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At least 685 records · Page 38

Evolution and Control of 2219 Aluminum Microstructural Features Through Electron Beam Freeform Fabrication

The layer-additive nature of the electron beam freeform fabrication (EBF3) process results in a tortuous thermal path producing complex microstructures including: small homogeneous equiaxed grains; dendritic growth contained within larger grains; and/or pervasive dendritic formation in the interpass regions of the deposits. Several process control variables contribute to the formation of these different microstructures, including translation speed, wire feed rate, beam current and accelerating voltage. In electron beam processing, higher accelerating voltages embed the energy deeper below the surface of the substrate. Two EBF3 systems have been established at NASA Langley, one with a low-voltage (10-30kV) and the other a high-voltage (30-60 kV) electron beam gun. Aluminum alloy 2219 was processed over a range of different variables to explore the design space and correlate the resultant microstructures with the processing parameters. This report is specifically exploring the impact of accelerating voltage. Of particular interest is correlating energy to the resultant material characteristics to determine the potential of achieving microstructural control through precise management of the heat flux and cooling rates during deposition.

Taminger, Karen M.↗

Metallurgical Mechanisms Controlling Mechanical Properties of Aluminum Alloy 2219 Produced by Electron Beam Freeform Fabrication

The electron beam freeform fabrication (EBF3) layer-additive manufacturing process has been developed to directly fabricate complex geometry components. EBF3 introduces metal wire into a molten pool created on the surface of a substrate by a focused electron beam. Part geometry is achieved by translating the substrate with respect to the beam to build the part one layer at a time. Tensile properties demonstrated for electron beam deposited aluminum and titanium alloys are comparable to wrought products, although the microstructures of the deposits exhibit cast features. Understanding the metallurgical mechanisms controlling mechanical properties is essential to maximizing application of the EBF3 process. Tensile mechanical properties and microstructures were examined for aluminum alloy 2219 fabricated over a range of EBF3 process variables. Unique microstructures were observed within the deposited layers and at interlayer boundaries, which varied within the deposit height due to microstructural evolution associated with the complex thermal history experienced during subsequent layer deposition. Microstructures exhibited irregularly shaped grains with interior dendritic structures, described based on overall grain size, morphology, distribution, and dendrite spacing, and were correlated with deposition parameters. Fracture features were compared with microstructural elements to define fracture paths and aid in definition of basic processing-microstructure-property correlations.

Domack, Marcia S.↗

Liquid Crystal-based Beam Steering Technologies for NASA Applications

Liquid crystal-based beam steering devices can provide electronic beam scanning to angles above 1 milliradian, sub-microradian beam pointing accuracy, as well as wave-front correction to maintain output optical beam quality. The liquid crystal technology effort will be summarized, and the potential application of the resulting devices to NASA space-based scenarios will be described.

Pouch, John↗

Holographic memory using beam steering

A method, apparatus, and system provide the ability for storing holograms at high speed. A single laser diode emits a collimated laser beam to both write to and read from a photorefractice crystal. One or more liquid crystal beam steering spatial light modulators (BSSLMs) or Micro-Electro-Mechanical Systems (MEMS) mirrors steer a reference beam, split from the collimated laser beam, at high speed to the photorefractive crystal.

Chao, Tien-Hsin↗

Holographic memory using beam steering

A method, apparatus, and system provide the ability for storing holograms at high speed. A single laser diode emits a collimated laser beam to both write to and read from a photorefractice crystal. One or more liquid crystal beam steering spatial light modulators (BSSLMs) steer a reference beam, split from the collimated laser beam, at high speed to the photorefractive crystal.

Chao, Tien-Hsin↗

Electron Beam Freeform Fabrication in the Space Environment

This viewgraph presentation describes the effect of microgravity on the fabrication of electron beam freeform (EBF) in aerospace environments. The contents include: 1) Electron Beam Freeform Fabrication (EBF3) Process Description; 2) Portable Electron Beam Freeform Fabrication System at NASA LaRC; 3) Electron Beam Freeform Fabrication in the Space Environment; 4) Effect of Gravity on Surface Tension; 5) Effect of Deposit Height on Cooling Path; 6) Microgravity Testing Aboard JSC's C-9; 7) Typical Test Flight Plates; 8) Direction and Height Trials for Process Control; 9) Effect of Wire Entry Direction into Molten Pool; 10) Microstructure of Single Layer EBF Deposits; 11) 0-g Deposit with Incorrect Standoff Distance; 12) Successful Demonstration of EBF in 0-g; and 13) Conclusion.

