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All sourcesNASA NTRSDOE OSTI
NASA NTRS1988

Apparatus for making molten silicon

A reactor apparatus (10) adapted for continuously producing molten, solar grade purity elemental silicon by thermal reaction of a suitable precursor gas, such as silane (SiH.sub.4), is disclosed. The reactor apparatus (10) includes an elongated reactor body (32) having graphite or carbon walls which are heated to a temperature exceeding the melting temperature of silicon. The precursor gas enters the reactor body (32) through an efficiently cooled inlet tube assembly (22) and a relatively thin carbon or graphite septum (44). The septum (44), being in contact on one side with the cooled inlet (22) and the heated interior of the reactor (32) on the other side, provides a sharp temperature gradient for the precursor gas entering the reactor (32) and renders the operation of the inlet tube assembly (22) substantially free of clogging. The precursor gas flows in the reactor (32) in a substantially smooth, substantially axial manner. Liquid silicon formed in the initial stages of the thermal reaction reacts with the graphite or carbon walls to provide a silicon carbide coating on the walls. The silicon carbide coated reactor is highly adapted for prolonged use for production of highly pure solar grade silicon. Liquid silicon (20) produced in the reactor apparatus (10) may be used directly in a Czochralski or other crystal shaping equipment.

Levin, Harry↗
NASA NTRS2008

System and method for suppressing sublimation using opacified aerogel

The present invention relates to a castable, aerogel-based, ultra-low thermal conductivity opacified insulation to suppress sublimation. More specifically, the present invention relates to an aerogel opacified with various opacifying or reflecting constituents to suppress sublimation and provide thermal insulation in thermoelectric modules. The opacifying constituent can be graded within the aerogel for increased sublimation suppression, and the density of the aerogel can similarly be graded to achieve optimal thermal insulation and sublimation suppression.

Sakamoto, Jeff S.↗
NASA NTRS2009

NASA Tech Briefs, March 2009

Topics covered include: Improved Instrument for Detecting Water and Ice in Soil; Real-Time Detection of Dust Devils from Pressure Readings; Determining Surface Roughness in Urban Areas Using Lidar Data; DSN Data Visualization Suite; Hamming and Accumulator Codes Concatenated with MPSK or QAM; Wide-Angle-Scanning Reflectarray Antennas Actuated by MEMS; Biasable Subharmonic Membrane Mixer for 520 to 600 GHz; Hardware Implementation of Serially Concatenated PPM Decoder; Symbolic Processing Combined with Model-Based Reasoning; Presentation Extensions of the SOAP; Spreadsheets for Analyzing and Optimizing Space Missions; Processing Ocean Images to Detect Large Drift Nets; Alternative Packaging for Back-Illuminated Imagers; Diamond Machining of an Off-Axis Biconic Aspherical Mirror; Laser Ablation Increases PEM/Catalyst Interfacial Area; Damage Detection and Self-Repair in Inflatable/Deployable Structures; Polyimide/Glass Composite High-Temperature Insulation; Nanocomposite Strain Gauges Having Small TCRs; Quick-Connect Windowed Non-Stick Penetrator Tips for Rapid Sampling; Modeling Unsteady Cavitation and Dynamic Loads in Turbopumps; Continuous-Flow System Produces Medical-Grade Water; Discrimination of Spore-Forming Bacilli Using spoIVA; nBn Infrared Detector Containing Graded Absorption Layer; Atomic References for Measuring Small Accelerations; Ultra-Broad-Band Optical Parametric Amplifier or Oscillator; Particle-Image Velocimeter Having Large Depth of Field; Enhancing SERS by Means of Supramolecular Charge Transfer; Improving 3D Wavelet-Based Compression of Hyperspectral Images; Improved Signal Chains for Readout of CMOS Imagers; SOI CMOS Imager with Suppression of Cross-Talk; Error-Rate Bounds for Coded PPM on a Poisson Channel; Biomorphic Multi-Agent Architecture for Persistent Computing; and Using Covariance Analysis to Assess Pointing Performance.

