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DOE OSTI2021

Perseverance’s Scanning Habitable Environments with Raman and Luminescence for Organics and Chemicals (SHERLOC) Investigation

The Scanning Habitable Environments with Raman and Luminescence for Organics and Chemicals (SHERLOC) is a robotic arm-mounted instrument on NASA’s Perseverance rover. SHERLOC has two primary boresights. The Spectroscopy boresight generates spatially resolved chemical maps using fluorescence and Raman spectroscopy coupled to microscopic images (10.1 μm/pixel). The second boresight is a Wide Angle Topographic Sensor for Operations and eNgineering (WATSON); a copy of the Mars Science Laboratory (MSL) Mars Hand Lens Imager (MAHLI) that obtains color images from microscopic scales (~13 μm/pixel) to infinity. SHERLOC Spectroscopy focuses a 40 μs pulsed deep UV neon-copper laser (248.6 nm), to a ~100 μm spot on a target at a working distance of ~48 mm. Fluorescence emissions from organics, and Raman scattered photons from organics and minerals, are spectrally resolved with a single diffractive grating spectrograph with a spectral range of 250 to ~370 nm. Because the fluorescence and Raman regions are naturally separated with deep UV excitation (<250 nm), the Raman region ~ 800 – 4000 cm -1 (250 to 273 nm) and the fluorescence region (274 to ~370 nm) are acquired simultaneously without time gating or additional mechanisms. SHERLOC science begins by using an Autofocus Context Imager (ACI) to obtain target focus and acquire 10.1 μm/pixel greyscale images. Chemical maps of organic and mineral signatures are acquired by the orchestration of an internal scanning mirror that moves the focused laser spot across discrete points on the target surface where spectra are captured on the spectrometer detector. ACI images and chemical maps (< 100 μm/mapping pixel) will enable the first Mars in situ view of the spatial distribution and interaction between organics, minerals, and chemicals important to the assessment of potential biogenicity (containing CHNOPS). Single robotic arm placement chemical maps can cover areas up to 7x7 mm in area and, with the < 10 min acquisition time per map, larger mosaics are possible with arm movements. This microscopic view of the organic geochemistry of a target at the Perseverance field site, when combined with the other instruments, such as Mastcam-Z, PIXL, and SuperCam, will enable unprecedented analysis of geological materials for both scientific research and determination of which samples to collect and cache for Mars sample return.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS2021

Perseverance’s Scanning Habitable Environments with Raman and Luminescence for Organics and Chemicals (SHERLOC) Investigation

The Scanning Habitable Environments with Raman and Luminescence for Organics and Chemicals (SHERLOC) is a robotic arm-mounted instrument on NASA’s Perseverance rover. SHERLOC has two primary boresights. The Spectroscopy boresight generates spatially resolved chemical maps using fluorescence and Raman spectroscopy coupled to microscopic images (10.1 μm/pixel). The second boresight is a Wide Angle Topographic Sensor for Operations and eNgineering (WATSON); a copy of the Mars Science Laboratory (MSL) Mars Hand Lens Imager (MAHLI) that obtains color images from microscopic scales (∼13 μm/pixel) to infinity. SHERLOC Spectroscopy focuses a 40 μs pulsed deep UV neon-copper laser (248.6 nm), to a ∼100 μm spot on a target at a working distance of ∼48 mm. Fluorescence emissions from organics, and Raman scattered photons from organics and minerals, are spectrally resolved with a single diffractive grating spectrograph with a spectral range of 250 to ∼370 nm. Because the fluorescence and Raman regions are naturally separated with deep UV excitation (<250 nm), the Raman region ∼ 800 – 4000 cm−1 (250 to 273 nm) and the fluorescence region (274 to ∼370 nm) are acquired simultaneously without time gating or additional mechanisms. SHERLOC science begins by using an Autofocus Context Imager (ACI) to obtain target focus and acquire 10.1 μm/pixel greyscale images. Chemical maps of organic and mineral signatures are acquired by the orchestration of an internal scanning mirror that moves the focused laser spot across discrete points on the target surface where spectra are captured on the spectrometer detector. ACI images and chemical maps (< 100 μm/mapping pixel) will enable the first Mars in situ view of the spatial distribution and interaction between organics, minerals, and chemicals important to the assessment of potential biogenicity (containing CHNOPS). Single robotic arm placement chemical maps can cover areas up to 7x7 mm in area and, with the < 10 min acquisition time per map, larger mosaics are possible with arm movements. This microscopic view of the organic geochemistry of a target at the Perseverance field site, when combined with the other instruments, such as Mastcam-Z, PIXL, and SuperCam, will enable unprecedented analysis of geological materials for both scientific research and determination of which samples to collect and cache for Mars sample return.

