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NASA NTRS2006

Evaluation Of Risk And Possible Mitigation Schemes For Previously Unidentified Hazards

This report presents the results of arc track testing conducted to determine if such a transfer of power to un-energized wires is possible and/or likely during an arcing event, and to evaluate an array of protection schemes that may significantly reduce the possibility of such a transfer. The results of these experiments may be useful for determining the level of protection necessary to guard against spurious voltage and current being applied to safety critical circuits. It was not the purpose of these experiments to determine the probability of the initiation of an arc track event only if an initiation did occur could it cause the undesired event: an inadvertent thruster firing. The primary wire insulation used in the Orbiter is aromatic polyimide, or Kapton , a construction known to arc track under certain conditions [3]. Previous Boeing testing has shown that arc tracks can initiate in aromatic polyimide insulated 28 volts direct current (VDC) power circuits using more realistic techniques such as chafing with an aluminum blade (simulating the corner of an avionics box or lip of a wire tray), or vibration of an aluminum plate against a wire bundle [4]. Therefore, an arc initiation technique was chosen that provided a reliable and consistent technique of starting the arc and not a realistic simulation of a scenario on the vehicle. Once an arc is initiated, the current, power and propagation characteristics of the arc depend on the power source, wire gauge and insulation type, circuit protection and series resistance rather than type of initiation. The initiation method employed for these tests was applying an oil and graphite mixture to the ends of a powered twisted pair wire. The flight configuration of the heater circuits, the fuel/oxider (or ox) wire, and the RCS jet solenoid were modeled in the test configuration so that the behavior of these components during an arcing event could be studied. To determine if coil activation would occur with various protection wire schemes, 145 tests were conducted using various fuel/ox wire alternatives (shielded and unshielded) and/or different combinations of polytetrafuloroethylene (PTFE), Mystik tape and convoluted wraps to prevent unwanted coil activation. Test results were evaluated along with other pertinent data and information to develop a mitigation strategy for an inadvertent RCS firing. The SSP evaluated civilian aircraft wiring failures to search for aging trends in assessing the wire-short hazard. Appendix 2 applies Weibull statistical methods to the same data with a similar purpose.

Linzey, William↗

NASA NTRS2006

An Update on Structural Seal Development at NASA GRC

A viewgraph presentation describing advanced structural seal development for NASA exploration is shown. The topics include: 1) GRC Structural Seals Team Research Areas; 2) Research Areas & Objective; 3) Wafer Seal Geometry/Flow Investigations; 4) Wafer Seal Installation DOE Study; 5) Results of Wafer Seal Installation DOE Study; 6) Wafer Geometry Study: Thickness Variations; 7) Wafer Geometry Study: Full-Size vs. Half-Size Wafers; 8) Spring Tube Seal Development; 9) Resiliency Improvement for Rene 41 Spring Tube; 10) Spring Tube Seals: Go-Forward Plan; 11) High Temperature Seal Preloader Development: TZM Canted Coil Spring; 12) TZM Canted Coil Spring Development; 13) Arc Jet Test Rig Development; and 14) Arc Jet Test Rig Status.

Dunlap, Pat↗

NASA NTRS2007

Current sheet Formation in a Conical Theta Pinch Faraday Accelerator with Radio-Frequency Assisted Discharge

The inductive formation of current sheets in a conical theta pinch FARAD (Faraday Accelerator with Radio-frequency Assisted Discharge) thruster is investigated experimentally with time-integrated photography. The goal is to help in understanding the mechanisms and conditions controlling the strength and extent of the current sheet, which are two indices important for FARAD as a propulsion concept. The profiles of these two indices along the inside walls of the conical acceleration coil are assumed to be related to the profiles of the strength and extent of the luminosity pattern derived from photographs of the discharge. The variations of these profiles as a function of uniform back-fill neutral pressure (with no background magnetic field and all parameters held constant) provided the first clues on the nature and qualitative dependencies of current sheet formation. It was found that there is an optimal pressure for which both indices reach a maximum and that the rate of change in these indices with pressure differs on either side of this optimal pressure. This allowed the inference that current sheet formation follows a Townsend-like breakdown mechanism modified by the existence of a finite pressure-dependent radio-frequency-generated electron density background. The observation that the effective location of the luminosity pattern favors the exit-half of the conical coil is explained as the result of the tendency of the inductive discharge circuit to operate near its minimal self-inductance. Movement of the peak in the luminosity pattern towards the upstream side of the cone with increasing pressure is believed to result from the need of the circuit to compensate for the increase in background plasma resistivity due to increasing pressure.