Source record↗
NASA NTRS2007

Ultra-Thin, Triple-Bandgap GaInP/GaAs/GaInAs Monolithic Tandem Solar Cells

The performance of state-of-the-art, series-connected, lattice-matched (LM), triple-junction (TJ), III-V tandem solar cells could be improved substantially (10-12%) by replacing the Ge bottom subcell with a subcell having a bandgap of approx.1 eV. For the last several years, research has been conducted by a number of organizations to develop approx.1-eV, LM GaInAsN to provide such a subcell, but, so far, the approach has proven unsuccessful. Thus, the need for a high-performance, monolithically integrable, 1-eV subcell for TJ tandems has remained. In this paper, we present a new TJ tandem cell design that addresses the above-mentioned problem. Our approach involves inverted epitaxial growth to allow the monolithic integration of a lattice-mismatched (LMM) approx.1- eV GaInAs/GaInP double-heterostructure (DH) bottom subcell with LM GaAs (middle) and GaInP (top) upper subcells. A transparent GaInP compositionally graded layer facilitates the integration of the LM and LMM components. Handle-mounted, ultra-thin device fabrication is a natural consequence of the inverted-structure approach, which results in a number of advantages, including robustness, potential low cost, improved thermal management, incorporation of back-surface reflectors, and possible reclamation/reuse of the parent crystalline substrate for further cost reduction. Our initial work has concerned GaInP/GaAs/GaInAs tandem cells grown on GaAs substrates. In this case, the 1- eV GaInAs experiences 2.2% compressive LMM with respect to the substrate. Specially designed GaInP graded layers are used to produce 1-eV subcells with performance parameters nearly equaling those of LM devices with the same bandgap (e.g., LM, 1-eV GaInAsP grown on InP). Previously, we reported preliminary ultra-thin tandem devices (0.237 cm2) with NREL-confirmed efficiencies of 31.3% (global spectrum, one sun) (1), 29.7% (AM0 spectrum, one sun) (2), and 37.9% (low-AOD direct spectrum, 10.1 suns) (3), all at 25 C. Here, we include recent results of testing similar devices under the concentrated AMO spectrum, and also present the first demonstration of a high-efficiency, ultra-thin GaInP/GaAs/GaInAs tandem cell processed on a flexible kapton handle.

Wanlass, M. W.↗
NASA NTRS2007

Toward a III-V Multijunction Space Cell Technology on Si

High efficiency compound semiconductor solar cells grown on Si substrates are of growing interest in the photovoltaics community for both terrestrial and space applications. As a potential substrate for III-V compound photovoltaics, Si has many advantages over traditional Ge and GaAs substrates that include higher thermal conductivity, lower weight, lower material costs, and the potential to leverage the extensive manufacturing base of the Si industry. Such a technology that would retain high solar conversion efficiency at reduced weight and cost would result in space solar cells that simultaneously possess high specific power (W/kg) and high power density (W/m2). For terrestrial solar cells this would result in high efficiency III-V concentrators with improved thermal conductivity, reduced cost, and via the use of SiGe graded interlayers as active component layers the possibility of integrating low bandgap sub-cells that could provide for extremely high conversion efficiency.1 In addition to photovoltaics, there has been an historical interest in III-V/Si integration to provide optical interconnects in Si electronics, which has become of even greater relevance recently due to impending bottlenecks in CMOS based circuitry. As a result, numerous strategies to integrate GaAs with Si have been explored with the primary issue being the approx.4% lattice mismatch between GaAs and Si. Among these efforts, relaxed, compositionally-graded SiGe buffer layers where the substrate lattice constant is effectively tuned from Si to that of Ge so that a close lattice match to subsequent GaAs overlayers have shown great promise. With this approach, threading dislocation densities (TDDs) of approx.1 x 10(exp 6)/sq cm have been uniformly achieved in relaxed Ge layers on Si,5 leading to GaAs on Si with minority carrier lifetimes greater than 10 ns,6 GaAs single junction solar cells on Si with efficiencies greater than 18%,7 InGaAs CW laser diodes on Si,8 and room temperature GaInP red laser diodes on Si.9 Here we report on the first high performance dual junction GaInP/GaAs solar cells grown on Si using this promising SiGe engineered substrate approach.

