to the limiting dip altitudes determined by magnetic field line geometry and by the functional form of the F-region neutral wind velocity.

Bailey, G. J.↗
NASA NTRS1988

Plasma bulk flow in Jupiter's dayside middle magnetosphere

Using the plasma data obtained during the Voyager 1 encounter and the full response function of the Plasma Science (PLS) experiment, convective plasma velocities have been determined in the dayside middle magnetosphere of Jupiter (r = 10-25 Jupiter radii). It is found that temperature anisotropies have very little effect on plasma velocity determination and that the plasma data are well approximated by convected, isotropic Maxwellian ion distribution functions. The insensitivity of the analysis to any thermal anisotropies which may exist allows a good determination of the bulk plasma flow velocity. In addition to the subcorotational azimuthal flow, there exists a substantial nonazimuthal component of plasma flow. This nonazimuthal flow is mostly aligned (antialigned) with the local magnetic field but also exhibits a cross-field component. The velocity pattern is inconsistent with enhanced plasma outflow in the active sector, as suggested by the corotating convection model of plasma transport. The contribution of field-aligned flow along the curved magnetic field lines to the stress on the magnetic field is evaluated. In the region studied, such flow contributes up to one half the stress produced by the azimuthal plasma flow.

Sands, Mark R.↗
NASA NTRS1999

Advanced Techniques for Assessment of Postural and Locomotor Ataxia, Spatial Orientation, and Gaze Stability

In addition to adapting to microgravity, major neurovestibular problems of space flight include postflight difficulties with standing, walking, turning corners, and other activities that require stable upright posture and gaze stability. These difficulties inhibit astronauts' ability to stand or escape from their vehicle during emergencies. The long-ter7n goal of the NSBRI is the development of countermeasures to ameliorate the effects of long duration space flight. These countermeasures must be tested with valid and reliable tools. This project aims to develop quantitative, parametric approaches for assessing gaze stability and spatial orientation during normal gait and when gait is perturbed. Two of this year's most important findings concern head fixation distance and ideal trajectory analysis. During a normal cycle of walking the head moves up and down linearly. A simultaneous angular pitching motion of the head keeps it aligned toward an imaginary point in space at a distance of about one meter in front of a subject and along the line of march. This distance is called the head fixation distance. Head fixation distance provides the fundamental framework necessary for understanding the functional significance of the vestibular reflexes that couple head motion to eye motion. This framework facilitates the intelligent design of counter-measures for the effects of exposure to microgravity upon the vestibular ocular reflexes. Ideal trajectory analysis is a simple candidate countermeasure based upon quantifying body sway during repeated up and down stair stepping. It provides one number that estimates the body sway deviation from an ideal sinusoidal body sway trajectory normalized on the subject's height. This concept has been developed with NSBRI funding in less than one year. These findings are explained in more detail below. Compared to assessments of the vestibuo-ocular reflex, analysis of vestibular effects on locomotor function is relatively less well developed and quantified. We are improving this situation by applying methodologies such as nonlinear orbital stability to quantify responses and by using multivariate statistical approaches to link together the responses across separate tests. In this way we can exploit the information available and increase the ability to discriminate between normal and pathological responses. Measures of stability and orientation are compared to measures such as dynamic visual acuity and with balance function tests. The responses of normal human subjects and of patients having well documented pathophysiologies are being characterized. When these studies are completed, we should have a clearer idea about normal and abnormal patterns of eye, head, and body movements during locomotion and their stability in a wide range of environments. We plan eventually to use this information to validate the efficacy of candidate neurovestibular and neuromuscular rehabilitative techniques. Some representative studies made during this year are summarized.

Wall, Conrad., III↗
NASA NTRS1994

Idealized textile composites for experimental/analytical correlation

Textile composites are fiber reinforced materials produced by weaving, braiding, knitting, or stitching. These materials offer possible reductions in manufacturing costs compared to conventional laminated composites. Thus, they are attractive candidate materials for aircraft structures. To date, numerous experimental studies have been performed to characterize the mechanical performance of specific textile architectures. Since many materials and architectures are of interest, there is a need for analytical models to predict the mechanical properties of a specific textile composite material. Models of varying sophistication have been proposed based on mechanics of materials, classical laminated plate theory, and the finite element method. These modeling approaches assume an idealized textile architecture and generally consider a single unit cell. Due to randomness of the textile architectures produced using conventional processing techniques, experimental data obtained has been of limited use for verifying the accuracy of these analytical approaches. This research is focused on fabricating woven textile composites with highly aligned and accurately placed fiber tows that closely represent the idealized architectures assumed in analytical models. These idealized textile composites have been fabricated with three types of layer nesting configurations: stacked, diagonal, and split-span. Compression testing results have identified strength variations as a function of nesting. Moire interferometry experiments are being used to determine localized deformations for detailed correlation with model predictions.