Hallock, Ashley K.↗

NASA NTRS1993

Sensor tip for a robotic gripper and method of manufacture

A sensor tip (10) for use in a robotic hand has a three-dimensional compliant elastomeric body (12) with an outer boundary (22) having a circular base (24) and a convex surface (26) extending therefrom. Four strain transducers (14, 16, 18, and 20) produce electrical signals indicative of the strain at various positions near the boundary of the elastomeric body (12) resulting from forces exerted upon the sensor tip (10) by an object which the robotic hand is manipulating. The transducers (14, 16, 18, and 20) are positioned about the convex surface (26) so as to produce signals that may be decoupled to determine the normal and tangential forces and the applied torque. A buffer amplifier circuit (34), one for each of the transducers (14, 16, 18, and 20), receives the signals and provides quasi-steady state force information. The circuit (34) connects the respective transducer (40) in a feedback loop around an amplifier (36) and has desirable attributes for static charge buffering. The sensor tip (10) is calibrated to determine proportionality constants for the decoupling algorithm for use of a force delivering system (60), which uses voice coils (74) to apply a force that is linearly related to the current introduced to each of the coils (74). A method of manufacture of the sensor tip (10) results in improved bonding between the transducers (14, 16, 18, and 20) and the elastomeric body (12) for better performance and longer life of the sensor tip (10).

Lorenz, Robert D.↗

NASA NTRS1993

Superconducting energy storage magnet

A superconducting magnet is formed having composite conductors arrayed in coils having turns which lie on a surface defining substantially a frustum of a cone. The conical angle with respect to the central axis is preferably selected such that the magnetic pressure on the coil at the widest portion of the cone is substantially zero. The magnet structure is adapted for use as an energy storage magnet mounted in an earthen trench or tunnel where the strength the surrounding soil is lower at the top of the trench or tunnel than at the bottom. The composite conductor may be formed having a ripple shape to minimize stresses during charge up and discharge and has a shape for each ripple selected such that the conductor undergoes a minimum amount of bending during the charge and discharge cycle. By minimizing bending, the working of the normal conductor in the composite conductor is minimized, thereby reducing the increase in resistance of the normal conductor that occurs over time as the conductor undergoes bending during numerous charge and discharge cycles.

Boom, Roger W.↗

NASA NTRS1991

DC current monitor

A non-intrusive DC current monitor is presented which emulates the theoretical operation of an AC transformer. A conductor, carrying the current to be measured, acts as the primary of a DC current transformer. This current is passed through the center of a secondary coil, and core positioned thereabout, and produces a magnetic flux which induces a current in the secondary proportional to the current flowing in the primary. Means are provided to periodically reset the transformer core such that the measurement inaccuracies associated with core saturation are obviated. A reset current is caused to periodically flow through the secondary coil which produces a magnetic flux oppositely polarized to the flux created by the current in the primary, thus allowing ongoing measurements to be made.