Ringel, S. A.↗
NASA NTRS2009

Drifting Recovery Base Concept for GEO Derelict Object Capture

Over 250 objects hover within 6 m/sec of perfect geostationary orbit. Over half of these objects lie within 0.1 m/sec of the GEO velocity. Such items have 62% of the total velocity required to achieve Earth gravitational escape. A conceptual architecture is proposed to clean this orbit area of derelict objects while providing a demonstration mission for many facets of future asteroid mining operations. These near-GEO objects average nearly 2000kg each, consisting of (typically functioning) power systems, batteries, and large quantities of components and raw aerospace-grade refined materials. Such a demonstration collection system could capture, collect and remove all GEO derelict objects in an international effort to create a depot of components and of aerospace-grade raw materials--with a total mass greater than that of the International Space Station--as a space scrap depot ready for transfer to lunar or Mars orbit, using only two heavy-lift launches and 2-3 years of on-orbit operations.

Bacon, John B.↗
NASA NTRS2010

Lunar Reference Suite to Support Instrument Development and Testing

Astronauts on long-duration lunar missions will need the capability to "high-grade" their samples - to select the highest value samples for transport to Earth - and to leave others on the Moon. Instruments that may be useful for such high-grading are under development. Instruments are also being developed for possible use on future lunar robotic landers, for lunar field work, and for more sophisticated analyses at a lunar outpost. The Johnson Space Center Astromaterials acquisition and Curation Office (JSC Curation) wll support such instrument testing by providing lunar sample "ground truth".

Allen, Carlton↗
NASA NTRS2010

Meeting Radiation Protection Requirements and Reducing Spacecraft Mass - A Multifunctional Materials Approach

Both crew and radio-sensitive systems, especially electronics must be protected from the effects of the space radiation environment. One method of mitigating this radiation exposure is to use passive-shielding materials. In previous vehicle designs such as the International Space Station (ISS), materials such as aluminum and polyethylene have been used as parasitic shielding to protect crew and electronics from exposure, but these designs add mass and decrease the amount of usable volume inside the vehicle. Thus, it is of interest to understand whether structural materials can also be designed to provide the radiation shielding capability needed for crew and electronics, while still providing weight savings and increased useable volume when compared against previous vehicle shielding designs. In this paper, we present calculations and analysis using the HZETRN (deterministic) and FLUKA (Monte Carlo) codes to investigate the radiation mitigation properties of these structural shielding materials, which includes graded-Z and composite materials. This work is also a follow-on to an earlier paper, that compared computational results for three radiation transport codes, HZETRN, HETC, and FLUKA, using the Feb. 1956 solar particle event (SPE) spectrum. In the following analysis, we consider the October 1989 Ground Level Enhanced (GLE) SPE as the input source term based on the Band function fitting method. Using HZETRN and FLUKA, parametric absorbed doses at the center of a hemispherical structure on the lunar surface are calculated for various thicknesses of graded-Z layups and an all-aluminum structure. HZETRN and FLUKA calculations are compared and are in reasonable (18% to 27%) agreement. Both codes are in agreement with respect to the predicted shielding material performance trends. The results from both HZETRN and FLUKA are analyzed and the radiation protection properties and potential weight savings of various materials and materials lay-ups are compared.

