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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Fused wire in weld root area verifies weld penetration in electron-beam-welded joints. Method could be used in automotive, aircraft, and machinery manufacturing when electron-beam-welds cannot be inspected ultrasonically.
Unlike typical CCN counters, this device counts the numbers of water droplets condensed on aerosol particles sampled on a microcover glass at various different relative humidities. The relative humidities ranged from 75 percent to a calculated value of 110 percent. A schematic of the apparatus is shown. The individual CCN can be identified in an optical micrograph and scanning electron micrograph and may be inspected for their chemical composition later.
Critical and non-critical bonding surfaces must be kept free of contamination that may cause potential unbonds. For example, an aft-dome section of a redesigned solid rocket motor that had been contaminated with hydraulic oil did not appear to be sufficiently cleaned when inspected by the optically stimulated electron emission process (Con Scan) after it had been cleaned using a hand double wipe cleaning method. As a result, current and new cleaning methodologies as well as solvent capability in removing various contaminant materials were reviewed and testing was performed. Bonding studies were also done to verify that the cleaning methods used in removing contaminants provide an acceptable bonding surface. The removal of contaminants from a metal surface and the strength of subsequent bonds were tested using the Martin Marietta and double-wipe cleaning methods. Results are reported.
A Type B Ca-, Al-rich 6-m-diam inclusion (CAI) found in the Vigarano C3V chondrite was inspected using optical and scanning electron microscopies and ion microprobe analyses. It was found that the primary constituents of the CAI inclusion are (in percent), melilite (52), fassaite, (20), anorthite (18), spinel (10), and trace Fe-Ni metal. It is noted that, while many of the properties of the inclusion indicate solidification from a melt droplet, the Al-26/Mg-26 isotopic systematics and some textural relationships are incompatible with single-stage closed system crystallization of a homogeneous molten droplet, indicating that the history of this inclusion must have been more complex than melt solidification alone. Moreover, there was unusually high content of Na in melilite, suggesting that the droplet did not form by melting of pristine high-temperature nebular condensates.
Scattering of the multilayer coatings used for our normal incidence soft X-ray telescope at a wavelength of 63.5 A has been measured at 1.54 A and grazing angles of incidence and at soft X-rays near normal incidence. Furthermore, the edge of the moon is used as a known test target to estimate the amount of scattering in the arcsec range from images obtained on the date of the solar eclipse on July 11, 1991. The internal surfaces of the coating are inspected by high-resolution electron microscopy. A theoretical model describing the evolution and replication of roughness from layer to layer throughout the structure, which is in agreement with all experimental data, is presented. We find that practically all roughness caused by the growth of the multilayer structure occurs at spatial frequencies which are too high to produce scattering. The substrate roughness is replicated at lower spatial frequencies which might produce scattering within the field of view of an instrument. However, roughness in this range is below the 0.5 A level, again resulting in insignificant amounts of scatter.
Optically stimulated electron emission (OSEE) used in inspection for contamination of critical bonding surfaces in solid rocket motors of Space Shuttle prior to formation of adhesive bonds on surfaces during manufacture and refurbishment. Fundamental OSEE inspection technique described in "Surface-Contamination Inspection Tool for Field Use" (MFS-25581) and "Detecting Contamination With Photoelectron Emission" (MFS-25619). OSEE measurement head easily portable, and measurement operation convenient and rapid, making it useful inspection technique in industrial environment. Reveals contamination in many situations in which other techniques do not work.
Simple optical technique enables quick, nondestructive inspection of surfaces of ceramic diaphragms and disks for fractures and discontinuities. Involves reflecting beam of light from laser at glancing angle of about 20 degrees to 25 degrees off surface inspected and examining pattern of reflected light on suitable viewing surface as beam swept across surface. When fracture present, reflection pattern separates into two or more speckled spots. Technique applied in inspection of ceramic diaphragms bearing electronic circuits. Also useful in detection of fatigue cracks on aircraft.
Using Polar/UVI global images, we have identified a period of successive minor auroral activations during which WIND was making a perigee pass through the near-Earth magnetotail. On the basis of images, these auroral brightenings are interpreted to be pseudobreakups due to the lack of significant global expansion. Large magnetic by the WIND spacecraft show a nearly one-to-one correspondence auroral intensifications. During intervals of large field auroral brightenings, energized ions have an Earthward velocity energized electrons generally remain isotropic. Closer inspection ion distribution functions indicate that the high velocity moments are not due to convective flows. Rather, the plasma is composed of a component and a stagnate cold component. We also trace the observed by WIND backwards in time to determine the source regions for the particles. Based upon these observations, we find that to zeroth order there is no difference in the behavior of the plasma during as compared to substorm expansive phase events.
Lasers have previously been evaluated to cut and drill through rock in high pressure and atmospheric conditions to support deep drilling for oil & gas, as well as breaking or cutting rock near the surface. This research evaluates using lasers to cut rocks in a lunar environment. Anorthosite and norite samples were cut in a rough vacuum (<1 Torr) environment using a continuous wave (CW) 2 kW laser. Power and cutting speed are varied to control the total power input. In total 30, 38mm cuts are performed with power levels ranging from 25% (525 W) to 100% (2100 W) and total energy inputs from 0.090 – 4.34 kJ/cm. The cuts are bisected and inspected with optical and scanning electron microscopy. The bisected areas are measured to determine the specific energy for material removal (J/mm 3 ) and the extent of the heat affected zone.
Live footage of the removal of the Integrated Electronics Assembly (I.E.A.) from the STS-33 is presented. The I.E.A. is then inspected at United Space Boosters, Inc. (U.S.B.I).
