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NASA NTRS1998

Operator's Manual for SHEBA Powered Tether Balloon System

The Surface Heat and Energy Budget of the Arctic (SHEBA) was an intensive field project which took place in the Arctic Ocean from October 1997 through October 1998. Its purpose was to measure as many facets of the Arctic environment as possible so that we would be able to better understand the interaction between the ice, atmosphere, and ocean and their interactions with global climate. One aspect of the atmospheric field component was launching tethered balloons to monitor the profiles of temperature, wind, pressure, and humidity, as well as examine the vertical structure of cloud droplet sizes and distributions. The tethered balloon that we used was one specially designed for use in freezing climates by SPEC Corporation in Boulder, Colorado. A special winch that was able to withstand Arctic temperature and weather became necessary when the testing of simple winch systems used in warmer climates failed under these extreme conditions. The purpose of this manual is to acquaint any new user to the powered tethered balloon system deployed at the The Surface Heat and Energy Budget of the Arctic (SHEBA ice camp. It includes a description of the preparations necessary to get ready for a launch, the mechanics of the actual launch, and an account of the proper procedure for taking down the equipment when finished. It will also include tips on how to minimize potential equipment failures, some trouble shooting, and some safety ideas. This manual is designed so that new operators can use the system with minimal previous training. At the end of this manual, the reader will find a quick checklist.

Lappen, Cara-Lyn↗

NASA NTRS1991

A near-infrared imaging survey of interacting galaxies - The disk-disk merger candidates subset

Near-infrared imaging obtained for systems believed to be advanced disk-disk mergers are presented and discussed. These systems were chosen from a sample of approximately 170 objects from the Arp Atlas of Peculiar Galaxies which have been imaged in the JHK bands as part of an investigation into the stellar component of interacting galaxies. Of the eight remnants which show optical signs of a disk-disk merger, the near-infrared surface brightness profiles are well-fitted by an r exp 1/4 law over all measured radii in four systems, and out to radii of about 3 kpc in three systems. These K band profiles indicate that most of the remnants in the sample either have finished or are in the process of relaxing into a mass distribution like that of normal elliptical galaxies.

Stanford, S. A.↗

NASA NTRS2002

Comparison Made of Operating Characteristics of Spiral Bevel Gears Manufactured Using Different Methods

Spiral bevel gears are important components on all current rotorcraft drive systems. These components are required to operate at high speeds, high loads, and for an extremely large number of load cycles. In this application, spiral bevel gears are used to redirect the shaft from the horizontal gas turbine engine to the vertical rotor. Because of the high expense of manufacturing these gears, methods that can achieve the same level of performance at reduced cost are highly desirable to aerospace gear manufacturers. Gears manufactured for aerospace applications use high-quality materials and are manufactured to tight tolerances. Special manufacturing machine tools and computer numerically controlled coordinate measurement systems have enabled rotorcraft drive system manufacturers to produce extremely high-quality gears during their normal production. Because of low production rates for rotorcraft, these gears are manufactured in small batches, and thus are unable to benefit from the economics of high production numbers as in other industries. In this investigation, two different manufacturing methods, face-milled and face-hobbed, were used to fabricate spiral bevel gears. For face-milled spiral bevel gears, grinding of the contacting surfaces is the final manufacturing step. At least two different specialty machines are needed to generate the teeth for face-milled spiral bevel gears. For face-hobbed gears, hard cutting is the final manufacturing process. The same machine is used to rough cut and finish cut the gears. This study compared the operational behavior of face-milled spiral bevel gears with that of face-hobbed spiral bevel gears. Test hardware was manufactured to fit within NASA Glenn Research Center's Spiral Bevel Test Facility and to aerospace quality standards. Tests were conducted for stress, vibration, and noise. A comparison of the results attained indicated that the face-hobbed gears had a lower alternating stress level with a more even distribution of loading across the teeth, and slightly reduced levels of vibration and noise. Results of this study show that the face-hobbed method is a viable and lower-cost alternative for producing aerospace-quality spiral-bevel gears.