Rohit Bhartia↗

NASA NTRS1999

Bring'em Back Alive or at Least Carefully

Within the next decade, the world's space agencies plan to launch a variety of robotic spacecraft that will return samples from the surface of Mars, the tail of a comet, the nucleus of a comet, the surface of an asteroid, and the solar wind. Most of these places are not considered likely spots for life, but any mission returning from a location with the potential for harboring life will require special containment and handling because of the possible inclusion of living entities within returned samples. In its 1997 report on sample return from Mars, the Space Studies Board of the National Research Council (NRC) noted that the only risk of significant adverse effects would be from returning a replicating organism. Furthermore, the report noted: 'While the probability of returning a replicating biological entity in a sample from Mars' is judged to be low and the risk of pathogenic or ecological effects is lower still, the risk is not zero. Therefore, it is reasonable that NASA adopt a prudent approach, erring on the side of caution and safety when dealing with returned samples. More recently, a 1998 NRC report on small solar system bodies (asteroids, comets, planetary satellites, and interplanetary dust) recommended a similarly cautious approach for samples returned from anywhere else within the solar system that could have environmental conditions conducive for harboring life. We have not detected life elsewhere in the solar system, at least not yet. Nonetheless, the rationale behind the conservative approach to sample handling is similar to the environmental, health, and safety measures taken on Earth when transporting or handling infectious agents or importing non-native organisms to a new area. Better safe than sorry.

Race, Margaret S.↗

NASA NTRS1989

Planning time-optimal robotic manipulator motions and work places for point-to-point tasks

A method is presented which combines simple time-optimal motions in an optimal manner to yield the minimum-time motions for an important class of complex manipulator tasks composed of point-to-point moves such as assembly, electronic component insertion, and spot welding. This method can also be used to design manipulator actions and work places so that tasks can be completed in minimum time. The method has been implemented in a computer-aided design software system. Several examples are presented. Experimental results show the method's validity and utility.

Dubowsky, S.↗

NASA NTRS1988

Exponential sensor array geometry and simulation

The polar exponential arrays whose geometric parameters are presently analyzed have proven superior to X-Y raster imaging sensors when wide FOV, high central resolution, and rotation- and zoom-invariance are required; attractive applications for such arrays are in spacecraft docking/tracking/stationkeeping and mobile robot navigation. Attention is given to optimal designs minimizing sensor configuration and computation requirements, and the relation of geometric parameters to the three-dimensional sensing precision requirements driving sensor design. A method for smooth patching of the 'blind-spot' singularity in the sensor with a uniformly high-resolution 'fovea' is also presented.

Weiman, Carl F. R.↗

DOE OSTI2022

The EGS Collab Project – Stimulations at Two Depths

The EGS Collab project, supported by the US Department of Energy, is performing intensively monitored rock stimulation and flow tests at the 10-m scale in an underground research laboratory to address challenges in implementing enhanced geothermal systems (EGS). Data and observations from the field tests are compared to simulations to understand processes and build confidence in numerical modeling of the processes. We have completed Experiment 1 (of 3), which examined hydraulic fracturing in a well-characterized underground fractured phyllite test bed at a depth of approximately 1.5 km at the Sanford Underground Research Facility (SURF) in Lead, South Dakota. Testbed characterization included fracture mapping, borehole acoustic and optical televiewers, full waveform sonic, conductivity, resistivity, temperature, campaign p- and s-wave investigations and electrical resistance tomography. Borehole geophysical techniques including passive seismic, continuous active source seismic monitoring, electrical resistance tomography, fiber-based distributed strain, distributed temperature, and distributed acoustic monitoring, were used to carefully monitor stimulation events and flow tests. More than a dozen stimulations and nearly one year of flow tests were performed. Quality data and detailed observations were collected and analyzed during stimulation and water flow tests using ambient temperature and chilled water. We achieved adaptive control of the tests using real-time monitoring and rapid dissemination of data and near-real-time simulation. More detailed numerical simulation was performed to answer key experimental design questions, forecast fracture propagation trajectories and extents, and analyze and evaluate results. Data are freely available from the Geothermal Data Repository. Experiment 2 examines the potential for hydraulic shearing in amphibolite at a depth of about 1.25 km at SURF. This site has a different set of stress and fracture conditions than Experiment 1. The Experiment 2 testbed consists of nine subhorizontal boreholes configured in two fans of two boreholes which surround the testbed and contain grouted-in electrical resistance tomography, seismic sensors, active seismic sources and distributed fiber sensors. A “five-spot” set of test wells that extends from a custom mined alcove includes an injection well and four production/monitoring wells. The testbed was characterized geophysically and hydrologically, and three stimulations have been performed using the Step-Rate Injection Method for Fracture In-Situ Properties (SIMFIP) tool to measure strains, and a new strain quantifying tool (downhole robotic strain analysis tool -DORSA) was deployed in a monitoring hole during stimulation. Real-time data were broadcast during stimulations to allow real-time response to arising issues.