Canter, Stanley↗

NASA NTRS1991

Linear magnetic spring and spring/motor combination

A magnetic spring, or a spring and motor combination, providing a linear spring force characteristic in each direction from a neutral position, in which the spring action may occur for any desired coordinate of a typical orthogonal coordinate system. A set of magnets are disposed, preferably symmetrically about a coordinate axis, poled orthogonally to the desired force direction. A second set of magnets, respectively poled opposite the first set, are arranged on the sprung article. The magnets of one of the sets are spaced a greater distance apart than those of the other, such that an end magnet from each set forms a pair having preferably planar faces parallel to the direction of spring force, the faces being offset so that in a neutral position the outer edge of the closer spaced magnet set is aligned with the inner edge of the greater spaced magnet set. For use as a motor, a coil can be arranged with conductors orthogonal to both the magnet pole directions and the direction of desired spring force, located across from the magnets of one set and fixed with respect to the magnets of the other set. In a cylindrical coordinate system having axial spring force, the magnets are radially poled and motor coils are concentric with the cylinder axis.

Patt, Paul J.↗

NASA NTRS1991

Sensor tip for a robotic gripper and method of manufacture

Lorenz, Robert D.↗

NASA NTRS1984

Vapor degreasing system

A vapor degreasing method and apparatus wherein a second cooling coil is used to prevent escape of solvent or solvent vapor from a degreaser. Gaseous refrigerant from the second coil can be released to the freeboard space above the solvent vapor zone to provide a barrier layer.

du Fresne, Eugene R.↗

NASA NTRS2007

Progress on the PT-1 Prototype Plasmoid Thruster

The design and construction of a plasmoid thruster prototype is described. This thruster operates by expelling inductively formed plasmoids at high velocities. These plasmoids are field reversed configuration plasmas which are formed by reversing a magnetic flux frozen in an ionized gas inside a theta-pinch coil. The pinch coil is a unique multi-turn, multi-lead design chosen for optimization of inductance and field uniformity. A table-top bread-board demonstrator has been built at MSFC, and will be delivered to Radiance Technologies Inc. for further testing at the Auburn Space Power Institute.

Eskridge, Richard H.↗

NASA NTRS1989

Monocoil reciprocating permanent magnet electric machine with self-centering force

A linear reciprocating machine has a tubular outer stator housing a coil, a plunger and an inner stator. The plunger has four axially spaced rings of radially magnetized permanent magnets which cooperate two at a time with the stator to complete first or second opposite magnetic paths. The four rings of magnets and the stators are arranged so that the stroke of the plunger is independent of the axial length of the coil.

Bhate, Suresh K.↗

NASA NTRS2008

Actuated atomizer

An actuated atomizer is adapted for spray cooling or other applications wherein a well-developed, homogeneous and generally conical spray mist is required. The actuated atomizer includes an outer shell formed by an inner ring; an outer ring; an actuator insert and a cap. A nozzle framework is positioned within the actuator insert. A base of the nozzle framework defines swirl inlets, a swirl chamber and a swirl chamber. A nozzle insert defines a center inlet and feed ports. A spool is positioned within the coil housing, and carries the coil windings having a number of turns calculated to result in a magnetic field of sufficient strength to overcome the bias of the spring. A plunger moves in response to the magnetic field of the windings. A stop prevents the pintle from being withdrawn excessively. A pintle, positioned by the plunger, moves between first and second positions. In the first position, the head of the pintle blocks the discharge passage of the nozzle framework, thereby preventing the atomizer from discharging fluid. In the second position, the pintle is withdrawn from the swirl chamber, allowing the atomizer to release atomized fluid. A spring biases the pintle to block the discharge passage. The strength of the spring is overcome, however, by the magnetic field created by the windings positioned on the spool, which withdraws the plunger into the spool and further compresses the spring.