Handschuh, Robert F.↗

NASA NTRS1986

Amphibious Airplane

The airplane pictured is the new Air Shark I, a four-place amphibian that makes extensive use of composite materials and cruises at close to 200 miles per hour under power from a 200-horsepower engine. Air Shark I is a "homebuilt" airplane, assembled from a kit of parts and components furnished by Freedom Master Corporation, Satellite Beach, Florida. The airplane incorporates considerable NASA technology and its construction benefited from research assistance provided by Kennedy Space Center (KSC) In designing the Shark, company president Arthur M. Lueck was able to draw on NASA's aeronautical technology bank through KSC's computerized "recon" library. As a result of his work at KSC, the wing of the Air Shark I is a new airfoil developed by Langley Research Center for light aircraft. In addition, Lueck opted for NASA-developed "winglets," vertical extensions of the wing that reduce drag by smoothing air turbulence at the wingtips. The NASA technology bank also contributed to the hull design. Lueck is considering application of NASA laminar flow technology-means of smoothing the airflow over wing and fuselage-to later models for further improvement of the Shark's aerodynamic efficiency. A materials engineer, Lueck employed his own expertise in designing and selecting the materials for the composite segments, which include all structural members, exposed surfaces and many control components. The materials are fiber reinforced plastics, or FRP They offer a high strength-to-weight ratio, with a nominal strength rating about one and a half times that of structural steel. They provide other advantages: the materials can be easily molded into finished shapes without expensive tooling or machining, and they are highly corrosion resistant. The first homebuilt to be offered by Freedom Master, Air Shark I completed air and water testing in mid-1985 and the company launched production of kits.

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NASA NTRS1994

A land-surface Testbed for EOSDIS

The main objective of the Testbed project was to deliver satellite images via the Internet to scientific and educational users free of charge. The main method of operations was to store satellite images on a low cost tape library system, visually browse the raw satellite data, access the raw data filed, navigate the imagery through 'C' programming and X-Windows interface software, and deliver the finished image to the end user over the Internet by means of file transfer protocol methods. The conclusion is that the distribution of satellite imagery by means of the Internet is feasible, and the archiving of large data sets can be accomplished with low cost storage systems allowing multiple users.

Emery, William↗

NASA NTRS2003

Home Insulation With the Stroke of a Brush

Hy-Tech Thermal Solutions, LLC, of Melbourne, Florida, is producing a very complex blend of ceramic vacuum-filled refractory products designed to minimize the path of hot air transfer through ceilings, walls, and roofs. The insulating ceramic technology blocks the transfer of heat outward when applied to paint on interior walls and ceilings, and prevents the transfer of heat inward when used to paint exterior walls and roofs, effectively providing year-round comfort in the home. As a manufacturer and marketer of thermal solutions for residential, commercial, and industrial applications, Hy-Tech Thermal Solutions attributes its success to the high performance insulating ceramic microsphere originally developed from NASA thermal research at Ames Research Center. Shaped like a hollow ball so small that it looks as if it is a single grain of flour to the naked eye (slightly thicker than a human hair), the microsphere is noncombustible and fairly chemical-resistant, and has a wall thickness about 1/10 of the sphere diameter, a compressive strength of about 4,000 pounds per square inch, and a softening point of about 1,800 C. Hy-Tech Thermal Solutions improved upon these properties by removing all of the gas inside and creating a vacuum. In effect, a 'mini thermos bottle' is produced, acting as a barrier to heat by reflecting it away from the protected surface. When these microspheres are combined with other materials, they enhance the thermal resistance of those materials. In bulk, the tiny ceramic 'beads' have the appearance of a fine talcum powder. Their inert, nontoxic properties allow them to mix easily into any type of paint, coating, adhesive, masonry, or drywall finish. Additionally, their roundness causes them to behave like ball bearings, rolling upon each other, and letting the coatings flow smoothly. When applied like paint to a wall or roof, the microsphere coating shrinks down tight and creates a dense film of the vacuum cells. The resulting ceramic layer improves fire resistance, protects from ultraviolet rays, repels insects such as termites, and shields from the destructive forces of nature.

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NASA NTRS1992

Changes in oxidation state of chromium during LDEF exposure

The solar collector used for the McDonnell-Douglas Cascade Variable Heat Pipe, Experiment A0076 (Michael Grote - Principal Investigator) was finished with black chromium plating as a thermal control coating. The coating is metallic for low emittance, and is finely microcrystalline to a dimension which yields its high absorptivity. An underplate of nickel was applied to the aluminum absorber plate in order to achieve optimal absorptance characteristics from the black chromium plate surface. Experiment A0076 was located at tray position F9, receiving a projected 8.7 x 10 exp 21 atomic oxygen atoms/sq cm and 11,200 ESH solar radiation. During retrieval, it was observed that the aluminized kapton thermal blankets covering most of the tray were severely eroded by atomic oxygen, and that a 'flap' of aluminum foil was overlaying a roughly triangular shaped portion of the absorber panel. The aluminum foil 'flap' was lost sometime between the Long Duration Exposure Facility (LDEF) retrieval and deintegration. At deintegration, the black chromium was observed to have discolored where it had been covered by the foil 'flap'. A summary of the investigation into the cause of the discoloration is presented.