Taminger, Karen M.↗

Metallurgical Mechanisms Controlling Mechanical Properties of Aluminum Alloy 2219 Produced By Electron Beam Freeform Fabrication

The electron beam freeform fabrication (EBF3) layer-additive manufacturing process has been developed to directly fabricate complex geometry components. EBF3 introduces metal wire into a molten pool created on the surface of a substrate by a focused electron beam. Part geometry is achieved by translating the substrate with respect to the beam to build the part one layer at a time. Tensile properties have been demonstrated for electron beam deposited aluminum and titanium alloys that are comparable to wrought products, although the microstructures of the deposits exhibit features more typical of cast material. Understanding the metallurgical mechanisms controlling mechanical properties is essential to maximizing application of the EBF3 process. In the current study, mechanical properties and resulting microstructures were examined for aluminum alloy 2219 fabricated over a range of EBF3 process variables. Material performance was evaluated based on tensile properties and results were compared with properties of Al 2219 wrought products. Unique microstructures were observed within the deposited layers and at interlayer boundaries, which varied within the deposit height due to microstructural evolution associated with the complex thermal history experienced during subsequent layer deposition. Microstructures exhibited irregularly shaped grains, typically with interior dendritic structures, which were described based on overall grain size, morphology, distribution, and dendrite spacing, and were correlated with deposition parameters. Fracture features were compared with microstructural elements to define fracture paths and aid in definition of basic processing-microstructure-property correlations.

Domack, Marcia S.↗

Development of a Silicon Carbide Molecular Beam Nozzle for Simulation Planetary Flybys and Low-Earth Orbit

From commercial origins as a molybdenum molecular beam nozzle, a ceramic nozzle of silicon carbide (SiC) was developed for space environment simulation. The nozzle is mechanically stable under extreme conditions of temperature and pressure. A heated, continuous, supersonically-expanded hydrogen beam with a 1% argon seed produced an argon beam component of nearly 4 km/s, with an argon flux exceeding 1x1014 /cm2.s. This nozzle was part of a molecular beam machine used in the Atmospheric Experiments Branch at NASA Goddard Space Flight Center to characterize the performance of the University of Texas at Dallas Ram Wind Sensor (RWS) aboard the Air Force Communications/Navigation Outage Forecasting System (C/NOFS) launched in the Spring of 2008.

Patrick, E. L.↗

Suppressing Ghost Diffraction in E-Beam-Written Gratings

A modified scheme for electron-beam (E-beam) writing used in the fabrication of convex or concave diffraction gratings makes it possible to suppress the ghost diffraction heretofore exhibited by such gratings. Ghost diffraction is a spurious component of diffraction caused by a spurious component of grating periodicity as described below. The ghost diffraction orders appear between the main diffraction orders and are typically more intense than is the diffuse scattering from the grating. At such high intensity, ghost diffraction is the dominant source of degradation of grating performance. The pattern of a convex or concave grating is established by electron-beam writing in a resist material coating a substrate that has the desired convex or concave shape. Unfortunately, as a result of the characteristics of electrostatic deflectors used to control the electron beam, it is possible to expose only a small field - typically between 0.5 and 1.0 mm wide - at a given fixed position of the electron gun relative to the substrate. To make a grating larger than the field size, it is necessary to move the substrate to make it possible to write fields centered at different positions, so that the larger area is synthesized by "stitching" the exposed fields.

Wilson, Daniel↗

Optical Beam-Shear Sensors

A technique for measuring optical beam shear is based on collecting light from the four quadrants of the beam and comparing the optical power collected from each quadrant with that from the other three quadrants. As used here, "shear" signifies lateral displacement of a beam of light from a nominal optical axis. A sensor for implementing this technique consists of a modified focusing lens and a quad-cell photodetector, both centered on the nominal optical axis. The modification of the lens consists in cutting the lens into four sectors (corresponding to the four quadrants) by sawing along two orthogonal diameters, then reassembling the lens following either of two approaches described next. In one approach, the lens is reassembled by gluing the sectors back together. In the simplest variant of this approach, the kerf of the saw matches the spacing of the photodetector cells, so that the focus of each sector crosses the axis of symmetry to fall on the opposite photodetector cell (see figure). In another variant of this approach, the lens sectors are spaced apart to make their individual foci to fall on separate photodetector cells, without crossing the optical axis. In the case of a sufficiently wide beam, the modified lens could be replaced with four independent lenses placed in a square array, each focusing onto an independent photodetector

Martin, Stefan↗

Digital Beam Deflectors Based Partly on Liquid Crystals

A digital beam deflector based partly on liquid crystals has been demonstrated as a prototype of a class of optical beam-steering devices that contain no mechanical actuators or solid moving parts. Such beam-steering devices could be useful in a variety of applications, including free-space optical communications, switching in fiber-optic communications, general optical switching, and optical scanning. Liquid crystals are of special interest as active materials in nonmechanical beam steerers and deflectors because of their structural flexibility, low operating voltages, and the relatively low costs of fabrication of devices that contain them.

Pouch, John J.↗

Resistively Heated SiC Nozzle for Generating Molecular Beams

An improved nozzle has been developed to replace nozzles used previously in an apparatus that generates a substantially unidirectional beam of molecules passing through a vacuum at speeds of several kilometers per second. The basic principle of operation of the apparatus is the same for both the previous and the present nozzle designs. The main working part of the nozzle is essentially a cylinder that is closed except that there is an inlet for a pressurized gas and, at one end, the cylinder is closed by a disk that contains a narrow central hole that serves as an outlet. The cylinder is heated to increase the thermal speeds of the gas molecules into the desired high-speed range. Heated, pressurized gas escapes through the outlet into a portion of the vacuum chamber that is separated, by a wall, from the rest of the vacuum chamber. In this portion of the vacuum chamber, the gas undergoes a free jet expansion. Most of the expanded gas is evacuated and thus does not become part of the molecular beam. A small fraction of the expanded beam passes through a narrow central orifice in the wall and thereby becomes a needle- thin molecular beam in the portion of the vacuum on the downstream side of the wall.