Atwell, William↗
NASA NTRS2010

NASA Education Activities on the International Space Station: A National Laboratory for Inspiring, Engaging, Educating and Employing the Next Generation

The International Space Station (ISS) National Lab Education Project has been created as a part of the ISS National Lab effort mandated by the U.S. Congress The project seeks to expand ISS education of activities so that they reach a larger number of students with clear educational metrics of accomplishments. This paper provides an overview of several recent ISS educational payloads and activities. The expected outcomes of the project, consistent with those of the NASA Office of Education, are also described. NASA performs numerous education activities as part of its ISS program. These cover the gamut from formal to informal educational opportunities in grades Kindergarten to grade 12, Higher Education (undergraduate and graduate University) and informal educational venues (museums, science centers, exhibits). Projects within the portfolio consist of experiments performed onboard the ISS using onboard resources which require no upmass, payloads flown to ISS or integrated into ISS cargo vehicles, and ground based activities that follow or complement onboard activities. Examples include ground based control group experiments, flight or experiment following lesson plans, ground based activities involving direct interaction with ISS or ground based activities considering ISS resources in their solution set. These projects range from totally NASA funded to projects which partner with external entities. These external agencies can be: other federal, state or local government agencies, commercial entities, universities, professional organizations or non-profit organizations. This paper will describe the recent ISS education activities and discuss the approach, outcomes and metrics associated with the projects.

Severance, Mark T.↗
NASA NTRS2011

Virginia Demonstration Project Encouraging Middle School Students in Pursuing STEM Careers

Encouraging students at all grade levels to consider pursuing a career in Science, Technology, Engineering, and Mathematics (STEM) fields i s a national focus. In 2005, the Naval Surface Warfare Center, Dahlgren Division (NSWCDD), a Department of Defense laboratory located in Da hlgren, Virginia, began work on the Virginia Demonstration Project (VDP) with the goal of increasing more student interest in STEM educatio n and pursuing STEM careers. This goal continues as the program enters its sixth year. This project has been successful through the partici pation of NSWCDD's scientists and engineers who are trained as mentor s to work in local middle school classrooms throughout the school year, As an extension of the in-class activities, several STEM summer aca demies have been conducted at NSWCDD, These academies are supported by the Navy through the VDP and the STEM Learning Module Project. These projects are part of more extensive outreach efforts offered by the National Defense Education Program (NDEP), sponsored by the Director, Defense Research and Engineering. The focus of this paper is on the types of activities conducted at the summer academy, an overview of the academy planning process, and recommendations to help support a nati onal plan of integrating modeling and simulation-based engineering and science into all grade levels. based upon the lessons learned

Bachman, Jane T.↗
NASA NTRS2005

Generating Mosaics of Astronomical Images

"Montage" is the name of a service of the National Virtual Observatory (NVO), and of software being developed to implement the service via the World Wide Web. Montage generates science-grade custom mosaics of astronomical images on demand from input files that comply with the Flexible Image Transport System (FITS) standard and contain image data registered on projections that comply with the World Coordinate System (WCS) standards. "Science-grade" in this context signifies that terrestrial and instrumental features are removed from images in a way that can be described quantitatively. "Custom" refers to user-specified parameters of projection, coordinates, size, rotation, and spatial sampling. The greatest value of Montage is expected to lie in its ability to analyze images at multiple wavelengths, delivering them on a common projection, coordinate system, and spatial sampling, and thereby enabling further analysis as though they were part of a single, multi-wavelength image. Montage will be deployed as a computation-intensive service through existing astronomy portals and other Web sites. It will be integrated into the emerging NVO architecture and will be executed on the TeraGrid. The Montage software will also be portable and publicly available.

Bergou, Attila↗
NASA NTRS2010

Reliability of High-Voltage Tantalum Capacitors. Parts 3 and 4)

Weibull grading test is a powerful technique that allows selection and reliability rating of solid tantalum capacitors for military and space applications. However, inaccuracies in the existing method and non-adequate acceleration factors can result in significant, up to three orders of magnitude, errors in the calculated failure rate of capacitors. This paper analyzes deficiencies of the existing technique and recommends more accurate method of calculations. A physical model presenting failures of tantalum capacitors as time-dependent-dielectric-breakdown is used to determine voltage and temperature acceleration factors and select adequate Weibull grading test conditions. This model is verified by highly accelerated life testing (HALT) at different temperature and voltage conditions for three types of solid chip tantalum capacitors. It is shown that parameters of the model and acceleration factors can be calculated using a general log-linear relationship for the characteristic life with two stress levels.