EGS Collab, Enhanced Geothermal Systems, EGS, fiel↗

NASA NTRS1992

Proceedings of the 8th Annual Summer Conference: NASA/USRA Advanced Design Program

Papers presented at the 8th Annual Summer Conference are categorized as Space Projects and Aeronautics projects. Topics covered include: Systematic Propulsion Optimization Tools (SPOT), Assured Crew Return Vehicle Post Landing Configuration Design and Test, Autonomous Support for Microorganism Research in Space, Bioregenerative System Components for Microgravity, The Extended Mission Rover (EMR), Planetary Surface Exploration MESUR/Autonomous Lunar Rover, Automation of Closed Environments in Space for Human Comfort and Safety, Walking Robot Design, Extraterrestrial Surface Propulsion Systems, The Design of Four Hypersonic Reconnaissance Aircraft, Design of a Refueling Tanker Delivering Liquid Hydrogen, The Design of a Long-Range Megatransport Aircraft, and Solar Powered Multipurpose Remotely Powered Aircraft.

Source record↗

NASA NTRS1991

Collision avoidance sensor skin

The objective was to totally eliminate the possibility of a robot (or any mechanism for that matter) inducing a collision in space operations. We were particularly concerned that human beings were safe under all circumstances. This was apparently accomplished, and it is shown that GSFC has a system that is ready for space qualification and flight. However, it soon became apparent that much more could be accomplished with this technology. Payloads could be made invulnerable to collision avoidance and the blind spots behind them eliminated. This could be accomplished by a simple, non-imaging set of 'Capaciflector' sensors on each payload. It also is evident that this system could be used to align and dock the system with a wide margin of safety. Throughout, lighting problems could be ignored, and unexpected events and modeling errors taken in stride. At the same time, computational requirements would be reduced. This can be done in a simple, rugged, reliable manner that will not disturb the form factor of space systems. It will be practical for space applications. The lab experiments indicate we are well on the way to accomplishing this. Still, the research trail goes deeper. It now appears that the sensors can be extended to end effectors to provide precontact information and make robot docking (or any docking connection) very smooth, with minimal loads impacted back into the mating structures. This type of ability would be a major step forward in basic control techniques in space. There are, however, baseline and restructuring issues to be tackled. The payloads must get power and signals to them from the robot or from the astronaut servicing tool. This requires a standard electromechanical interface. Any of several could be used. The GSFC prototype shown in this presentation is a good one. Sensors with their attendant electronics must be added to the payloads, end effectors, and robot arms and integrated into the system.

Source record↗

NASA NTRS1985

Time optimal robotic manipulator motions and work places for point to point tasks

High productivity requires that manipulators perform complex tasks quickly. Recently, optimal control algorithms have been developed which enable manipulators to move quickly, but only for simple motions. A method is presented here which combines simple time optimal motions in an optimal manner to yield the minimum time motions for an important class of complex manipulator tasks composed of point to point moves, such as assembly, electronic component insertion and spot welding. This method can also be used to design manipulator actions and work places so that tasks can be completd in minimum time. The method has been implemented in a CAD software package. Examples are presented which show the methods effectiveness.

