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At least 631 records · Page 35
All sourcesNASA NTRSDOE OSTI
NASA NTRS1943

A theoretical investigation of the lateral oscillations of an airplane with free rudder with special reference to the effect of friction

Charts showing the variation in dynamic stability with the rudder hinge-moment characteristics are presented. A stabilizing rudder floating tendency combined with a high degree of aerodynamic balance is shown to lead to oscillations of increasing amplitude. This dynamic instability is increased by viscous-friction in the rudder control system. The presence of solid friction in the rudder control system will cause steady oscillations of constant amplitude if the floating angle of the rudder per unit angle of sideslip is stabilizing and greater than a certain critical value that depends on other airplane parameters, such as vertical-tail area and airplane moment of inertia about the vertical axis. The amplitude of the steady oscillation is proportional to the amount of friction and is generally quite small but increases as the condition of dynamic instability is approached. An approximate method of calculating the amplitudes of the steady oscillation is explained and is illustrated by a numerical example. A more accurate step-by-step calculation of the motion is also made and it is shown that the agreement with the approximate method is good.

Greenberg, Harry↗
NASA NTRS2008

Enabling and Enhancing Space Mission Success and Reduction of Risk through the Application of an Integrated Data Architecture

The engineering phases of design, development, test, and evaluation (DDT and E) and subsequent planning, preparation, and operation (Ops) of space vehicles in a complex and distributed environment requires massive and continuous flows of information across the enterprise and across temporal stages of the vehicle lifecycle. The resulting capabilities at each subsequent stage depend in part on the capture, preparation, storage, and subsequent provision of information from prior stages. The United States National Aeronautics and Space Administration (NASA) is currently designing a fleet of new vehicles that will replace the Space Shuttle and expand space operations and exploration capabilities. This includes the 2 stage human rated lift vehicle Ares 1 and its associated crew vehicle the Orion, and a service module; the heavy lift cargo vehicle, Ares 5, and an associated cargo stage known as the Earth Departure Stage; and a Lunar Lander vehicle that contains a descent stage, and ascent stage, and a habitation module. A variety of concurrent assorted ground operations infrastructure including software and facilities are also being developed, assorted technology and assembly designs and development for equipment such as EVA suits, life support systems, command and control technologies are also in the pipeline. The development is occurring in a distributed manner, with project deliverables being contributed by a large and diverse assortment of vendors and most space faring nations. Critical information about all of the components, software, and procedures must be shared during the DDT and E phases and then made readily available to the mission operations staff for access during the planning, preparation, and operations phases, and also need to be readily available for system to system interactions. The Constellation Data Systems Project (CxDS) is identifying the needs, and designing and deploying systems and processes to support these needs. This paper details the steps and processes that NASA is applying within the Constellation Program to manage this data and information, and to insure that the correct information is available, correctly annotated, and can be provisioned digitally to enhance response times, and support engineering analysis and anomaly resolution.

Brummett, Robert C.↗
NASA NTRSDate not supplied

A Comparison of Stratospheric Smoke Events Seen by SAGE II (1984-2005) and SAGE III (2017-2021)

The ongoing Stratospheric Aerosol and Gas Experiment aboard the International Space Station (SAGE III/ISS) has mostly occurred during a period of relatively low aerosol loading. At the same time, it has almost observed a number of small to moderate injections of volcanic material in the stratosphere from the Aoba/Ambae eruption of 2018 to that of Karymsky in 2022. In addition, two of the largest known smoke intrusions into the stratosphere have occurred during the SAGE III/ISS mission (the British Columbia fire of August 2017 and the Australian Wildfire Event of 2019/2020). At least two other much smaller smoke events have also been observed in the SAGE III data (California Creek in September 2020 and McKay Creek in June 2021). Particularly with the two large events, it is tempting to speculate that these events are increasing in intensity and frequency possibly due to ongoing climate change. Realistically, change is difficult to assess since instrument data sets that can be used for quantifying historical events can be quite different in what and where they provide measurements. This complicates comparing one event to another potentially separated by many years. An exception to this issues are the measurements by SAGE III/ISS and those of its predecessor SAGE II (1984-2005). Both use the same measurement strategy, measure aerosol extinction coefficient at 1020 nm, and have similar spatial/temporal coverage. Both instruments are known to observe smoke events in the stratosphere. However, both have the same low observation density characteristic of solar occultation such that near-global coverage takes almost a month and characterizing effectively instant events like smoke and volcanic events take a matter of weeks depending on the vagaries of where the observations are being made at a critical juncture unlike instruments with high temporal/spatial resolution like limb-scatter instruments such as OMPS and OSIRIS. The goal of this work will be to use the same analysis approach to both the SAGE II and SAGE III data and compare both the frequency and intensity of smoke events observed by these instruments. While we do not expect to be able to make conclusions about change between the periods, the analysis is a first step in interpreting changes in the contribution of smoke to the stratospheric aerosol budget between the time frames encompassed by these instruments.