Teverovsky, Alexander↗
NASA NTRS2011

Advanced Gear Alloys for Ultra High Strength Applications

Single tooth bending fatigue (STBF) test data of UHS Ferrium C61 and C64 alloys are presented in comparison with historical test data of conventional gear steels (9310 and Pyrowear 53) with comparable statistical analysis methods. Pitting and scoring tests of C61 and C64 are works in progress. Boeing statistical analysis of STBF test data for the four gear steels (C61, C64, 9310 and Pyrowear 53) indicates that the UHS grades exhibit increases in fatigue strength in the low cycle fatigue (LCF) regime. In the high cycle fatigue (HCF) regime, the UHS steels exhibit better mean fatigue strength endurance limit behavior (particularly as compared to Pyrowear 53). However, due to considerable scatter in the UHS test data, the anticipated overall benefits of the UHS grades in bending fatigue have not been fully demonstrated. Based on all the test data and on Boeing s analysis, C61 has been selected by Boeing as the gear steel for the final ERDS demonstrator test gearboxes. In terms of potential follow-up work, detailed physics-based, micromechanical analysis and modeling of the fatigue data would allow for a better understanding of the causes of the experimental scatter, and of the transition from high-stress LCF (surface-dominated) to low-stress HCF (subsurface-dominated) fatigue failure. Additional STBF test data and failure analysis work, particularly in the HCF regime and around the endurance limit stress, could allow for better statistical confidence and could reduce the observed effects of experimental test scatter. Finally, the need for further optimization of the residual compressive stress profiles of the UHS steels (resulting from carburization and peening) is noted, particularly for the case of the higher hardness C64 material.

Shen, Tony↗
NASA NTRS2012

Wireless Self-Acquistion of 12-Lead ECG via Android Smart Phone

Researchers at NASA s Johnson Space Center and at Orbital Research, Inc. (a NASA SBIR grant recipient) have recently developed a dry-electrode harness that allows for self-acquisition of resting 12-lead ECGs by minimally trained laypersons. When used in conjunction with commercial wireless (e.g., Bluetooth(TM) or 802.11-enabled) 12-lead ECG devices and custom smart phone-based software, the collected 12-lead ECG data can also immediately be forwarded from any geographic location within cellular range to the user s physician(s) of choice. The system can also be used to immediately forward to central receiving stations 12-lead ECG data collected during space flight or during activities in any remote terrestrial location supported by an internet or cellular phone infrastructure. The main novel aspects of the system are first, the dry-electrode 12-lead ECG harness itself, and second, an accompanying Android(TM) smart phone-based wireless 12-lead ECG capability. The ECG harness nominally employs dry electrodes manufactured by Orbital Research, Inc, recently cleared through the Food and Drug Administration (FDA). However, other dry electrodes that are not yet FDA cleared, for example those recently developed by Nanosonic, Inc as part of another NASA SBIR grant, can also be used. The various advantageous features of the harness include: 1) laypersons can be quickly instructed on its correct use, remotely if necessary; 2) all tangled "leadwire spaghetti" is eliminated, as is the common clinical problem of "leadwire reversal"; 3) all adhesives and disposables are also eliminated, the harness being fully reusable; if multiple individuals intend to use use the same harness, then standard antimicrobial wipes can be employed to sterilize the dry electrodes (and harness surface if needed) between users; 5) padded cushions at the lateral sides of the torso function to press the left arm (LA) and right arm (RA) dry electrodes mounted on the cushions against sideward or downward-rested arms of the subject; 6) sufficient distal placement of the arm electrodes achieves good electrode abutment to the arms without the need for adhesives, straps, bands, bracelets, or gloves; 7) padding over the sternum avoids "tenting" in the V1 through V3 (and, when present, the V3R) electrode positions; 8) easy-to-don, one-piece design with an adjustable, front-side single point of connection and an adjustable shoulder strap; and 9) Lund or "modified Lund" placement of the dry electrodes, the results of which more effectively reproduce results from "standard" 12-lead ECG placements than do results from Mason-Likar placements. The main limitation of the harness is that "one size does not fit all", meaning that an appropriately sized harness (small, medium, large, etc) must be chosen on the basis of an individual's size. To facilitate the use of the harness with inexpensive, commodity-grade cell phones and tablet devices, 12-lead ECG software is also being developed to accompany the harness for wireless use with Android. For this part of the project, NASA has teamed with TopCoder, Inc and the Harvard-affiliated NASA Tournament Lab in sponsoring java-based software programming contests through TopCoder. While ECG signals from the harness can already be wirelessly received and thoroughly processed (locally or remotely) by commercial-grade conventional (as well as advanced) 12-lead ECG software running on Microsoft Windows(TM), the Android-based software, once completed, will "cast a wider net" by allowing for a greater percentage of cell phone owners to participate in inexpensive, store-and-forward recordings of 12-lead ECGs worldwide, including for example Android cell phone users in many remote, third-world locations. At the time of writing, the Android 12-lead ECG software platform consists of a basic but expanding graphical user interface and accompanying software that: 1) wirelessly receives the 12-lead ECG data stream from a Bluetooth-based, FDA-cleared 12-leaCG device attached to the harness; 2) locally stores the same data in binary format to the SD card on the Android cell phone; and 3) makes the data stream in available in real time, for now to TopCoder's java programming contestants.