Dubowsky, S.↗

NASA NTRS2024

Universal Coating by 3D Hybrid Programmable Matter

Motivated by the prospect of nano-robots that assist human physiological functions at the nanoscale, we investigate the coating problem in the three-dimensional model for hybrid programmable matter. In this model, a single agent with strictly limited viewing range and the computational capability of a deterministic finite automaton can act on passive tiles by picking up a tile, moving, and placing it at some spot. The goal of the coating problem is to fill each node of some surface graph of size n with a tile. We first solve the problem on a restricted class of graphs with a single tile type, and then use constantly many tile types to encode this graph in certain surface graphs capturing the surface of 3D objects. Our algorithm requires O(n^2) steps, which is worst-case optimal compared to an agent with global knowledge and no memory restrictions.

programmable matter↗

NASA NTRS1992

Application of a laser scanner to three dimensional visual sensing tasks

The issues are described which are associated with using a laser scanner for visual sensing and the methods developed by the author to address them. A laser scanner is a device that controls the direction of a laser beam by deflecting it through a pair of orthogonal mirrors, the orientations of which are specified by a computer. If a calibrated laser scanner is combined with a calibrated camera, it is possible to perform three dimensional sensing by directing the laser at objects within the field of view of the camera. There are several issues associated with using a laser scanner for three dimensional visual sensing that must be addressed in order to use the laser scanner effectively. First, methods are needed to calibrate the laser scanner and estimate three dimensional points. Second, methods to estimate three dimensional points using a calibrated camera and laser scanner are required. Third, methods are required for locating the laser spot in a cluttered image. Fourth, mathematical models that predict the laser scanner's performance and provide structure for three dimensional data points are necessary. Several methods were developed to address each of these and has evaluated them to determine how and when they should be applied. The theoretical development, implementation, and results when used in a dual arm eighteen degree of freedom robotic system for space assembly is described.

Ryan, Arthur M.↗

NASA NTRS2010

NASA Tech Briefs, May 2010

Topics covered include: Instrument for Analysis of Greenland's Glacier Mills Cryogenic Moisture Apparatus; A Transportable Gravity Gradiometer Based on Atom Interferometry; Three Methods of Detection of Hydrazines; Crossed, Small-Deflection Energy Analyzer for Wind/Temperature Spectrometer; Wavefront Correction for Large, Flexible Antenna Reflector; Novel Micro Strip-to-Waveguide Feed Employing a Double-Y Junction; Thin-Film Ferro Electric-Coupled Microstripline Phase Shifters With Reduced Device Hysteresis; Two-Stage, 90-GHz, Low-Noise Amplifier; A 311-GHz Fundamental Oscillator Using InP HBT Technology; FPGA Coprocessor Design for an Onboard Multi-Angle Spectro-Polarimetric Imager; Serrating Nozzle Surfaces for Complete Transfer of Droplets; Turbomolecular Pumps for Holding Gases in Open Containers; Triaxial Swirl Injector Element for Liquid-Fueled Engines; Integrated Budget Office Toolbox; PLOT3D Export Tool for Tecplot; Math Description Engine Software Development Kit; Astronaut Office Scheduling System Software; ISS Solar Array Management; Probabilistic Structural Analysis Program; SPOT Program; Integrated Hybrid System Architecture for Risk Analysis; System for Packaging Planetary Samples for Return to Earth; Offset Compound Gear Drive; Low-Dead-Volume Inlet for Vacuum Chamber; Simple Check Valves for Microfluidic Devices; A Capillary-Based Static Phase Separator for Highly Variable Wetting Conditions; Gimballing Spacecraft Thruster; Finned Carbon-Carbon Heat Pipe with Potassium Working Fluid; Lightweight Heat Pipes Made from Magnesium; Ceramic Rail-Race Ball Bearings; Improved OTEC System for a Submarine Robot; Reflector Surface Error Compensation in Dual-Reflector Antennas; Enriched Storable Oxidizers for Rocket Engines; Planar Submillimeter-Wave Mixer Technology with Integrated Antenna; Widely Tunable Mode-Hop-Free External-Cavity Quantum Cascade Laser; Non-Geiger-Mode Single-Photon Avalanche Detector with Low Excess Noise; Using Whispering-Gallery-Mode Resonators for Refractometry; RF Device for Acquiring Images of the Human Body; Reactive Collision Avoidance Algorithm; Fast Solution in Sparse LDA for Binary Classification; Modeling Common-Sense Decisions in Artificial Intelligence; Graph-Based Path-Planning for Titan Balloons; Nanolaminate Membranes as Cylindrical Telescope Reflectors; Air-Sea Spray Airborne Radar Profiler Characterizes Energy Fluxes in Hurricanes; Large Telescope Segmented Primary Mirror Alignment; and Simplified Night Sky Display System.