Tilton, Charles↗

NASA NTRS2008

Development of Eddy Current Techniques for Detection of Deep Fatigue Cracks in Multi-Layer Airframe Components

Thick, multi-layer aluminum structure has been widely used in aircraft design in critical wing splice areas. The multi-layer structure generally consists of three or four aluminum layers with different geometry and varying thickness, which are held together with fasteners. The detection of cracks under fasteners with ultrasonic techniques in subsurface layers away from the skin is impeded primarily by interlayer bonds and faying sealant condition. Further, assessment of such sealant condition is extremely challenging in terms of complexity of structure, limited access, and inspection cost. Although Eddy current techniques can be applied on in-service aircraft from the exterior of the skin without knowing sealant condition, the current eddy current techniques are not able to detect defects with wanted sensitivity. In this work a series of low frequency eddy current probes have been designed, fabricated and tested for this application. A probe design incorporating a shielded magnetic field sensor concentrically located in the interior of a drive coil has been employed to enable a localized deep diffusion of the electromagnetic field into the part under test. Due to the required low frequency inspections, probes have been testing using a variety of magnetic field sensors (pickup coil, giant magneto-resistive, anisotropic magneto-resistive, and spin-dependent tunneling). The probe designs as well as capabilities based upon a target inspection for sub-layer cracking in an airframe wing spar joint is presented.

Wincheski, Russell A.↗

NASA NTRS2008

Making Superconducting Welds between Superconducting Wires

A technique for making superconducting joints between wires made of dissimilar superconducting metals has been devised. The technique is especially suitable for fabrication of superconducting circuits needed to support persistent electric currents in electromagnets in diverse cryogenic applications. Examples of such electromagnets include those in nuclear magnetic resonance (NMR) and magnetic resonance imaging (MRI) systems and in superconducting quantum interference devices (SQUIDs). Sometimes, it is desirable to fabricate different parts of a persistent-current-supporting superconducting loop from different metals. For example, a sensory coil in a SQUID might be made of Pb, a Pb/Sn alloy, or a Cu wire plated with Pb/Sn, while the connections to the sensory coil might be made via Nb or Nb/Ti wires. Conventional wire-bonding techniques, including resistance spot welding and pressed contact, are not workable because of large differences between the hardnesses and melting temperatures of the different metals. The present technique is not subject to this limitation. The present technique involves the use (1) of a cheap, miniature, easy-to-operate, capacitor-discharging welding apparatus that has an Nb or Nb/Ti tip and operates with a continuous local flow of gaseous helium and (2) preparation of a joint in a special spark-discharge welding geometry. In a typical application, a piece of Nb foil about 25 m thick is rolled to form a tube, into which is inserted a wire that one seeks to weld to the tube (see figure). The tube can be slightly crimped for mechanical stability. Then a spark weld is made by use of the aforementioned apparatus with energy and time settings chosen to melt a small section of the niobium foil. The energy setting corresponds to the setting of a voltage to which the capacitor is charged. In an experiment, the technique was used to weld an Nb foil to a copper wire coated with a Pb/Sn soft solder, which is superconducting. The joint was evaluated as part of a persistent-current circuit having an inductance of 1 mH. A current was induced in a loop, and no attenuation of the current after a time interval 1,000 s was discernible in a measurement having a fractional accuracy of 10(exp -4): This observation supports the conclusion that the weld had an electrical resistance <10(exp -10) omega.

Penanen, Konstantin I.↗

NASA NTRS2008

Magnetostrictive valve assembly

A magnetostrictive valve assembly includes a housing that defines a passage with a seat being formed therein. A magnetically-biased and axially-compressed magnetostrictive assembly slidingly fitted in the passage is configured as a hollow and open-ended conduit adapted to support a flow of a fluid therethrough. Current-carrying coil(s) disposed about the passage in the region of the magnetostrictive assembly generate a magnetic field in the passage when current flows through the coil(s). A hollow valve body with side ports is coupled on one end thereof to an axial end of the magnetostrictive assembly. The other end of the valve body is designed to seal with the seat formed in the housing's passage when brought into contact therewith.

