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NASA NTRS1990

A new fabrication method for precision antenna reflectors for space flight and ground test

The use of higher frequencies on communications satellites has led to the requirement for increasingly precise antenna reflectors for use in space. Typical industry fabrication methods for space antenna reflectors employ successive molding techniques for reflector face sheets and a final fit-up to a master mold in order to achieve the required accuracies. However, new missions at much higher frequencies will require greater accuracies than may be achievable using these present methods. A new approach for the fabrication of ground-test antenna reflectors is to machine the reflective surface into a stainless steel and fiberglass composite structure. A 2.7-m diameter ground-test antenna reflector fabricated using this method has an accuracy of better than 0.013 mm (0.0005 in.) rms. A similar design concept for a solid surface reflector for use on spacecraft would involve fabrication in a similar manner but using space-qualified materials. This report describes the design, analysis, and fabrication of the 2.7-m-diameter precision antenna reflector for antenna ground test and the extension of this technology to precision space antenna reflectors.

Sharp, G. Richard↗

NASA NTRS1991

New Polyimide Has Many Uses

Low-toxicity and low-mutogenicity monomer key to new high-performance polyimide. LaRC-IA is thermoplastic polyimide made from 3-4'-oxydianiline and 4,4'-oxydiphthalic anhydride. Good processing characteristics, low toxicity, and no mutagenicity. Adhesives, composite matrix resins, heat resin moldings, and coating films made of new polymer found to exhibit properties identical or superior to commercially available polyimides. Potential applications wide ranging. With and without end capping, employed to prepare unfilled moldings, coatings and free films, adhesive tape, adhesively bonded substrates, prepregs, and composites.

St. Clair, Terry L.↗

NASA NTRS1991

A semi-automated process for the production of custom-made shoes

A more efficient, cost-effective and timely way of designing and manufacturing custom footware is needed. A potential solution to this problem lies in the use of computer-aided design and manufacturing (CAD/CAM) techniques in the production of custom shoes. A prototype computer-based system was developed, and the system is primarily a software entity which directs and controls a 3-D scanner, a lathe or milling machine, and a pattern-cutting machine to produce the shoe last and the components to be assembled into a shoe. The steps in this process are: (1) scan the surface of the foot to obtain a 3-D image; (2) thin the foot surface data and create a tiled wire model of the foot; (3) interactively modify the wire model of the foot to produce a model of the shoe last; (4) machine the last; (5) scan the surface of the last and verify that it correctly represents the last model; (6) design cutting patterns for shoe uppers; (7) cut uppers; (8) machine an inverse mold for the shoe innersole/sole combination; (9) mold the innersole/sole; and (10) assemble the shoe. For all its capabilities, this system still requires the direction and assistance of skilled operators, and shoemakers to assemble the shoes. Currently, the system is running on a SUN3/260 workstation with TAAC application accelerator. The software elements of the system are written in either Fortran or C and run under a UNIX operator system.

Farmer, Franklin H.↗

NASA NTRS1986

Composite ingot casting

A method and system for continuously or semicontinuously casting a composite metal article, such as a structurally composite ingot or the like, wherein one of the principal structural components of the ingot comprises an aluminum-lithium alloy. During such casting by a D.C. (direct chill) conventional tubular mold or electromagnetic process, the aluminum-lithium structural component of a structurally composite ingot is encircled or peripherally encased by a· further outer metal cladding component that can be cast simultaneously with the aluminum-lithium component such as another outer aluminous alloy from which lithium is absent as a constituent or impurity, although it may be present and tolerated as a trace element. In this arrangement the aluminum-lithium structural component is prevented during casting from coming into direct contact with the chilling coolant, normally water, with which lithium can react violently. Only the outer aluminous alloy envelope is subjected to the direct contact of a liquid coolant whereby as it solidifies, this outer envelope or . peripheral sheath acts as an impervious secondary mold for and protects the inner aluminum--lithium alloy structural component which is then directly controllably chilled and solidified.

George J Binczewski↗

NASA NTRS1992

Durable, Low-Surface-Energy Treatments

Chemical treatment for creation of durable, low-surface-energy coatings for glass, ceramics and other protonated surfaces easily applied, and creates very thin semipermanent film with extremely low surface tension. Exhibits excellent stability; surfaces retreated if coating becomes damaged or eroded. Uses include water-repellent surfaces, oil-repellent surfaces, antimigration barriers, corrosion barriers, mold-release agents, and self-cleaning surfaces. Film resists wetting by water, alcohols, hydrocarbon solvents, and silicone oil. Has moderate resistance to abrasion, such as rubbing with cloths, and compression molding to polymers and composite materials.