The acceptance of surface mounting in the electronics industry has been slowed by problems with component availability, electrical testing, and inspection. Industry suppliers and users have been working to solve these problems, and they are easing. Component manufacturers are offering substantially more devices in surface mountable packages. Automated test equipment vendors are offering test fixtures for surface mount circuit boards. And just recently, solder connection inspection has been automated through a partership effort with a major electronics manufacturer. The results achieved in this effort are presented.
Six 48-Ah individual pressure vessel (IPV) Ni/H2 cells containing 26 and 31 percent KOH electrolyte were life cycle tested in low Earth orbit. All three cells containing 31 percent KOH failed (3729, 4165, and 11,355 cycles), while those with 26 percent KOH were cycled over 14,000 times in the continuing test. Destructive physical analysis (DPA) of the failed cells included visual inspections, measurements of electrode thickness, scanning electron microscopy, chemical analysis, and measurements of nickel electrode capacity in an electrolyte flooded cell. The cycling failure was due to a decrease of nickel electrode capacity. As possible causes of the capacity decrease, researchers observed electrode expansion, rupture, and corrosion of the nickel electrode substrate, active material redistribution, and accumulation of electrochemically undischargeable active material with cycling.
Six 48-Ah individual pressure vessel (IPV) Ni/H2 cells containing 26 and 31 percent KOH electrolyte were life cycle tested in low earth orbit. All three cells containing 31 percent KOH failed (3729, 4165, and 11,355 cycles), while those with 26 percent KOH were cycled over 14,000 times in the continuing test. Destructive physical analysis (DPA) of the failed cells included visual inspections, measurements of electrode thickness, scanning electron microscopy, chemical analysis, and measurements of nickel electrode capacity in an electrolyte flooded cell. The cycling failure was due to a decrease of nickel electrode capacity. As possible causes of the capacity decrease, researchers observed electrode expansion, rupture, and corrosion of the nickel electrode substrate, active material redistribution, and accumulation of electrochemically undischargeable active material with cycling.
The original research objective was to demonstrate the ability of optical fiber spectrometry to determine contamination levels on solid rocket motor cases in order to identify surface conditions which may result in poor bonds during production. The capability of using the spectral features to identify contaminants with other sensors which might only indicate a potential contamination level provides a real enhancement to current inspection systems such as Optical Stimulated Electron Emission (OSEE). The optical fiber probe can easily fit into the same scanning fixtures as the OSEE. The initial data obtained using the Guided Wave Model 260 spectrophotometer was primarily focused on determining spectra of potential contaminants such as HD2 grease, silicones, etc. However, once we began taking data and applying multivariate analysis techniques, using a program that can handle very large data sets, i.e., Unscrambler 2, it became apparent that the techniques also might provide a nice scientific tool for determining oxidation and chemisorption rates under controlled conditions. As the ultimate power of the technique became recognized, considering that the chemical system which was most frequently studied in this work is water + D6AC steel, we became very interested in trying the spectroscopic techniques to solve a broad range of problems. The complexity of the observed spectra for the D6AC + water system is due to overlaps between the water peaks, the resulting chemisorbed species, and products of reaction which also contain OH stretching bands. Unscrambling these spectral features, without knowledge of the specific species involved, has proven to be a formidable task.
A "NASA Tech Briefs" article describing an inspection tool and technique known as Optically Stimulated Electron Emission (OSEE) led to the formation of Photo Acoustic Technology, Inc. (PAT). PAT produces sensors and scanning systems which assure surface cleanliness prior to bonding, coating, painting, etc. The company's OP1000 series realtime pre-processing detection capability assures 100 percent surface quality testing. The technique involves brief exposure of the inspection surface to ultraviolet radiation. The energy interacts with the surface layer, causing free electrons to be emitted from the surface to be picked up by the detector. When contamination is present, it interferes with the electron flow in proportion to the thickness of the contaminant layer enabling measurement by system signal output. OP1000 systems operate in conventional atmospheres on all types of material and detect both organic and inorganic contamination.
Using optically stimulated electron emission (OSEE), Thiokol has monitored bond surfaces in process for contamination on the Redesigned Solid Rocket Motor (RSRM). This technique provides process control information to help assure bond surface quality and repeatability prior to bonding. This paper will describe OSEE theory of operation and the instrumentation implemented at Thiokol Corporation since 1987. Data from process hardware will be presented.
Real-time holography has been used to confirm the presence of non-uniformity in the construction of an International Space Station cold plate. Ultrasonic C-scans have previously shown suspected areas of cooling fin disbonds. But both neural-net processed and visual holography did not evidence any progressive permanent changes resulting from 3000 pressurization and relaxation cycles of a Dash 8 cold plate. Neural-net and visual inspections were performed of characteristic patterns generated from electronic time-average holograms of the vibrating cold plate. Normal modes of vibration were excited at very low amplitudes for this purpose, The neural nets were trained to flag very small changes in the mode shapes as encoded in the characteristic patterns. Both the whole cold plate and a zoomed region were inspected. The inspections were conducted before, after, and during pressurization and relaxation cycles of the cold plate. A water-filled cold plate was pressurized to 120 psig (827 kPa) and relaxed for each cycle. Each cycle required 5 seconds. Both the artificial neural networks and the inspectors were unable to detect changes in the mode shapes of the relaxed cold plate. The cold plate was also inspected visually using real-time holography and double-exposure holography. Regions of non-uniformity correlating with the C-scans were apparent, but the interference patterns did not change after 3000 pressurization and relaxation cycles. These tests constituted the first practical application of a neural-net inspection technique developed originally with support from the Director's Discretionary Fund at the Glenn Research Center at Lewis Field.
Vacuum-type neutron image intensifier tube improves image detection in thermal neutron radiographic inspection. This system converts images to an electron image, and with electron acceleration and demagnification between the input target and output screen, produces a bright image viewed through a closed circuit television system.