Adams, Daniel O.↗
NASA NTRS2007

Pointing History Engine for the Spitzer Space Telescope

The Pointing History Engine (PHE) is a computer program that provides mathematical transformations needed to reconstruct, from downlinked telemetry data, the attitude of the Spitzer Space Telescope (formerly known as the Space Infrared Telescope Facility) as a function of time. The PHE also serves as an example for development of similar pointing reconstruction software for future space telescopes. The transformations implemented in the PHE take account of the unique geometry of the Spitzer telescope-pointing chain, including all data on relative alignments of components, and all information available from attitude-determination instruments. The PHE makes it possible to coordinate attitude data with observational data acquired at the same time, so that any observed astronomical object can be located for future reference and re-observation. The PHE is implemented as a subroutine used in conjunction with telemetry-formatting services of the Mission Image Processing Laboratory of NASA s Jet Propulsion Laboratory to generate the Boresight Pointing History File (BPHF). The BPHF is an archival database designed to serve as Spitzer s primary astronomical reference documenting where the telescope was pointed at any time during its mission.

Bayard, David↗
NASA NTRS1973

An Approximate Equation For The Multiply Scattered Contribution to A Lidar Return

An approximate equation is developed which describes the contribution of Nth order scattering to a lidar return. This development assumes a homogeneous scattering medium characterized by a scattering function sharply peaked in the forward direction and relatively insensitive to angle near the backscatter direction. The derivation includes the effects of finite divergence of the transmitted laser beam, finite receiver field of view, finite separation between the laser and the receiver and nonparallel system alignment. The derivation presented uses small angle approximations to reduce the time dependent multiple scattering problem to a time independent form which is then solved with techniques previously developed for multiple small angle nuclear scattering.

Eloranta, Edwin W.↗
NASA NTRS1978

Extending the field of view of KD/asterisk/P electrooptic modulators

The use of KD(asterisk)P as a polarization rotator has been limited to small field of view instruments. To investigate this limitation, the index ellipsoid is used to describe the optical properties of KD(asterisk)P and to calculate the retardance and fast axis as a function of the angle of incidence and voltage. Computed converging light patterns are then compared with observed intensity patterns formed by KD(asterisk)P. Finally, computed intensity patterns are used to demonstrate how the field of view of KD(asterisk)P can be increased when properly aligned with a positive uniaxial crystal.

West, E. A.↗
NASA NTRS1980

Delta V errors due to attitude correction maneuvers of a spinning spacecraft

A statistical error analysis has been performed to evaluate the change in velocity of a spin stabilized spacecraft due to thruster induced attitude correction maneuvers. Analytical expressions were developed to determine the mean and variance of the velocity in terms of the nominal values and uncertainties of key spacecraft parameters. These parameters include thrust, thruster timing, thruster alignment, plume impingement force and estimated spacecraft mass. Typical values of these parameters and their uncertainties for NASA's Galileo spacecraft were used to evaluate these expressions. The results of the analysis allow the effect of attitude correction maneuvers to be evaluated with respect to the functional requirements on nongravitational acceleration. Other results include the identification of major sources of delta V error and studies of the sensitivity of delta V to variations in the error sources.

Zipursky, H. J.↗
NASA NTRS1986

Theoretical analysis of segmented Wolter/LSM X-ray telescope systems

The Segmented Wolter I/LSM X-ray Telescope, which consists of a Wolter I Telescope with a tilted, off-axis convex spherical Layered Synthetic Microstructure (LSM) optics placed near the primary focus to accommodate multiple off-axis detectors, has been analyzed. The Skylab ATM Experiment S056 Wolter I telescope and the Stanford/MSFC nested Wolter-Schwarzschild x-ray telescope have been considered as the primary optics. A ray trace analysis has been performed to calculate the RMS blur circle radius, point spread function (PSF), the meridional and sagittal line functions (LST), and the full width half maximum (PWHM) of the PSF to study the spatial resolution of the system. The effects on resolution of defocussing the image plane, tilting and decentrating of the multilayer (LSM) optics have also been investigated to give the mounting and alignment tolerances of the LSM optic. Comparison has been made between the performance of the segmented Wolter/LSM optical system and that of the Spectral Slicing X-ray Telescope (SSXRT) systems.