L. W. Thomason↗
NASA NTRS1988

A self-adaptive computational method for transonic turbulent flow past a real projectile

An attempt to develop an effective solution-adaptive computational method for complex unsteady flow problems is reported. The adaptive grid generation technique is critically examined to understand its application to self-adaptive computational procedures. A complex flow problem involving an impulsive Mach 0.96 transonic turbulent flow past a real secant-ogive-cylinder-boattail projectile, including the base flow region at zero angle of attack, is considered. The coupling of the grid generation code to the unsteady Navier-Stokes code makes it possible to generate a new grid network adaptive to the computed solution at every time step.

Hsu, C.-C.↗
NASA NTRS2001

Microshutter Arrays for the NGST NIRSpec

We are developing a programmable multiobject field selector for the NGST NIRSpec. This device is a microshutter array, a close-packed 2000 x 2000 array of 100 micrometer x 100 micrometer shutters fabricated with Micro-ElectroMechanical Systems (MEMS) technologies. The shutters are opened using a magnet scanned over the array. The shutters are held open by electrostatic potentials on adjacent vertical electrodes. Modeling of the magnetic actuation of the microshutters allowed optimization of the magnetic field configuration, the distance between magnet and shutters, and the force and torque produced by the magnet. The results of laboratory tests are consistent with our modeling. We have demonstrated actuation, latching and addressing. We are able to rotate shutters out of the plane up to 90 degree and more, to latch them electrostatically to the walls and release them selectively. During the last six month all critical elements of the array have been demonstrated. Fabrication processes were developed to deposit vertical electrodes on support grid side walls and insulated light-shields that block the gaps between shutters and the support grid. Physical optics analysis was performed to assess the expected optical performance of the microshutters. A preliminary Fourier optics analysis on the microshutter array performance has been carried out. More detailed analysis of wave propagation through 3D structures is a next step. An optical test station for verifying optical parameters of the shutter array at room temperature has been developed. It allows to measure parameters, such as transmission, scattering, contrast ratio, and diffraction of the array structure. Initial data have been acquired and are being analyzed and compared to theoretical predictions.

Moseley, Harvey↗
NASA NTRS2009

Deriving Safety Cases from Automatically Constructed Proofs

Formal proofs provide detailed justification for the validity of claims and are widely used in formal software development methods. However, they are often complex and difficult to understand, because the formalism in which they are constructed and encoded is usually machine-oriented, and they may also be based on assumptions that are not justified. This causes concerns about the trustworthiness of using formal proofs as arguments in safety-critical applications. Here, we present an approach to develop safety cases that correspond to formal proofs found by automated theorem provers and reveal the underlying argumentation structure and top-level assumptions. We concentrate on natural deduction style proofs, which are closer to human reasoning than resolution proofs, and show how to construct the safety cases by covering the natural deduction proof tree with corresponding safety case fragments. We also abstract away logical book-keeping steps, which reduces the size of the constructed safety cases. We show how the approach can be applied to the proofs found by the Muscadet prover.

Basir, Nurlida↗
NASA NTRS2018

Area Coverage Planning with 3-axis Steerable, 2D Framing Sensors

Existing algorithms for Agile Earth Observing Satellites((Lemaitre et al. 2002)) were largely created for 1D line sensors that acquire images in linear swaths. However, imaging satellites increasingly use 2D framing sensors (cameras) that capture discrete rectangular images. We describe tiling step-stare approaches that are more suited to rectangular image footprints than are 1D swath-based algorithms. Optimal area planning for these 2D framing instruments is an NPcomplete problem and intractable for large areas, so we present four approximation algorithms. Strategies are compared against a prior 2D framing instrument algorithm (Knight 2014) in three computational experiments. The impact of observer agility on schedule makespan is examined. Makespans vary more as observer agility decreases toward a critical point, then vary less after the critical point, suggesting a possible problem phase transition.

