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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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NASA NTRS1995

Laser Opto-Electronic Correlator for Robotic Vision Automated Pattern Recognition

A compact laser opto-electronic correlator for pattern recognition has been designed, fabricated, and tested. Specifically it is a translation sensitivity adjustable compact optical correlator (TSACOC) utilizing convergent laser beams for the holographic filter. Its properties and performance, including the location of the correlation peak and the effects of lateral and longitudinal displacements for both filters and input images, are systematically analyzed based on the nonparaxial approximation for the reference beam. The theoretical analyses have been verified in experiments. In applying the TSACOC to important practical problems including fingerprint identification, we have found that the tolerance of the system to the input lateral displacement can be conveniently increased by changing a geometric factor of the system. The system can be compactly packaged using the miniature laser diode sources and can be used in space by the National Aeronautics and Space Administration (NASA) and ground commercial applications which include robotic vision, and industrial inspection of automated quality control operations. The personnel of Standard International will work closely with the Jet Propulsion Laboratory (JPL) to transfer the technology to the commercial market. Prototype systems will be fabricated to test the market and perfect the product. Large production will follow after successful results are achieved.

Laser Opto-Electronic↗

NASA NTRS1991

Far-ultraviolet mapping of the Cygnus Loop with the Voyager 2 Ultraviolet Spectrometer

FUV maps of the Cygnus Loop made using spectroscopic data from the Voyager 2 Ultraviolet Spectrometer are presented. Emission line features at about 980 and about 1035 A dominate the 500-1700 A spectra of the Cygnus Loop as observed with Voyager. Maps were generated in the light of these two features. The 980 and 1035 A maps are compared with X-ray and optical images of the Cygnus Loop that have been sampled in the same manner. From this comparison it is clear that the 980 A feature arises mainly from regions of bright optical emission, whereas the 1035 A emission more closely resembles the X-ray emission. This general impression can be confirmed by inspection of the spectra as a function of position. Spectra extracted from positions corresponding to the primary shock front show the 1035 A feature to be relatively strong, while the 980 A feature is brighter when substantial optical emission is present within the aperture.

Blair, William P.↗

NASA NTRS2012

Autonomous Cryogenics Loading Operations Simulation Software: Knowledgebase Autonomous Test Engineer

The Simulation Software, KATE (Knowledgebase Autonomous Test Engineer), is used to demonstrate the automatic identification of faults in a system. The ACLO (Autonomous Cryogenics Loading Operation) project uses KATE to monitor and find faults in the loading of the cryogenics int o a vehicle fuel tank. The KATE software interfaces with the IHM (Integrated Health Management) systems bus to communicate with other systems that are part of ACLO. One system that KATE uses the IHM bus to communicate with is AIS (Advanced Inspection System). KATE will send messages to AIS when there is a detected anomaly. These messages include visual inspection of specific valves, pressure gauges and control messages to have AIS open or close manual valves. My goals include implementing the connection to the IHM bus within KATE and for the AIS project. I will also be working on implementing changes to KATE's Ul and implementing the physics objects in KATE that will model portions of the cryogenics loading operation.