Richard, James A.↗

NASA NTRS2009

Room-Temperature-Cured Copolymers for Lithium Battery Gel Electrolytes

Polyimide-PEO copolymers (PEO signifies polyethylene oxide) that have branched rod-coil molecular structures and that can be cured into film form at room temperature have been invented for use as gel electrolytes for lithium-ion electric-power cells. These copolymers offer an alternative to previously patented branched rod-coil polyimides that have been considered for use as polymer electrolytes and that must be cured at a temperature of 200 C. In order to obtain sufficient conductivity for lithium ions in practical applications at and below room temperature, it is necessary to imbibe such a polymer with a suitable carbonate solvent or ionic liquid, but the high-temperature cure makes it impossible to incorporate and retain such a liquid within the polymer molecular framework. By eliminating the high-temperature cure, the present invention makes it possible to incorporate the required liquid.

Meador, Mary Ann B.↗

NASA NTRS2009

Radial Halbach Magnetic Bearings

Radial Halbach magnetic bearings have been investigated as part of an effort to develop increasingly reliable noncontact bearings for future high-speed rotary machines that may be used in such applications as aircraft, industrial, and land-vehicle power systems and in some medical and scientific instrumentation systems. Radial Halbach magnetic bearings are based on the same principle as that of axial Halbach magnetic bearings, differing in geometry as the names of these two types of bearings suggest. Both radial and axial Halbach magnetic bearings are passive in the sense that unlike most other magnetic bearings that have been developed in recent years, they effect stable magnetic levitation without need for complex active control. Axial Halbach magnetic bearings were described in Axial Halbach Magnetic Bearings (LEW-18066-1), NASA Tech Briefs, Vol. 32, No. 7 (July 2008), page 85. In the remainder of this article, the description of the principle of operation from the cited prior article is recapitulated and updated to incorporate the present radial geometry. In simplest terms, the basic principle of levitation in an axial or radial Halbach magnetic bearing is that of the repulsive electromagnetic force between (1) a moving permanent magnet and (2) an electric current induced in a stationary electrical conductor by the motion of the magnetic field. An axial or radial Halbach bearing includes multiple permanent magnets arranged in a Halbach array ("Halbach array" is defined below) in a rotor and multiple conductors in the form of wire coils in a stator, all arranged so the rotary motion produces an axial or radial repulsion that is sufficient to levitate the rotor. A basic Halbach array (see Figure 1) consists of a row of permanent magnets, each oriented so that its magnetic field is at a right angle to that of the adjacent magnet, and the right-angle turns are sequenced so as to maximize the magnitude of the magnetic flux density on one side of the row while minimizing it on the opposite side. The advantage of this configuration is that it makes it possible to approach the theoretical maximum force per unit area that could be exerted by a given amount of permanent-magnet material. The configuration is named after physicist Klaus Halbach, who conceived it for use in particle accelerators. Halbach arrays have also been studied for use in magnetic-levitation ("maglev") railroad trains. In a radial Halbach magnetic bearing, the basic Halbach arrangement is modified into a symmetrical arrangement of sector-shaped permanent magnets mounted on the outer cylindrical surface of a drum rotor (see Figure 2). The magnets are oriented to concentrate the magnetic field on their radially outermost surface. The stator coils are mounted in a stator shell surrounding the rotor.

Eichenberg, Dennis J.↗

NASA NTRS2009

Numerical Investigation of Near-Field Plasma Flows in Magnetic Nozzles

The development and application of a multidimensional numerical simulation code for investigating near-field plasma processes in magnetic nozzles are presented. The code calculates the time-dependent evolution of all three spatial components of both the magnetic field and velocity in a plasma flow, and includes physical models of relevant transport phenomena. It has been applied to an investigation of the behavior of plasma flows found in high-power thrusters, employing a realistic magnetic nozzle configuration. Simulation of a channel-flow case where the flow was super-Alfvenic has demonstrated that such a flow produces adequate back-emf to significantly alter the shape of the total magnetic field, preventing the flow from curving back to the magnetic field coil in the near-field region. Results from this simulation can be insightful in predicting far-field behavior and can be used as a set of self-consistent boundary conditions for far-field simulations. Future investigations will focus on cases where the inlet flow is sub-Alfvenic and where the flow is allowed to freely expand in the radial direction once it is downstream of the coil.

Sankaran, Kamesh↗