Chien, Steve↗
NASA NTRSDate not supplied

Uncertainty Quantification of CFD Model Assumptions Against Sonic Boom Noise Prediction of a Commercial Supersonic Transport

This paper presents the results of uncertainty modeling of sonic boom noise generation from commercial supersonic transport considering the Spalart-Allmaras (SA) turbulence modeling parameters as well as Mach number, angle of attack and altitude. Sample generation and analysis for this uncertainty model was performed by UQPCE, which is a software package developed at the NASA Langley Research Center. To build the uncertainty model, 42 cases of sonic boom noise calculation were performed. Computation of the ground noise can be briefly summarized in two steps. First, the near field pressure waveforms are sampled from CFD calculation using the NASA Langley’s FUN3D solver. Second, this information is passed to an atmospheric propagation code, sBOOM, which solves an augmented Burger’s equation and simulates how the near field waveforms will change while passing through the atmosphere. The ground signature is further processed to obtain the perceived loudness, PLdB. Having a high spatial resolution near the shockwave in the CFD calculation is critical in sonic boom noise prediction. Because the variation in the input parameters for the current uncertainty quantification (UQ) study is likely to lead to change in shock location, angle and strength, the grid adaptation for shock capturing is independently applied for each condition. The final mesh used in the CFD calculation consists of approximately 420 million cells. The pressure signatures are sampled at three, four and five body lengths away from the aircraft to make sure the three dimensional effects around the aircraft are resolved. The results of the UQ analysis shows that within the three aleatory variables, the angle of attack had the most impact against ground noise, followed by the altitude and the Mach number. Between the two SA model parameters, the Kármán constant (𝜅) was significantly more important than the turbulent Prandtl number (𝜎), but these two parameters were only marginally significant in the overall prediction variance in ground noise. The UQ procedure explained in this paper can be widely applied to other model parameters.

Uncertainty Quantification↗
NASA NTRSDate not supplied

Quantifying the Sensitivity of Condition Incidence Parameters in the Evidence Library

One approach to quantifying spaceflight risk at NASA makes use event driven probabilistic techniques. The Medical Extensible Dynamic Probabilistic Risk Assessment Tool (MEDPRAT) is such a tool that estimates medical risk metrics via simulation and enables optimization of medical resources subject to mission constraints [1]. Previous analyses have informed medical set composition, exercise countermeasures, and water intake, where each analysis quantifies the risk associated with proposed variations in system design. As future mission profiles extend beyond Low-Earth Orbit (LEO) and lengthen in duration, understanding these risks and contributing factors is critical. MEDPRAT employs Monte Carlo sampling techniques to simulate missions and track the occurrence of medical events. These events follow fault-tree-like progressions through levels of severity and mitigation via medical treatment to many possible outcomes and these are reported throughout the mission. Making this possible, are the medical databases that contain evidence gathered by the Human Research Program (HRP). Quantifying the impact of uncertainty or variability in the input data is an important step in evaluating the credibility of modeling and simulation results. In this work, we investigate the sensitivity of medical risk metrics with respect to the condition incidence parameters within the Evidence Library (EL) [2] as the medical database input for MEDPRAT. The medical conditions, contained in the EL, are equipped with incidence rates that describe the likelihood that the condition will occur. These incidence rates reflect historical spaceflight data or when appropriate, terrestrial data. In this presentation, we will explore how uncertainty in these rates propagate to the medical risk described by MEDPRAT. These results identify the conditions and parameters with the largest contribution to medical risks.

Ian Lim↗
NASA NTRS1951

A theoretical analysis of the effect of time lag in an automatic stabilization system on the lateral oscillatory stability of an airplane

A method is presented for determining the effect of time lag in an automatic stabilization system on the lateral oscillatory stability of an airplane. The method is based on an analytical-graphical procedure. The critical time lag of the airplane-autopilot system is readily determined from the frequency-response analysis. The method is applied to a typical present-day airplane equipped with an automatic pilot sensitive to yawing acceleration and geared to the rudder so that rudder control is applied in proportion to the yawing acceleration. The results calculated for this airplane-autopilot system by this method are compared with the airplane motions calculated by a step-by-step procedure.