Schlegel, Todd T.↗
NASA NTRS2012

Materials for Heated Head Automated Thermoplastic Tape Placement

NASA Langley Research Center (LaRC) is currently pursuing multiple paths to develop out of autoclave (OOA) polymeric composite materials and processes. Polymeric composite materials development includes the synthesis of new and/or modified thermosetting and thermoplastic matrix resins designed for specific OOA processes. OOA processes currently under investigation include vacuum bag only (VBO) prepreg/composite fabrication, resin transfer molding (RTM), vacuum assisted resin transfer molding (VARTM) and heated head automated thermoplastic tape placement (HHATP). This paper will discuss the NASA Langley HHATP facility and capabilities and recent work on characterizing thermoplastic tape quality and requirements for quality part production. Samples of three distinct versions of APC-2 (AS4/PEEK) thermoplastic dry tape were obtained from two materials vendors, TENCATE, Inc. and CYTEC Engineered Materials** (standard grade and an experimental batch). Random specimens were taken from each of these samples and subjected to photo-microscopy and surface profilometry. The CYTEC standard grade of APC-2 tape had the most voids and splits and the highest surface roughness and/or waviness. Since the APC-2 tape is composed of a thermoplastic matrix, it offers the flexibility of reprocessing to improve quality, and thereby improve final quality of HHATP laminates. Discussions will also include potential research areas and future work that is required to advance the state of the art in the HHATP process for composite fabrication.

Jensen, Brian J.↗
NASA NTRS2012

Barrier infrared detector

A superlattice-based infrared absorber and the matching electron-blocking and hole-blocking unipolar barriers, absorbers and barriers with graded band gaps, high-performance infrared detectors, and methods of manufacturing such devices are provided herein. The infrared absorber material is made from a superlattice (periodic structure) where each period consists of two or more layers of InAs, InSb, InSbAs, or InGaAs. The layer widths and alloy compositions are chosen to yield the desired energy band gap, absorption strength, and strain balance for the particular application. Furthermore, the periodicity of the superlattice can be "chirped" (varied) to create a material with a graded or varying energy band gap. The superlattice based barrier infrared detectors described and demonstrated herein have spectral ranges covering the entire 3-5 micron atmospheric transmission window, excellent dark current characteristics operating at least 150K, high yield, and have the potential for high-operability, high-uniformity focal plane arrays.