Golden, Johnny L.↗

NASA NTRS1999

Inlet Spillage Drag Predictions Using the AIRPLANE Code

AIRPLANE (Jameson/Baker) is a steady inviscid unstructured Euler flow solver. It has been validated on many HSR geometries. It is implemented as MESHPLANE, an unstructured mesh generator, and FLOPLANE, an iterative flow solver. The surface description from an Intergraph CAD system goes into MESHPLANE as collections of polygonal curves to generate the 3D mesh. The flow solver uses a multistage time stepping scheme with residual averaging to approach steady state, but R is not time accurate. The flow solver was ported from Cray to IBM SP2 by Wu-Sun Cheng (IBM); it could only be run on 4 CPUs at a time because of memory limitations. Meshes for the four cases had about 655,000 points in the flow field, about 3.9 million tetrahedra, about 77,500 points on the surface. The flow solver took about 23 wall seconds per iteration when using 4 CPUs. It took about eight and a half wall hours to run 1,300 iterations at a time (the queue limit is 10 hours). A revised version of FLOPLANE (Thomas) was used on up to 64 CPUs to finish up some calculations at the end. We had to turn on more communication when using more processors to eliminate noise that was contaminating the flow field; this added about 50% to the elapsed wall time per iteration when using 64 CPUs. This study involved computing lift and drag for a wing/body/nacelle configuration at Mach 0.9 and 4 degrees pitch. Four cases were considered, corresponding to four nacelle mass flow conditions.

Thomas, Scott D.↗

NASA NTRS2019

Helium Balloon Valve Improvement

The NASA Balloon Program Office (BPO), located at Wallops Flight Facility asked the Mechanical Systems Branch (Code 548) to improve the design of their balloon valve. BPO uses two main types of balloons, Zero Pressure Balloon (ZPB) and Super Pressure Balloon (SPB), which both use the valve. It is used for termination of the ZPB, and inflation and termination of the SPB. During launch campaigns the valve showed signs of helium leakage which lead the BPO to ask for an improvement. As part of a Professional Readiness Engineering Program (PREP), research and review of the current valve was conducted and a new design was prepared. The current custom designed valve consists of a "pie" plate that is actuated up and down via a gear rack that is driven by a globe motor. When closed the knife edge of the pie plate bites into a silicone gasket to seal the structure. Unfortunately, the gasket material permanently deforms after being compressed and the plate itself bends under the force induced by the motor, introducing two possible helium leak paths. The new custom designed valve utilizes o-rings instead of one gasket to reduce the possibility of leakage from permanent deformation. One o-ring seals the valve structure to its mating surface and a spring energized o-ring is used in a piston design to seal the valve once it's closed. The design also utilizes different materials to increase stiffness and strength so that it is less likely to bend under the force from the motor. Currently the new valve has finished the design and analysis phases and is proceeding towards manufacturing and testing.

Seo, Lindsey↗

NASA NTRSDate not supplied

Subsonic Single Aft Engine (SUSAN) Transport Aircraft Concept and Trade Space Exploration

A trade space exploration of a new NASA regional transport aircraft concept called the SUbsonic Single Aft eNgine (SUSAN) Electrofan is presented. The SUSAN concept uses a 20MW Electrified Aircraft Propulsion (EAP) system to enable advance Propulsion Airframe Integration (PAI) in transport category aircraft. Alternative fuels will be used to reduce the amount of emissions per energy used. By combining these features there is the potential to reduce aircraft emissions by 50% per passenger/mile while retaining the size, speed, and range of large regional jets. SUSAN is has a 750 mile economic mission, a 2500 mile design range and a maximum capacity of 180 passengers. The SUSAN configuration utilizes a single aft mounted engine and distributed electric wing-mounted thrusters on a tube and wing arrangement with a T-tail empennage. The SUSAN Electrofan employs a hybrid powertrain to enable: single turbofan operation on a large transport category aircraft; increased aerodynamic and propulsive efficiency through placement of electric engines; optimized turbofan sizing and efficiency through control and electric boosting, reduced control surface sizing through thrust augmentation. A single use battery is employed as the power source in case of turbofan failure. The design study also considers the constraints of operating within the current airport, airspace and economic constraints. This paper presents the status of the trade space exploration; however the concept definition is not finished. Forward work includes optimizing the overall aircraft configuration and including certain hard to model features like boundary layer ingestion or natural laminar flow across all appliable subsystems. Additional work forward work is a more extensive analysis of the configuration using alternative fuels.