Source record↗

NASA NTRS2019

Mars Small-Spacecraft Human Exploration Resource Prospector with Aero-braking (SHERPA): Demonstrating an End-to-End Mission to Phobos Distant Retrograde Orbit

This paper summarizes an end-to-end mission design concept exploring the feasibility of using small satellites together with aero-capture technology to achieve Mars orbit insertion, and subsequent injection into a Phobos-stabilized (or distant retrograde) orbit. The science and mission objectives are to carry out a survey of the mineralogy and morphology of Phobos, to answer basic questions concerning its origin and formation, to test the cohesiveness of Phobos regolith, and to search for potential landing sites for future human or robotic spacecraft. The Mars Small-Spacecraft Human Exploration Resource Prospector with Aero-braking (SHERPA) spacecraft is based on a combination flight-tested prototype vehicle and instruments, and first principle sizing of consumables. The resulting system is fitted with an inflatable aerodynamic decelerator to effect aero-capture into a Mars elliptical orbit, on its way to achieving Phobos orbit. A computational fluid dynamics tool is used to analyze the flow-field and identify potential hot spots during aerodynamic flight. This work advocates for the use of small satellites to test out technologies and operational concepts used in sustained human exploration of Mars, and to carry out scientific exploration of the Mars system. Consistent with a systems engineering approach, this work combines elements of the NASA Human Exploration and Operations Mission Directorate, the Space Technology Mission Directorate, and the Science Mission Directorate, and proposes a scenario for science acquisition, technology verification, trajectory validation, and in-situ resource exploration. We believe these type of missions are essential forerunners to human crewed missions to Mars.

Mission Design↗

NASA NTRS2008

Orbital Express Advanced Video Guidance Sensor

In May 2007 the first US fully autonomous rendezvous and capture was successfully performed by DARPA's Orbital Express (OE) mission. Since then, the Boeing ASTRO spacecraft and the Ball Aerospace NEXTSat have performed multiple rendezvous and docking maneuvers to demonstrate the technologies needed for satellite servicing. MSFC's Advanced Video Guidance Sensor (AVGS) is a primary near-field proximity operations sensor integrated into ASTRO's Autonomous Rendezvous and Capture Sensor System (ARCSS), which provides relative state knowledge to the ASTRO GN&C system. This paper provides an overview of the AVGS sensor flying on Orbital Express, and a summary of the ground testing and on-orbit performance of the AVGS for OE. The AVGS is a laser-based system that is capable of providing range and bearing at midrange distances and full six degree-of-freedom (6DOF) knowledge at near fields. The sensor fires lasers at two different frequencies to illuminate the Long Range Targets (LRTs) and the Short Range Targets (SRTs) on NEXTSat. Subtraction of one image from the other image removes extraneous light sources and reflections from anything other than the corner cubes on the LRTs and SRTs. This feature has played a significant role for Orbital Express in poor lighting conditions. The very bright spots that remain in the subtracted image are processed by the target recognition algorithms and the inverse-perspective algorithms, to provide 3DOF or 6DOF relative state information. Although Orbital Express has configured the ASTRO ARCSS system to only use AVGS at ranges of 120 m or less, some OE scenarios have provided opportunities for AVGS to acquire and track NEXTSat at greater distances. Orbital Express scenarios to date that have utilized AVGS include a berthing operation performed by the ASTRO robotic arm, sensor checkout maneuvers performed by the ASTRO robotic arm, 10-m unmated operations, 30-m unmated operations, and Scenario 3-1 anomaly recovery. The AVGS performed very well during the pre-unmated operations, effectively tracking beyond its 10-degree Pitch and Yaw limit-specifications, and did not require I-LOAD adjustments before unmated operations. AVGS provided excellent performance in the 10-m unmated operations, effectively tracking and maintaining lock for the duration of this scenario, and showing good agreement between the short and long range targets. During the 30-m unmated operations, the AVGS continuously tracked the SRT to 31.6 m, exceeding expectations, and continuously tracked the LRT from 8.8 m out to 31.6 m, with good agreement between these two target solutions. After this scenario was aborted at a 10-m separation during remate operations, the AVGS tracked the LRT out 54.3 m, until the relative attitude between the vehicles was too large. The vehicles remained apart for eight days, at ranges from 1 km to 6 km. During the approach to remate in this recovery operation, the AVGS began tracking the LRT at 150 m, well beyond the OE planned limits for AVGS ranges, and functioned as the primary sensor for the autonomous rendezvous and docking.