Sternfield, Leonard↗
NASA NTRS1996

Surface and Atmospheric Parameter Retrieval From AVIRIS Data: The Importance of Non-Linear Effects

AVIRIS data represent a new and important approach for the retrieval of atmospheric and surface parameters from optical remote sensing data. Not only as a test for future space systems, but also as an operational airborne remote sensing system, the development of algorithms to retrieve information from AVIRIS data is an important step to these new approaches and capabilities. Many things have been learned since AVIRIS became operational, and the successive technical improvements in the hardware and the more sophisticated calibration techniques employed have increased the quality of the data to the point of almost meeting optimum user requirements. However, the potential capabilities of imaging spectrometry over the standard multispectral techniques have still not been fully demonstrated. Reasons for this are the technical difficulties in handling the data, the critical aspect of calibration for advanced retrieval methods, and the lack of proper models with which to invert the measured AVIRIS radiances in all the spectral channels. To achieve the potential of imaging spectrometry, these issues must be addressed. In this paper, an algorithm to retrieve information about both atmospheric and surface parameters from AVIRIS data, by using model inversion techniques, is described. Emphasis is put on the derivation of the model itself as well as proper inversion techniques, robust to noise in the data and an inadequate ability of the model to describe natural variability in the data. The problem of non-linear effects is addressed, as it has been demonstrated to be a major source of error in the numerical values retrieved by more simple, linear-based approaches. Non-linear effects are especially critical for the retrieval of surface parameters where both scattering and absorption effects are coupled, as well as in the cases of significant multiple-scattering contributions. However, sophisticated modeling approaches can handle such non-linear effects, which are especially important over vegetated surfaces. All the data used in this study were acquired during the 1991 Multisensor Airborne Campaign (MAC-Europe), as part of the European Field Experiment on a Desertification-threatened Area (EFEDA), carried out in Spain in June-July 1991.

Green Robert O.↗
NASA NTRS2000

COTS-Based Fault Tolerance in Deep Space: Qualitative and Quantitative Analyses of a Bus Network Architecture

Using COTS products, standards and intellectual properties (IPs) for all the system and component interfaces is a crucial step toward significant reduction of both system cost and development cost as the COTS interfaces enable other COTS products and IPs to be readily accommodated by the target system architecture. With respect to the long-term survivable systems for deep-space missions, the major challenge for us is, under stringent power and mass constraints, to achieve ultra-high reliability of the system comprising COTS products and standards that are not developed for mission-critical applications. The spirit of our solution is to exploit the pertinent standard features of a COTS product to circumvent its shortcomings, though these standard features may not be originally designed for highly reliable systems. In this paper, we discuss our experiences and findings on the design of an IEEE 1394 compliant fault-tolerant COTS-based bus architecture. We first derive and qualitatively analyze a -'stacktree topology" that not only complies with IEEE 1394 but also enables the implementation of a fault-tolerant bus architecture without node redundancy. We then present a quantitative evaluation that demonstrates significant reliability improvement from the COTS-based fault tolerance.

Tai, Ann T.↗
NASA NTRS2004

Developing Advanced Support Technologies for Planetary Exploration Missions

The United States Vision for Space Exploration calls for sending robots and humans to explore the Earth s moon, the planet Mars, and beyond. The National Aeronautics and Space Administration (NASA) is developing a set of design reference missions that will provide further detail to these plans. Lunar missions are expected to provide a stepping stone, through operational research and evaluation, in developing the knowledge base necessary to send crews on long duration missions to Mars and other distant destinations. The NASA Exploration Systems Directorate (ExSD), in its program of bioastronautics research, manages the development of technologies that maintain human life, health, and performance in space. Using a systems engineering process and risk management methods, ExSD s Human Support Systems (HSS) Program selects and performs research and technology development in several critical areas and transfers the results of its efforts to NASA exploration mission/systems development programs in the form of developed technologies and new knowledge about the capabilities and constraints of systems required to support human existence beyond Low Earth Orbit. HSS efforts include the areas of advanced environmental monitoring and control, extravehicular activity, food technologies, life support systems, space human factors engineering, and systems integration of all these elements. The HSS Program provides a structured set of deliverable products to meet the needs of exploration programs. these products reduce the gaps that exist in our knowledge of and capabilities for human support for long duration, remote space missions. They also reduce the performance gap between the efficiency of current space systems and the greater efficiency that must be achieved to make human planetary exploration missions economically and logistically feasible. In conducting this research and technology development program, it is necessary for HSS technologists and program managers to develop a common currency for decision making and the allocation of funding. A high level assessment is made of both the knowledge gaps and the system performance gaps across the program s technical project portfolio. This allows decision making that assures proper emphasis areas and provides a key measure of annual technological progress, as exploration mission plans continue to mature.