Ralph H. Jansen↗

NASA NTRS2004

The Influence of Sizings on the Durability of High-Temperature Polymer Composites

To increase performance and durability of high-temperature composites for potential rocket engine components, it is necessary to optimize wetting and interfacial bonding between high modulus carbon fibers and high-temperature polyimide resins. Sizings commercially supplied on most carbon fibers are not compatible with polyimides. In this study, the chemistry of sizings on two high-modulus carbon fibers (M40J and M60J, Toray) was characterized as was the chemistry of PMR-II-50 fluorinated polyimide resin. The carbon fibers were characterized using single filament wetting, scanning electron microscopy, fourier transform infrared spectroscopy, and x-ray photoelectron spectroscopic measurements. The polyimide matrix resins were coated onto glass filaments for characterization by wetting measurements. Surface energy components were obtained by wetting with nondispersive (methylene iodide), acidic (ethylene glycol), and basic (formamide) probes. A continuous desizing system that uses an environmentally friendly chemical-mechanical process was developed for tow level fiber. Composites were fabricated with fibers containing the manufacturer's sizing, desized, and further treated with a reactive finish. Results of room-temperature tests after thermal aging show that the reactive finish produces a higher strength and more durable interface compared to the manufacturer's sizing. When exposed to moisture blistering tests, however, the better bonded composite displayed a tendency to delaminate, presumably due to trapping of volatiles.

Allred, Ronald E.↗

NASA NTRS1991

Experimental determination of residual stress

Residual stresses in finished parts have often been regarded as factors contributing to premature part failure and geometric distortions. Currently, residual stresses in welded structures and railroad components are being investigated. High residual stresses formed in welded structures due primarily to the differential contractions of the weld material as it cools and solidifies can have a profound effect on the surface performance of the structure. In railroad wheels, repeated use of the brakes causes high residual stresses in the rims which may lead to wheel failure and possible derailment. The goals of the study were: (1) to develop strategies for using x-ray diffraction to measure residual stress; (2) to subject samples of Inconel 718 to various mechanical and heat treatments and to measure the resulting stress using x-ray diffraction; and (3) to measure residual stresses in ferromagnetic alloys using magnetoacoustics.

Ferguson, Milton W.↗

NASA NTRS1990

The Hubble Space Telescope optical systems failure report

The findings of the Hubble Space Telescope Optical Systems Board of Investigation are reported. The Board was formed to determine the cause of the flaw in the telescope, how it occurred, and why it was not detected before launch. The Board conducted its investigation to include interviews with personnel involved in the fabrication and test of the telescope, review of documentation, and analysis and test of the equipment used in the fabrication of the telescope's mirrors. The investigation proved that the primary mirror was made in the wrong shape (a 0.4-wave rms wavefront error at 632.8 nm). The primary mirror was manufactured by the Perkin-Elmer Corporation (Hughes Danbury Optical Systems, Inc.). The critical optics used as a template in shaping the mirror, the reflective null corrector (RNC), consisted of two small mirrors and a lens. This unit had been preserved by the manufacturer exactly as it was during the manufacture of the mirror. When the Board measured the RNC, the lens was incorrectly spaced from the mirrors. Calculations of the effect of such displacement on the primary mirror show that the measured amount, 1.3 mm, accounts in detail for the amount and character of the observed image blurring. No verification of the reflective null corrector's dimensions was carried out by Perkin-Elmer after the original assembly. There were, however, clear indications of the problem from auxiliary optical tests made at the time. A special optical unit called an inverse null corrector, designed to mimic the reflection from a perfect primary mirror, was built and used to align the apparatus; when so used, it clearly showed the error in the reflective null corrector. A second null corrector was used to measure the vertex radius of the finished primary mirror. It, too, clearly showed the error in the primary mirror. Both indicators of error were discounted at the time as being themselves flawed. The Perkin-Elmer plan for fabricating the primary mirror placed complete reliance on the reflective null corrector as the only test to be used in both manufacturing and verifying the mirror's surface with the required precision. This methodology should have alerted NASA management to the fragility of the process and the possibility of gross error. Such errors had been seen in other telescope programs, yet no independent tests were planned, although some simple tests to protect against major error were considered and rejected. During the critical time period, there was great concern about cost and schedule, which further inhibited consideration of independent tests.