Wehner, Walter S.↗

NASA NTRS2002

Aerospace Safety Advisory Panel

This report presents the results of the Aerospace Safety Advisory Panel (ASAP) activities during 2002. The format of the report has been modified to capture a long-term perspective. Section II is new and highlights the Panel's view of NASA's safety progress during the year. Section III contains the pivotal safety issues facing NASA in the coming year. Section IV includes the program area findings and recommendations. The Panel has been asked by the Administrator to perform several special studies this year, and the resulting white papers appear in Appendix C. The year has been filled with significant achievements for NASA in both successful Space Shuttle operations and International Space Station (ISS) construction. Throughout the year, safety has been first and foremost in spite of many changes throughout the Agency. The relocation of the Orbiter Major Modifications (OMMs) from California to Kennedy Space Center (KSC) appears very successful. The transition of responsibilities for program management of the Space Shuttle and ISS programs from Johnson Space Center (JSC) to NASA Headquarters went smoothly. The decision to extend the life of the Space Shuttle as the primary NASA vehicle for access to space is viewed by the Panel as a prudent one. With the appropriate investments in safety improvements, in maintenance, in preserving appropriate inventories of spare parts, and in infrastructure, the Space Shuttle can provide safe and reliable support for the ISS for the foreseeable future. Indications of an aging Space Shuttle fleet occurred on more than one occasion this year. Several flaws went undetected in the early prelaunch tests and inspections. In all but one case, the problems were found prior to launch. These incidents were all handled properly and with safety as the guiding principle. Indeed, launches were postponed until the problems were fully understood and mitigating action could be taken. These incidents do, however, indicate the need to analyze the Space Shuttle certification criteria closely. Based on this analysis, NASA can determine the need to receritfy the vehicles and to incorporate more stringent inspections throughout the process to minimize launch schedule impact. A highly skilled and experience workforce will be increasingly important for safe and reliable operations as the Space Shuttle vehicles and infrastructure continue to age.

Source record↗

NASA NTRS1994

Topological analysis of chaotic orbits: Revisiting Hyperion

There is emerging interest in the possibility of chaotic evolution in astrophysical systems. To mention just one example, recent well-sampled ground-based observations of the Saturian satellite Hyperion strongly suggest that it is exhibiting chaotic behavior. We present a general technique, the method of close returns, for the analysis of data from astronomical objects believed to be exhibiting chaotic motion. The method is based on the extraction of pieces of the evolution that exhibit nearly periodic behavior-episodes during which the object stays near in phase space to some unstable periodic orbit. Such orbits generally act as skeletal features, tracing the topological organization of the manifold on which the chaotic dynamics takes place. This method does not require data sets as lengthy as other nonlinear analysis techniques do and is therefore well suited to many astronomical observing programs. Well sampled data covering between twenty and forty characteristic periods of the system have been found to be sufficient for the application of this technique. Additional strengths of this method are its robustness in the presence of noise and the ability for a user to clearly distinguish between periodic, random, and chaotic behavior by inspection of the resulting two-dimensional image. As an example of its power, we analyze close returns in a numerically generated data set, based on a model for Hyperion extensively studied in the literature, corresponding to nightly observations of the satellite. We show that with a small data set, embedded unstable periodic orbits can be extracted and that these orbits can be responsible for nearly periodic behavior lasting a substantial fraction of the observing run.

Boyd, Patricia T.↗

NASA NTRS1972

Metallic positive expulsion diaphragms

High-cycle life ring-reinforced hemispherical type positive expulsion diaphragm performance was demonstrated by room temperature fluid expulsion tests of 13" diameter, 8 mil thick stainless steel configurations. A maximum of eleven (11) leak-free, fluid expulsions were achieved by a 25 deg cone angle diaphragm hoop-reinforced with .110-inch cross-sectional diameter wires. This represents a 70% improvement in diaphragm reversal cycle life compared to results previously obtained. The reversal tests confirmed analytic predictions for diaphragm cycle life increases due to increasing values of diaphragm cone angle, radius to thickness ratio and material strain to necking capacity. Practical fabrication techniques were demonstrated for forming close-tolerance, thin corrugated shells and for obtaining closely controlled reinforcing ring stiffness required to maximize diaphragm cycle life. A non-destructive inspection technique for monitoring large local shell bending strains was developed.

Gleich, D.↗

NASA NTRS1978

Digital pointing control

The digital pointing control system developed for the Space Shuttle Data Bus is discussed. The device, which interfaces with NASA standard sensor units, contains a front panel controller, a development system to load, inspect, print, and store the program and data, and a 'test jig' to provide closed-loop controller operation. The system is described with particular reference to the tracker-gyro interfaces, the control algorithms and compensation procedures, Kalman-estimation filtering, the proportional power output, and the discrete output capability. The results of simulation studies are presented and the development status is noted.