Ting, David Z.↗
NASA NTRS2012

Space Operations Learning Center

The Space Operations Learning Center (SOLC) is a tool that provides an online learning environment where students can learn science, technology, engineering, and mathematics (STEM) through a series of training modules. SOLC is also an effective media for NASA to showcase its contributions to the general public. SOLC is a Web-based environment with a learning platform for students to understand STEM through interactive modules in various engineering topics. SOLC is unique in its approach to develop learning materials to teach schoolaged students the basic concepts of space operations. SOLC utilizes the latest Web and software technologies to present this educational content in a fun and engaging way for all grade levels. SOLC uses animations, streaming video, cartoon characters, audio narration, interactive games and more to deliver educational concepts. The Web portal organizes all of these training modules in an easily accessible way for visitors worldwide. SOLC provides multiple training modules on various topics. At the time of this reporting, seven modules have been developed: Space Communication, Flight Dynamics, Information Processing, Mission Operations, Kids Zone 1, Kids Zone 2, and Save The Forest. For the first four modules, each contains three components: Flight Training, Flight License, and Fly It! Kids Zone 1 and 2 include a number of educational videos and games designed specifically for grades K-6. Save The Forest is a space operations mission with four simulations and activities to complete, optimized for new touch screen technology. The Kids Zone 1 module has recently been ported to Facebook to attract wider audience.

Lui, Ben↗
NASA NTRS2012

Process Sensitivity, Performance, and Direct Verification Testing of Adhesive Locking Features

Phase I: The use of adhesive locking features or liquid locking compounds (LLCs) (e.g., Loctite) as a means of providing a secondary locking feature has been used on NASA programs since the Apollo program. In many cases Loctite was used as a last resort when (a) self-locking fasteners were no longer functioning per their respective drawing specification, (b) access was limited for removal & replacement, or (c) replacement could not be accomplished without severe impact to schedule. Long-term use of Loctite became inevitable in cases where removal and replacement of worn hardware was not cost effective and Loctite was assumed to be fully cured and working. The NASA Engineering & Safety Center (NESC) and United Space Alliance (USA) recognized the need for more extensive testing of Loctite grades to better understand their capabilities and limitations as a secondary locking feature. These tests, identified as Phase I, were designed to identify processing sensitivities, to determine proper cure time, the correct primer to use on aerospace nutplate, insert and bolt materials such as A286 and MP35N, and the minimum amount of Loctite that is required to achieve optimum breakaway torque values. The .1900-32 was the fastener size tested, due to wide usage in the aerospace industry. Three different grades of Loctite were tested. Results indicate that, with proper controls, adhesive locking features can be successfully used in the repair of locking features and should be considered for design. Phase II: Threaded fastening systems used in aerospace programs typically have a requirement for a redundant locking feature. The primary locking method is the fastener preload and the traditional redundant locking feature is a self-locking mechanical device that may include deformed threads, non-metallic inserts, split beam features, or other methods that impede movement between threaded members. The self-locking resistance of traditional locking features can be directly verified during assembly by measuring the dynamic prevailing torque. Adhesive locking features or LLCs are another method of providing redundant locking, but a direct verification method has not been used in aerospace applications to verify proper installation when using LLCs because of concern for damage to the adhesive bond. The reliability of LLCs has also been questioned due to failures observed during testing with coupons for process verification, although the coupon failures have often been attributed to a lack of proper procedures. It is highly desirable to have a direct method of verifying the LLC cure or bond integrity. The purpose of the Phase II test program was to determine if the torque applied during direct verification of an adhesive locking feature degrades that locking feature. This report documents the test program used to investigate the viability of such a direct verification method. Results of the Phase II testing were positive, and additional investigation of direct verification of adhesive locking features is merited.

Golden, Johnny L.↗