Willis, Paul B.↗

NASA NTRS1992

Masks For Deposition Of Aspherical Optical Surfaces

Masks of improved design developed for use in fabrication of aspherical, rotationally symmetrical surfaces of mirrors, lenses, and lens molds by evaporative deposition onto rotating substrates. In deposition chamber, source and mask aligned with axis of rotation of substrate. Mask shadows source of rotating substrate. Azimuthal opening (as function of radius) in mask proportional to desired thickness (as function of radius) to which material deposited on substrate. Combination of improved masks and modern coating chambers provides optical surfaces comparable or superior to those produced by conventional polishing, computer-controlled polishing, replication from polished molds, and diamond turning, at less cost in material, labor, and capital expense.

Rogers, John R.↗

NASA NTRS1992

Cheaper Custom Shielding Cups For Arc Welding

New way of making special-purpose shielding cups for gas/tungsten arc welding from hobby ceramic greatly reduces cost. Pattern machined in plastic. Plaster-of-paris mold made, and liquid ceramic poured into mold. Cost 90 percent less than cup machined from lava rock.

Morgan, Gene E.↗

NASA NTRS1991

Helmet of a laminate construction of polycarbonate and polysulfone polymeric material

An article of laminate construction is disclosed which is comprised of an underlayer of polycarbonate polymer material to which is applied a chemically resistant outer layer of polysulfone. The layers which are joined by compression-heat molding, are molded to form the shape of a body protective shell such as a space helmet comprising a shell of polycarbonate, polysulfone laminate construction attached at its open end to a sealing ring adapted for connection to a space suit. The front portion of the shell provides a transparent visor for the helmet. An outer visor of polycarbonate polysulfone laminate construction is pivotally mounted to the sealing ring for covering the transparent visor portion of the shell during extravehicular activities. The polycarbonate under layer of the outer visor is coated on its inner surface with a vacuum deposit of gold to provide additional thermal radiation resistance.

Kosmo, Joseph J.↗

NASA NTRS1991

Plastic superconductor bearings any size-any shape: 77 K and up

'Friction free' bearings at 77 K or higher are possible using the high T(sub c) copper oxide ceramic superconductors. The conventional method for making such bearings is to use a sintered ceramic monolith. This puts great restraints on size, shape, and postforming machining. The material is hard and abrasive. It is possible to grind up ceramic superconductors and suspend the granules in a suitable matrix. Mechanical properties improve and are largely dependent on the binder. The Meissner effect is confined to individual grains containing electron vortices. Tracks, rails, levitation areas, and bearings can be made this way with conventional plastic molding and extruding machines or by painting. The parts are easily machined. The sacrifice is in bulk electrical conductivity. A percolating wick feed for LN2 is used to cool remote superconductors and large areas quite effectively. A hollow spheroid or cylinder of superconductor material is molded with the internal surfaces shielded by the Meissner effect. It can be thought of as the DC magnetic analog of the Faraday cage and the inside is the 'Meissner space'. It is selective. The AC fields are transmitted with minor attenuation. Particle size and distribution have a profound effect on final magnetic and electrical characteristics.

Reick, Franklin G.↗

NASA NTRS1991

Cartilage formation in the CELLS 'double bubble' hardware

The CELLS experiment scheduled to be flown on the first International Microgravity Laboratory is designed to study the effect of microgravity on the cartilage formation, by measuring parameters of growth in a differentiating cartilage cell culture. This paper investigates the conditions for this experiment by studying cartilage differentiation in the 'bubble exchange' hardware with the 'double bubble' design in which the bubbles are joined by a flange which also overlays the gasket. Four types of double bubbles (or double gas permeable membranes) were tested: injection-molded bubbles 0.01- and 0.005-in. thick, and compression molded bubbles 0.015- and 0.01-in. thick. It was found that double bubble membranes of 0.005- and 0.010-in. thickness supported cartilage differentiation, while the 0.015-in. bubbles did not. It was also found that nodule count, used in this study as a parameter, is not the best measure of the amount of cartilage differentiation.

Duke, P. J.↗

NASA NTRS1993

Polyimides Containing Amide And Perfluoroisopropyl Links

New polyimides synthesized from reactions of aromatic hexafluoroisopropyl dianhydrides with asymmetric amide diamines. Soluble to extent of at least 10 percent by weight at temperature of about 25 degrees C in common amide solvents such as N-methylpyrrolidone, N,N-dimethylacetamide, and N,N-dimethylformamide. Polyimides form tough, flexible films, coatings, and moldings. Glass-transition temperatures ranged from 300 to 365 degrees C, and crystalline melting temperatures observed between 543 and 603 degrees C. Display excellent physical, chemical, and electrical properties. Useful as adhesives, laminating resins, fibers, coatings for electrical and decorative purposes, films, wire enamels, and molding compounds.