Studer, P. A.↗

NASA NTRS2012

Mini AERCam for In-Space Inspection

The NASA Johnson Space Center Engineering Directorate has developed the Miniature Autonomous Extravehicular Robotic Camera (Mini AERCam) as a free-flying, robotic inspection vehicle intended for future external inspection and remote viewing of human spacecraft. The Mini AERCam technology demonstration unit has been successfully integrated into the approximate form and function of a nanosatellite flight system by leveraging the success of AERCam Sprint flight system and related free-flyer technology development. The Mini AERCam free flyer can be operated via remote piloting from a control station supporting teleoperation and supervised autonomous commanding, with functions such as automatic stationkeeping, point-to-point maneuvering, and automatic docking. Free-flyer testing has been conducted on an air-bearing table and in a six degree-of-freedom closed-loop orbital simulation, and enhancements have been made to provide additional capabilities for future space-based inspection. This presentation will provide a technical overview of the Mini AERCam development, including strategies for spacecraft integration.

Fredrickson, Steven E.↗

NASA NTRS2017

UAV Inspection of Electrical Transmission Infrastructure with Path Conformance Autonomy and Lidar-Based Geofences NASA Report on UTM Reference Mission Flights at Southern Company Flights November 2016

Flights at low altitudes in close proximity to electrical transmission infrastructure present serious navigational challenges: GPS and radio communication quality is variable and yet tight position control is needed to measure defects while avoiding collisions with ground structures. To advance unmanned aerial vehicle (UAV) navigation technology while accomplishing a task with economic and societal benefit, a high voltage electrical infrastructure inspection reference mission was designed. An integrated air-ground platform was developed for this mission and tested in two days of experimental flights to determine whether navigational augmentation was needed to successfully conduct a controlled inspection experiment. The airborne component of the platform was a multirotor UAV built from commercial off-the-shelf hardware and software, and the ground component was a commercial laptop running open source software. A compact ultraviolet sensor mounted on the UAV can locate 'hot spots' (potential failure points in the electric grid), so long as the UAV flight path adequately samples the airspace near the power grid structures. To improve navigation, the platform was supplemented with two navigation technologies: lidar-to-polyhedron preflight processing for obstacle demarcation and inspection distance planning, and trajectory management software to enforce inspection standoff distance. Both navigation technologies were essential to obtaining useful results from the hot spot sensor in this obstacle-rich, low-altitude airspace. Because the electrical grid extends into crowded airspaces, the UAV position was tracked with NASA unmanned aerial system traffic management (UTM) technology. The following results were obtained: (1) Inspection of high-voltage electrical transmission infrastructure to locate 'hot spots' of ultraviolet emission requires navigation methods that are not broadly available and are not needed at higher altitude flights above ground structures. (2) The sensing capability of a novel airborne UV detector was verified with a standard ground-based instrument. Flights with this sensor showed that UAV measurement operations and recording methods are viable. With improved sensor range, UAVs equipped with compact UV sensors could serve as the detection elements in a self-diagnosing power grid. (3) Simplification of rich lidar maps to polyhedral obstacle maps reduces data volume by orders of magnitude, so that computation with the resultant maps in real time is possible. This enables real-time obstacle avoidance autonomy. Stable navigation may be feasible in the GPS-deprived environment near transmission lines by a UAV that senses ground structures and compares them to these simplified maps. (4) A new, formally verified path conformance software system that runs onboard a UAV was demonstrated in flight for the first time. It successfully maneuvered the aircraft after a sudden lateral perturbation that models a gust of wind, and processed lidar-derived polyhedral obstacle maps in real time. (5) Tracking of the UAV in the national airspace using the NASA UTM technology was a key safety component of this reference mission, since the flights were conducted beneath the landing approach to a heavily used runway. Comparison to autopilot tracking showed that UTM tracking accurately records the UAV position throughout the flight path.

Moore, Andrew J.↗

NASA NTRS2018

Technologies and Operations for High Voltage Corona Detection with UAVs

Autonomous UAV transmission line inspection served as a reference mission for NASA demonstration of UAV deployment for economic benefit; this paper reports corona sensing advances in development of that reference mission. Unmanned aerial vehicles can serve as a platform for autonomous sensing and location of high voltage coronal discharge. Simple processing of commercial corona camera imagery can automate discharge localization and documentation. Inexpensive ultraviolet point sensors can sense discharge when carried close to the defect with a UAV. Augmented with a parabolic mirror, point sensor range can be increased to a safe inspection standoff distance, at the cost of a narrowed field of view. Results from a test flight of an augmented UV sensor are described. The imaging approach is superior in sensitivity and acquisition time, while the point sensor approach has superior size, weight, cost and durability advantages.