Shealy, D. L.↗
NASA NTRS1995

Linear and nonlinear properties of the ULF waves driven by ring-beam distribution functions

The problem of the exitation of obliquely propagating magnetosonic waves which can steepen up (also known as shocklets) is considered. Shocklets have been observed upstream of the Earth's bow shock and at comets Giacobini-Zinner and Grigg-Skjellerup. Linear theory as well as two-dimensional (2-D) hybrid (fluid electrons, particle ions) simulations are used to determine the properties of waves generated by ring-beam velocity distributions in great detail. The effects of both proton and oxygen ring-beams are considered. The study of instabilities excited by a proton ring-beam is relevant to the region upstream of the Earth's bow shock, whereas the oxygen ring-beam corresponds to cometary ions picked up by the solar wind. Linear theory has shown that for a ring-beam, four instabilities are found, one on the nonresonant mode, one on the Alfven mode, and two along the magnetosonic/whistler branch. The relative growth rate of these instabilities is a sensitive function of parameters. Although one of the magnetosonic instabilities has maximum growth along the magnetic field, the other has maximum growth in oblique directions. We have studied the competition of these instabilities in the nonlinear regime using 2-D simulations. As in the linear limit, the nonlinear results are a function of beam density and distribution function. By performing the simulations as both initial value and driven systems, we have found that the outcome of the simulations can vary, suggesting that the latter type simulations is needed to address the observations. A general conclusion of the simulation results is that field-aligned beams do not result in the formation of shocklets, whereas ring-beam distributions can.

Killen, K.↗
NASA NTRS1999

NGST/XRCF Design and Build Wavescope System Pallet

Based on the successful Wavescope demonstration at MSFC at the end of March, the decision was made by the optical testing team to purchase an upgraded Wavescope from AOA. The MSFC version would include: a higher resolution camera (1000 x 1000 pixels); a higher density lenslet array (150 x 150); updated software; and longer cables (to accommodate the remote operation of the Wavescope optical head which was resident in the Beam Guide Tube). The AOA proposal for the new instrument was received in mid-April, and delivered to MSFC in mid-July. A considerable amount of effort was expended to provide the infrastructure needed for Wavescope operation, and to incorporate it into the overall test system. This was provided by the Wavescope System Pallet (WSP) built by UAH. The WSP is illustrated. Several instruments are incorporated on this pallet. These include the: Wavescope optical head; a PDI wavefront sensor; a point spread function sensor; a Leica light-based distance measuring sensor. In addition there is a single mode fiber point source (fed from a separate source pallet) which serves both as a reference for the Wavescope and as a source point for the test mirror. There is a dual function lens which both collimates the beam from the test image point, and images the test mirror onto the lenslet array. There is a high quality Collimator which can provide a flat input wavefront directly into the Wavescope. There are also various aids such as an alignment laser, an alignment telescope, alignment sticks and apertures. The WSP was delivered to MSFC on 7/28/99. An picture shows the WSP installed in the Guide Tube at the X-Ray Calibration Facility (XRCF).

Geary, Joe↗
NASA NTRS2010

International Space Station Powered Bolt Nut Anomaly and Failure Analysis Summary

A key mechanism used in the on-orbit assembly of the International Space Station (ISS) pressurized elements is the Common Berthing Mechanism. The mechanism that effects the structural connection of the Common Berthing Mechanism halves is the Powered Bolt Assembly. There are sixteen Powered Bolt Assemblies per Common Berthing Mechanism. The Common Berthing Mechanism has a bolt which engages a self aligning Powered Bolt Nut (PBN) on the mating interface (Figure 1). The Powered Bolt Assemblies are preloaded to approximately 84.5 kN (19000 lb) prior to pressurization of the CBM. The PBNs mentioned below, manufactured in 2009, will be used on ISS future missions. An on orbit functional failure of this hardware would be unacceptable and in some instances catastrophic due to the failure of modules to mate and seal the atmosphere, risking loss of crew and ISS functions. The manufacturing processes that create the PBNs need to be strictly controlled. Functional (torque vs. tension) acceptance test failures will be the result of processes not being strictly followed. Without the proper knowledge of thread tolerances, fabrication techniques, and dry film lubricant application processes, PBNs will be, and have been manufactured improperly. The knowledge gained from acceptance test failures and the resolution of those failures, thread fabrication techniques and thread dry film lubrication processes can be applied to many aerospace mechanisms to enhance their performance. Test data and manufactured PBN thread geometry will be discussed for both failed and successfully accepted PBNs.

Sievers, Daniel E.↗