Berdich, Debra P.↗
NASA NTRS2004

Developing Advanced Human Support Technologies for Planetary Exploration Missions

The United States Vision for Space Exploration calls for sending robots and humans to explore the Earth's moon, the planet Mars, and beyond. The National Aeronautics and Space Administration (NASA) is developing a set of design reference missions that will provide further detail to these plans. Lunar missions are expected to provide a stepping stone, through operational research and evaluation, in developing the knowledge base necessary to send crews on long duration missions to Mars and other distant destinations. The NASA Exploration Systems Directorate (ExSD), in its program of bioastronautics research, manages the development of technologies that maintain human life, health, and performance in space. Using a system engineering process and risk management methods, ExSD's Human Support Systems (HSS) Program selects and performs research and technology development in several critical areas and transfers the results of its efforts to NASA exploration mission/systems development programs in the form of developed technologies and new knowledge about the capabilities and constraints of systems required to support human existence beyond Low Earth Orbit. HSS efforts include the areas of advanced environmental monitoring and control, extravehicular activity, food technologies, life support systems, space human factors engineering, and systems integration of all these elements. The HSS Program provides a structured set of deliverable products to meet the needs of exploration programs. These products reduce the gaps that exist in our knowledge of and capabilities for human support for long duration, remote space missions. They also reduce the performance gap between the efficiency of current space systems and the greater efficiency that must be achieved to make human planetary exploration missions economically and logistically feasible. In conducting this research and technology development program, it is necessary for HSS technologists and program managers to develop a common currency for decision making and the allocation of funding. A high level assessment is made of both the knowledge gaps and the system performance gaps across the program s technical project portfolio. This allows decision making that assures proper emphasis areas and provides a key measure of annual technological progress, as exploration mission plans continue to mature.

Berdich, Debra P.↗
NASA NTRS2010

Physical and Electrical Characterization of Aluminum Polymer Capacitors

Conductive polymer aluminum capacitor (PA capacitor) is an evolution of traditional wet electrolyte aluminum capacitors by replacing liquid electrolyte with a solid, highly conductive polymer. On the other hand, the cathode construction in polymer aluminum capacitors with coating of carbon and silver epoxy for terminal connection is more like a combination of the technique that solid tantalum capacitor utilizes. This evolution and combination result in the development of several competing capacitor construction technologies in manufacturing polymer aluminum capacitors. The driving force of this research on characterization of polymer aluminum capacitors is the rapid progress in IC technology. With the microprocessor speeds exceeding a gigahertz and CPU current demands of 80 amps and more, the demand for capacitors with higher peak current and faster repetition rates bring conducting polymer capacitors to the center o( focus. This is because this type of capacitors has been known for its ultra-low ESR and high capacitance. Polymer aluminum capacitors from several manufacturers with various combinations of capacitance, rated voltage, and ESR values were obtained and tested. The construction analysis of the capacitors revealed three different constructions: conventional rolled foil, the multilayer stacking V-shape, and a dual-layer sandwich structure. The capacitor structure and its impact on the electrical characteristics has been revealed and evaluated. A destructive test with massive current over stress to fail the polymer aluminum capacitors reveals that all polymer aluminum capacitors failed in a benign mode without ignition, combustion, or any other catastrophic failures. The extraordinary low ESR (as low as 3 mOMEGA), superior frequency independence reported for polymer aluminum capacitors have been confirmed. For the applications of polymer aluminum capacitors in space programs, a thermal vacuum cycle test was performed. The results, as expected, show no impact on the electrical characteristics of the capacitors. The breakdown voltage of polymer capacitors has been evaluated using a steady step surge test. Initial results show the uniform distribution in the breakdown voltage for polymer aluminum capacitors. Polymer aluminum capacitors with a combination of very high capacitance, extraordinary low ESR, excellent frequency stability, and non-ignite benign failure mode make it a niche fit in space applications for both today and future. Polymer capacitors are apparently also the best substitutes of the currently used MnO2-based tantalum capacitors in the low voltage range. However, some critical aspects are still to be addressed in the next phase of the investigation for PA capacitors. These include the long term reliability test of 125 C dry life and 85 C/85%RH humidity, the failure mechanism and de-rating, the radiation tolerance, and the high temperature performance. All of the above requires the continuous NEPP funding and support.