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NASA NTRSDate not supplied

Electrical Discharge Machining of Additively Manufactured Superalloys Containing Oxide Dispersions

Superalloys can be strengthened by oxide dispersions to potentially improve their mechanical properties at high temperatures. Additive manufacturing has opened new paths for introducing oxide particles into superalloys with increased processing flexibility, to potentially provide oxide dispersion strengthening. Numerically controlled electrical discharge machining (EDM) has often been used as a machining process for initial sectioning, detailed roughing, and even finishing operations of conventional superalloys. The objective of this study was to examine how additively manufactured superalloys containing oxide dispersions respond when sectioned using EDM. Consistent sections of several superalloys, two containing an oxide dispersion, were sliced using a typical EDM machine with standard brass wire and a typical roughing condition set. Roughness, microstructure, and residual stress at the EDM surfaces were compared for the varied superalloys.

superalloys↗

NASA NTRS1989

Analytical optical scattering in clouds

An analytical optical model for scattering of light due to lightning by clouds of different geometry is being developed. The self-consistent approach and the equivalent medium concept of Twersky was used to treat the case corresponding to outside illumination. Thus, the resulting multiple scattering problem is transformed with the knowledge of the bulk parameters, into scattering by a single obstacle in isolation. Based on the size parameter of a typical water droplet as compared to the incident wave length, the problem for the single scatterer equivalent to the distribution of cloud particles can be solved either by Mie or Rayleigh scattering theory. The super computing code of Wiscombe can be used immediately to produce results that can be compared to the Monte Carlo computer simulation for outside incidence. A fairly reasonable inverse approach using the solution of the outside illumination case was proposed to model analytically the situation for point sources located inside the thick optical cloud. Its mathematical details are still being investigated. When finished, it will provide scientists an enhanced capability to study more realistic clouds. For testing purposes, the direct approach to the inside illumination of clouds by lightning is under consideration. Presently, an analytical solution for the cubic cloud will soon be obtained. For cylindrical or spherical clouds, preliminary results are needed for scattering by bounded obstacles above or below a penetrable surface interface.

Phanord, Dieudonne D.↗

NASA NTRS2000

STS-99 Crew Activities Report / Flight Day 11 Highlights

The primary objective of the STS-99 mission was to complete high resolution mapping of large sections of the Earth's surface using the Shuttle Radar Topography Mission (STRM), a specially modified radar system. This radar system produced unrivaled 3-D images of the Earth's Surface.. The mission was launched at 12:31 on February 11, 2000 onboard the space shuttle Endeavour. The mission was led by Commander Kevin Kregel. The crew was Pilot Dominic L. Pudwill Gorie and Mission Specialists Janet L. Kavandi, Janice E. Voss, Mamoru Mohri, the National Space Development Agency (Japanese Space Agency) and Gerhard P. J. Thiele, from DARA (German Space Agency). The astronauts finished the mapping operations early on day 11, and then retracted the 200 foot long mast into its payload bay canister. The mast, the longest rigid structure ever deployed in space, supported the external antenna during the mapping operation. The videotape shows the mast folding into the canister. The final stowage was delayed when the three latches on the lid of the canister failed to engage as expected. After a few procedures were executed the mast canister was sealed, on the third attempt, as shown on the videotape. The video also contains several views from the STRM. They include a computerized animation of a flight from Pasadena to Palmdale, a still view of Fiji, a view of the San Francisco Bay Area, and another of Pasadena.

Source record↗

NASA NTRSDate not supplied

Role of NDE and In-Situ Process Monitoring in Managing Risk of AM Space Hardware

The recently published NASA-STD-6030 defines the Additive Manufacturing (AM) Requirements for Spaceflight Systems. Key aspects of the certification approach include the development of a qualified material process (QMP) and material characterization determined by part classification. Nondestructive evaluation (NDE) of the full surface and volume is required for all part classifications except those with negligible risk. NASA is exploring the use of in-process monitoring data to improve risk posture and supplement post-build inspection for complex parts. Currently, the most challenging obstacle to overcome is linking the indications in the monitoring data to the physics of the process and the final material state of the finished part. NASA is undertaking studies to understand and quantify this relationship for various monitoring methods. The desired goal is to develop a protocol to establish this correlation for any monitoring method. Once this correlation is known, the critical defect size can be linked to a representative indication in the monitoring data, and the capability of the monitoring system can be tested using the 90/95 probability of detection requirement for NDE methods. This would enable the use of in-process monitoring as a defect screening activity for AM part certification. Many high-criticality components built with AM have high complexity and therefore limited inspectability, so using in-process monitoring can help address this certification gap. The use of adaptive, closed-loop monitoring systems that alter the locked process will require a new approach to the QMP.

additive manufacturing↗

NASA NTRSDate not supplied

Role of NDE and In-Situ Process Monitoring in Managing Risk of AM Space Hardware

advanced manufacturing↗