Moore, Andrew J.↗

NASA NTRS2008

Friction Stir Weld Restart+Reweld Repair Allowables

A friction stir weld (FSW) repair method has been developed and successfully implemented on Al 2195 plate material for the Space Shuttle External Fuel Tank (ET). The method includes restarting the friction stir weld in the termination hole of the original weld followed by two reweld passes. Room temperature and cryogenic temperature mechanical properties exceeded minimum FSW design strength and compared well with the development data. Simulated service test results also compared closely to historical data for initial FSW, confirming no change to the critical flaw size or inspection requirements for the repaired weld. Testing of VPPA fusion/FSW intersection weld specimens exhibited acceptable strength and exceeded the minimum design value. Porosity, when present at the intersection was on the root side toe of the fusion weld, the "worst case" being 0.7 inch long. While such porosity may be removed by sanding, this "worst case" porosity condition was tested "as is" and demonstrated that porosity did not negatively affect the strength of the intersection weld. Large, 15-inch "wide panels" FSW repair welds were tested to demonstrate strength and evaluate residual stresses using photo stress analysis. All results exceeded design minimums, and photo stress analysis showed no significant stress gradients due to the presence of the restart and multi-pass FSW repair weld.

Clifton, Andrew↗

NASA NTRS2010

Replacement/Refurbishment of JSC/NASA POD Specimens

The NASA Special NDE certification process requires demonstration of NDE capability by test per NASA-STD-5009. This test is performed with fatigue cracked specimens containing very small cracks. The certification test results are usually based on binomial statistics and must meet a 90/95 Probability of Detection (POD). The assumption is that fatigue cracks are tightly closed, difficult to detect, and inspectors and processes passing such a test are well qualified for inspecting NASA fracture critical hardware. The JSC NDE laboratory has what may be the largest inventory that exists of such fatigue cracked NDE demonstration specimens. These specimens were produced by the hundreds in the late 1980s and early 1990s. None have been produced since that time and the condition and usability of the specimens are questionable.

Castner, Willard L.↗

NASA NTRS2006

Characteristic Lifelength of Coherent Structure in the Turbulent Boundary Layer

A characteristic lifelength is defined by which a Gaussian distribution is fit to data correlated over a 3 sensor array sampling streamwise sidewall pressure. The data were acquired at subsonic, transonic and supersonic speeds aboard a Tu-144. Lifelengths are estimated using the cross spectrum and are shown to compare favorably with Efimtsov's prediction of correlation space scales. Lifelength distributions are computed in the time/frequency domain using an interval correlation technique on the continuous wavelet transform of the original time data. The median values of the lifelength distributions are found to be very close to the frequency averaged result. The interval correlation technique is shown to allow the retrieval and inspection of the original time data of each event in the lifelength distribution, thus providing a means to locate and study the nature of the coherent structure in the turbulent boundary layer. The lifelength data can be converted to lifetimes using the convection velocity. The lifetime of events in the time/frequency domain are displayed in Lifetime Maps. The primary purpose of the paper is to validate these new analysis techniques so that they can be used with confidence to further characterize coherent structure in the turbulent boundary layer.