Liu, David (Donghang)↗
NASA NTRSDate not supplied

Uncertainty Quantification of CFD Model Assumptions Against Sonic Boom Noise Prediction of a Commercial Supersonic Transport

This paper presents the results of uncertainty modeling of sonic boom noise generation from commercial supersonic transport considering the Spalart-Allmaras (SA) turbulence modeling parameters as well as Mach number, angle of attack and altitude. Sample generation and analysis for this uncertainty model was performed by UQPCE, which is a software package developed at the NASA Langley Research Center. To build the uncertainty model, 42 cases of sonic boom noise calculation were performed. Computation of the ground noise can be briefly summarized in two steps. First, the near field pressure waveforms are sampled from CFD calculation using the NASA Langley’s FUN3D solver. Second, this information is passed to an atmospheric propagation code, sBOOM, which solves an augmented Burger’s equation and simulates how the near field waveforms will change while passing through the atmosphere. The ground signature is further processed to obtain the perceived loudness, PLdB. Having a high spatial resolution near the shock wave in the CFD calculation is critical in sonic boom noise prediction. Because the variation in the input parameters for the current uncertainty quantification (UQ) study is likely to lead to change in shock location, angle and strength, the grid adaptation for shock capturing is independently applied for each condition. The final mesh used in the CFD calculation consists of approximately 420 million cells. The pressure signatures are sampled at three, four and five body lengths away from the aircraft to make sure the three dimensional effects around the aircraft are resolved. The results of the UQ analysis shows that within the three aleatory variables, the angle of attack had the most impact against ground noise, followed by the altitude and the Mach number. Between the two SA model parameters, the Kármán constant (𝜅) was significantly more important than the turbulent Prandtl number (𝜎), but these two parameters were only marginally significant in the overall prediction variance in ground noise. The UQ procedure explained in this paper can be widely applied to other model parameters.

Uncertainty Quantifications↗
NASA NTRS2011

Conical Probe Calibration and Wind Tunnel Data Analysis of the Channeled Centerbody Inlet Experiment

For a multi-hole test probe undergoing wind tunnel tests, the resulting data needs to be analyzed for any significant trends. These trends include relating the pressure distributions, the geometric orientation, and the local velocity vector to one another. However, experimental runs always involve some sort of error. As a result, a calibration procedure is required to compensate for this error. For this case, it is the misalignment bias angles resulting from the distortion associated with the angularity of the test probe or the local velocity vector. Through a series of calibration steps presented here, the angular biases are determined and removed from the data sets. By removing the misalignment, smoother pressure distributions contribute to more accurate experimental results, which in turn could be then compared to theoretical and actual in-flight results to derive any similarities. Error analyses will also be performed to verify the accuracy of the calibration error reduction. The resulting calibrated data will be implemented into an in-flight RTF script that will output critical flight parameters during future CCIE experimental test runs. All of these tasks are associated with and in contribution to NASA Dryden Flight Research Center s F-15B Research Testbed s Small Business Innovation Research of the Channeled Centerbody Inlet Experiment.

Truong, Samson Siu↗
NASA NTRS2019

Improved Processing Techniques for Inclusion-Free Steel for Bearing and Mechanical Component Applications

High hardness, high carbide powder metallurgy tools steels such as M62 enable the operation of ball bearings at extremely high load and stress levels. Operation under such conditions increases the potential for rolling contact fatigue failure attributed to ceramic particle inclusions. To address this challenge, industry has sought steel made from ever increasing levels of cleanliness but the results have been uneven owing to the random nature of the occurrence of material flaws. One common approach is to rely upon careful ingot inspections prior to bearing manufacture. By selecting the cleanest portion of an ingot, it is expected that bearings relatively free from material flaws will result. This approach is not always successful because detrimental flaws that exist deep within an ingot can pass inspection undetected potentially causing subsequent failure. Recent efforts to commercialize an intermetallic material, 60NiTi, for rolling element bearings demonstrates a pathway to produce bearing steel that is free from unwanted ceramic particle inclusions. In this paper, the process used to make bearing grade ceramic-free NiTi alloys is described and applied to steelmaking. At its core, the NiTi process differs from steel making in one key aspect. NiTi alloys are made from elementally pure starting materials that are melted, blended and processed in equipment absolutely free from exposure to oxygen and ceramics ensuring a ceramic particle-free product. In contrast, the predominant method to make bearing steel is to employ a successive series of purification steps to reduce contamination levels below required thresholds. This paper describes the processes developed and applied to high carbide tool steel, M62. The resulting material and microstructures are evaluated and compared to M62 prepared by conventional powder metallurgy techniques. It is hoped that the application of materials manufacturing techniques used for fracture sensitive ceramics and intermetallic materials like NiTi can provide a pathway to Ultra-Clean, Ceramic-Inclusion free steels for rolling element bearings and other failure critical applications.

Steel↗