Howard, Ricky↗

NASA NTRS1994

Dante's Volcano

This video contains two segments: one a 0:01:50 spot and the other a 0:08:21 feature. Dante 2, an eight-legged walking machine, is shown during field trials as it explores the inner depths of an active volcano at Mount Spurr, Alaska. A NASA sponsored team at Carnegie Mellon University built Dante to withstand earth's harshest conditions, to deliver a science payload to the interior of a volcano, and to report on its journey to the floor of a volcano. Remotely controlled from 80-miles away, the robot explored the inner depths of the volcano and information from onboard video cameras and sensors was relayed via satellite to scientists in Anchorage. There, using a computer generated image, controllers tracked the robot's movement. Ultimately the robot team hopes to apply the technology to future planetary missions.

Source record↗

NASA NTRS1995

Raman Spectroscopy as a Method for Mineral Identification on Lunar Robotic Exploration Missions

The sharp, nonoverlapping Raman bands for plagioclase, pyroxene, and olivine would be advantageous for on-surface, active mineralogical analysis of lunar materials. A robust, light-weight, low-power, rover-based Raman spectrometer with a laser exciting source, entirely transmission-mode holographic optics, and a charge-coupled device (CCD) detector could fit within a less than 20 cm cube. A sensor head on the end of an optical fiber bundle that carried the laser beam and returned the scattered radiation could be placed against surfaces at any desired angle by a deployment mechanism; otherwise, the instrument would need no moving parts. A modem micro-Raman spectrometer with its beam broadened (to expand the spot to 50-micrometer diameter) and set for low resolution (7/cm in the 100-1400/cm region relative to 514.5-nm excitation), was used to simulate the spectra anticipated from a rover instrument. We present spectra for lunar mineral grains, less than 1 mm soil fines, breccia fragments, and glasses. From frequencies of olivine peaks, we derived sufficiently precise forsterite contents to correlate the analyzed grains to known rock types and we obtained appropriate forsterite contents from weak signals above background in soil fines and breccias. Peak positions of pyroxenes were sufficiently well determined to distinguish among orthorhombic, monoclinic, and triclinic (pyroxenoid) structures; additional information can be obtained from pyroxene spectra, but requires further laboratory calibration. Plagioclase provided sharp peaks in soil fines and most breccias even when the glass content was high.

Wang, Alian↗

NASA NTRS1997

Real-Time 3D Visualization

Butler Hine, former director of the Intelligent Mechanism Group (IMG) at Ames Research Center, and five others partnered to start Fourth Planet, Inc., a visualization company that specializes in the intuitive visual representation of dynamic, real-time data over the Internet and Intranet. Over a five-year period, the then NASA researchers performed ten robotic field missions in harsh climes to mimic the end- to-end operations of automated vehicles trekking across another world under control from Earth. The core software technology for these missions was the Virtual Environment Vehicle Interface (VEVI). Fourth Planet has released VEVI4, the fourth generation of the VEVI software, and NetVision. VEVI4 is a cutting-edge computer graphics simulation and remote control applications tool. The NetVision package allows large companies to view and analyze in virtual 3D space such things as the health or performance of their computer network or locate a trouble spot on an electric power grid. Other products are forthcoming. Fourth Planet is currently part of the NASA/Ames Technology Commercialization Center, a business incubator for start-up companies.

Source record↗

NASA NTRSDate not supplied

Finite Element Thermal Model for Ultrasonic Welding of Thermoplastic Composites

Ultrasonic welding, UW, is a fast and energy-efficient technique for joining thermoplastic composites. It involves the use of high-frequency mechanical vibrations and a static welding force to melt and join adherends. Ultrasonic welding is an enabling technology to reduce the cost and complexity of in-space construction because lightweight thermoplastic composite components can be packaged compactly for launch and then efficiently assembled using supervised autonomous robotic technologies on site. However, the temperatures in space present challenges to UW, and it is critical that the efficacy of process parameters selected for manufacturing in space is understood prior to launch. To this end, a three-dimensional finite element model is presented in this technical presentation. The model incorporates equations for effects of viscoelastic heating and heat transfer on the welding process. The proposed model is applied to predict the temperature distribution in single lap shear, SLS, samples composed of AS4/PEEK (TC1200) composite that were welded using a terrestrial machine as part of a comprehensive weldability study. Thermocouple and infrared spot sensor data from the SLS samples provide empirical temperature measurements for calibration and validation of the UW thermal model. Calibration and validation of the model is an important step given the significant uncertainties in material properties such as the loss modulus and necessary assumptions in the physics implementations which allow the model to converge in an acceptable amount of time. The validated thermal model can be used to simulate the process for the space environment. Future validation sample testing is planned in a vacuum chamber. The result will be a model capable of guiding process parameter selection to ensure acceptable weld bonds when manufacturing in space.

Josh Fody↗