Palumbo, Daniel L.↗

NASA NTRS2008

Deriving Lifetime Maps in the Time/Frequency Domain of Coherent Structures in the Turbulent Boundary Layer

The lifetimes of coherent structures are derived from data correlated over a 3 sensor array sampling streamwise sidewall pressure at high Reynolds number (> 10(exp 8)). The data were acquired at subsonic, transonic and supersonic speeds aboard a Tupolev Tu-144. The lifetimes are computed from a variant of the correlation length termed the lifelength. Characteristic lifelengths are estimated by fitting a Gaussian distribution to the sensors cross spectra and are shown to compare favorably with Efimtsov s prediction of correlation space scales. Lifelength distributions are computed in the time/frequency domain using an interval correlation technique on the continuous wavelet transform of the original time data. The median values of the lifelength distributions are found to be very close to the frequency averaged result. The interval correlation technique is shown to allow the retrieval and inspection of the original time data of each event in the lifelength distributions, thus providing a means to locate and study the nature of the coherent structure in the turbulent boundary layer. The lifelength data are converted to lifetimes using the convection velocity. The lifetime of events in the time/frequency domain are displayed in Lifetime Maps. The primary purpose of the paper is to validate these new analysis techniques so that they can be used with confidence to further characterize the behavior of coherent structures in the turbulent boundary layer.

Palumbo, Dan↗

NASA NTRS2005

Sprayable Phase Change Coating Thermal Protection Material

NASA has expressed a need for reusable, environmentally friendly, phase change coating that is capable of withstanding the heat loads that have historically required an ablative thermal insulation. The Space Shuttle Program currently relies on ablative materials for thermal protection. The problem with an ablative insulation is that, by design, the material ablates away, in fulfilling its function of cooling the underlying substrate, thus preventing the insulation from being reused from flight to flight. The present generation of environmentally friendly, sprayable, ablative thermal insulation (MCC-l); currently use on the Space Shuttle SRBs, is very close to being a reusable insulation system. In actual flight conditions, as confirmed by the post-flight inspections of the SRBs, very little of the material ablates. Multi-flight thermal insulation use has not been qualified for the Space Shuttle. The gap that would have to be overcome in order to implement a reusable Phase Change Coating (PCC) is not unmanageable. PCC could be applied robotically with a spray process utilizing phase change material as filler to yield material of even higher strength and reliability as compared to MCC-1. The PCC filled coatings have also demonstrated potential as cryogenic thermal coatings. In experimental thermal tests, a thin application of PCC has provided the same thermal protection as a much thicker and heavier application of a traditional ablative thermal insulation. In addition, tests have shown that the structural integrity of the coating has been maintained and phase change performance after several aero-thermal cycles was not affected. Experimental tests have also shown that, unlike traditional ablative thermal insulations, PCC would not require an environmental seal coat, which has historically been required to prevent moisture absorption by the thermal insulation, prevent environmental degradation, and to improve the optical and aerodynamic properties. In order to reduce the launch and processing costs of a reusable space vehicle to an affordable level, refurbishment costs must be substantially reduced. A key component of such a cost effective approach is the use of a reusable, phase change, thermal protection coating.

Richardson, Rod W.↗

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↗

NASA NTRS2010

Development of Weld Inspection of the Ares I Crew Launch Vehicle Upper Stage

NASA is designing a new crewed launch vehicle called Ares I to replace the Space Shuttle after its scheduled retirement in 2010. This new launch vehicle will build on the Shuttle technology in many ways including using a first stage based upon the Space Shuttle Solid Rocket Booster, advanced aluminum alloys for the second stage tanks, and friction stir welding to assemble the second stage. Friction stir welding uses a spinning pin that is inserted in the joint between two panels that are to be welded. The pin mechanically mixes the metal together below the melting temperature to form the weld. Friction stir welding allows high strength joints in metals that would otherwise lose much of their strength as they are melted during the fusion welding process. One significant change from the Space Shuttle that impacts NDE is the implementation of self-reacting friction stir welding for non-linear welds on the primary metallic structure. The self-reacting technique differs from the conventional technique because the load of the pin tool pressing down on the metal being joined is reacted by a nut on the end of the tool rather than an anvil behind the part. No spacecraft has ever flown with a self-reacting friction stir weld, so this is a major advancement in the manufacturing process, bringing with it a whole new set of challenges for NDE to overcome. The metal microstructure and possible defects are different from other weld processes. Friction plug welds will be used to close out the hole remaining in the radial welds when friction stir welded. This plug welding also has unique challenges in inspection. The current state of development of these inspections will be presented, along with other information pertinent to NDE of the Ares I.

Russell, Sam↗