Dezem, James F.↗

NASA NTRS1993

INEL Spray-forming Research

Spray forming is a near-net-shape fabrication technology in which a spray of finely atomized liquid droplets is deposited onto a suitably shaped substrate or mold to produce a coherent solid. The technology offers unique opportunities for simplifying materials processing without sacrificing, and oftentimes substantially improving, product quality. Spray forming can be performed with a wide range of metals and nonmetals, and offers property improvements resulting from rapid solidification (e.g., refined microstructures, extended solid solubilities and reduced segregation). Economic benefits result from process simplification and the elimination of unit operations. Researchers at the Idaho National Engineering Laboratory (INEL) are developing spray-forming technology for producing near-net-shape solids and coatings of a variety of metals, polymers, and composite materials. Results from several spray forming programs are presented to illustrate the range of capabilities of the technique as well as the accompanying technical and economic benefits. Low-carbon steel strip greater than 0.75 mm thick and polymer membranes for gas/gas and liquid/liquid separations that were spray formed are discussed; recent advances in spray forming molds, dies, and other tooling using low-melting-point metals are described.

Mchugh, Kevin M.↗

NASA NTRS1993

Ultrasonic Polishing

The ultrasonic polishing process makes use of the high-frequency (ultrasonic) vibrations of an abradable tool which automatically conforms to the work piece and an abrasive slurry to finish surfaces and edges on complex, highly detailed, close tolerance cavities in materials from beryllium copper to carbide. Applications range from critical deburring of guidance system components to removing EDM recast layers from aircraft engine components to polishing molds for forming carbide cutting tool inserts or injection molding plastics. A variety of materials including tool steels, carbides, and even ceramics can be successfully processed. Since the abradable tool automatically conforms to the work piece geometry, the ultrasonic finishing method described offers a number of important benefits in finishing components with complex geometries.

Gilmore, Randy↗

NASA NTRS1991

Improved silicon nitride for advanced heat engines

The results of a four year program to improve the strength and reliability of injection-molded silicon nitride are summarized. Statistically designed processing experiments were performed to identify and optimize critical processing parameters and compositions. Process improvements were monitored by strength testing at room and elevated temperatures, and microstructural characterization by optical, scanning electron microscopes, and scanning transmission electron microscope. Processing modifications resulted in a 20 percent strength and 72 percent Weibull slope improvement of the baseline material. Additional sintering aids screening and optimization experiments succeeded in developing a new composition (GN-10) capable of 581.2 MPa at 1399 C. A SiC whisker toughened composite using this material as a matrix achieved a room temperature toughness of 6.9 MPa m(exp .5) by the Chevron notched bar technique. Exploratory experiments were conducted on injection molding of turbocharger rotors.

Yeh, Harry C.↗

NASA NTRS1991

Consolidation of graphite thermoplastic textile preforms for primary aircraft structure

The use of innovative cost effective material forms and processes is being considered for fabrication of future primary aircraft structures. Processes that have been identified as meeting these goals are textile preforms that use resin transfer molding (RTM) and consolidation forming. The Novel Composites for Wing and Fuselage Applications (NCWFA) program has as its objective the integration of innovative design concepts with cost effective fabrication processes to develop damage-tolerant structures that can perform at a design ultimate strain level of 6000 micro-inch/inch. In this on-going effort, design trade studies were conducted to arrive at advanced wing designs that integrate new material forms with innovative structural concepts and cost effective fabrication methods. The focus has been on minimizing part count (mechanical fasteners, clips, number of stiffeners, etc.), by using cost effective textile reinforcement concepts that provide improved damage tolerance and out-of-plane load capability, low-cost resin transfer molding processing, and thermoplastic forming concepts. The fabrication of representative Y spars by consolidation methods will be described. The Y spars were fabricated using AS4 (6K)/PEEK 150g commingled angle interlock 0/90-degree woven preforms with +45-degree commingled plies stitched using high strength Toray carbon thread and processed by autoclave consolidation.

Suarez, J.↗

NASA NTRS1991

Preliminary properties of a resin from ethynyl terminated materials

A blend composed of an ethynyl terminated aspartimide (brittle component) and an ethynyl terminated arylene ether oligomer (tough component) was thermally cured to yield a resin which underwent preliminary evaluation to determine the potential for use in structural applications on aerospace vehicles. The blend exhibited good compression moldability, allowing for fabrication of neat moldings, adhesive specimens and composites at temperatures of 250 C under a pressure of 1.4 MPa (200 psi). Neat resin moldings and adhesive specimens provided relatively high mechanical properties. Composite specimens provided promising results in spite of fiber misalignment, fiber washout, and a small amount of panel warpage.

Hergenrother, Paul M.↗

NASA NTRS1924

Micarta Propellers II : Method of Construction

The methods used in manufacturing Micarta propellers differ considerably from those employed with wood propellers on account of the hardness of the materials. The propellers must be formed accurately to size in a mold and afterwards balanced without the customary trimming of the material from the tips. Described here are the pressing and molding processes, filing, boring, balancing, and curing.

Caldwell, F W↗

NASA NTRS1940

The Development of Electrical Strain Gages

The design, construction, and properties of an electrical-resistance strain gage consisting of fine wires molded in a laminated plastic are described. The properties of such gages are discussed and also the problems of molding of wires in plastic materials, temperature compensation, and cementing and removal of the gages. Further work to be carried out on the strain gage, together with instrument problems, is discussed.

De Forest, A V↗