Cagiano, Steven↗

Proton Lateral Broadening Distribution Comparisons Between GRNTRN, MCNPX, and Laboratory Beam Measurements

Recent developments in NASA s deterministic High charge (Z) and Energy TRaNsport (HZETRN) code have included lateral broadening of primary ion beams due to small-angle multiple Coulomb scattering, and coupling of the ion-nuclear scattering interactions with energy loss and straggling. This new version of HZETRN is based on Green function methods, called GRNTRN, and is suitable for modeling transport with both space environment and laboratory boundary conditions. Multiple scattering processes are a necessary extension to GRNTRN in order to accurately model ion beam experiments, to simulate the physical and biological-effective radiation dose, and to develop new methods and strategies for light ion radiation therapy. In this paper we compare GRNTRN simulations of proton lateral broadening distributions with beam measurements taken at Loma Linda University Proton Therapy Facility. The simulated and measured lateral broadening distributions are compared for a 250 MeV proton beam on aluminum, polyethylene, polystyrene, bone substitute, iron, and lead target materials. The GRNTRN results are also compared to simulations from the Monte Carlo MCNPX code for the same projectile-target combinations described above.

Mertens, Christopher J.↗

Wind Tunnel Testing of a One-Dimensional Laser Beam Scanning and Laser Sheet Approach to Shock Sensing

A 15- by 15-cm supersonic wind tunnel application of a one-dimensional laser beam scanning approach to shock sensing is presented. The measurement system design allowed easy switching between a focused beam and a laser sheet mode for comparison purposes. The scanning results were compared to images from the tunnel Schlieren imaging system. The tests revealed detectable changes in the laser beam in the presence of shocks. The results lend support to the use of the one-dimensional scanning beam approach for detecting and locating shocks in a flow, but some issues must be addressed in regards to noise and other limitations of the system.

Tokars, Roger↗

Lidar Electro-Optic Beam Switch with a Liquid Crystal Variable Retarder

A document discusses a liquid crystal variable retarder, an electro-optic element that changes the polarization of an optical beam in response to a low-voltage electronic signal. This device can be fabricated so that the element creates, among other states, a half-wave of retardance that can be reduced to a very small retardance. When aligned to a polarized source, this can act to rotate the polarization by 90 in one state, but generate no rotation in the other state. If the beam is then incident on a polarization beam splitter, it will efficiently switch from one path to the other when the voltage is applied. The laser beam switching system has no moving parts, improving reliability over mechanical switching. It is low cost, tolerant of high laser power density, and needs only simple drive electronics, minimizing the required system resources.

Baer, James↗

SweepSAR: Beam-forming on Receive Using a Reflector-Phased Array Feed Combination for Spaceborne SAR

In this paper, an alternative approach is described that is suited for longer wavelength SARs in particular, employing a large, deployable reflector antenna and a much simpler phased array feed. To illuminate a wide swath, a substantial fraction of the phased array feed is excited on transmit to sub-illuminate the reflector. Shorter transmit pulses are required than for conventional SAR. On receive, a much smaller portion of the phased array feed is used to collect the return echo, so that a greater portion of the reflector antenna area is used. The locus of the portion of the phased array used on receive is adjusted using an analog beam steering network, to 'sweep' the receive beam(s) across the illuminated swath, tracking the return echo. This is similar in some respects to the whiskbroom approach to optical sensors, hence the name: SweepSAR.SweepSAR has advantages over conventional SAR in that it requires less transmit power, and if the receive beam is narrow enough, it is relatively immune to range ambiguities. Compared to direct radiating arrays with digital beam- forming, it is much simpler to implement, uses currently available technologies, is better suited for longer wavelength systems, and does not require extremely high data rates or onboard processing.

synthetic aperture radars (SARs)↗

Ultra-Wideband, Dual-Polarized, Beam-Steering P-Band Array Antenna

A dual-polarized, wide-bandwidth (200 MHz for one polarization, 100 MHz for the orthogonal polarization) antenna array at P-band was designed to be driven by NASA's EcoSAR digital beam former. EcoSAR requires two wide P-band antenna arrays mounted on the wings of an aircraft, each capable of steering its main beam up to 35deg off-boresight, allowing the twin radar beams to be steered at angles to the flight path. The science requirements are mainly for dual-polarization capability and a wide bandwidth of operation of up to 200 MHz if possible, but at least 100 MHz with high polarization port isolation and low cross-polarization. The novel design geometry can be scaled with minor modifications up to about four times higher or down to about half the current design frequencies for any application requiring a dual-polarized, wide-bandwidth steerable antenna array. EcoSAR is an airborne interferometric P-band synthetic aperture radar (SAR) research application for studying two- and three-dimensional fine-scale measurements of terrestrial ecosystem structure and biomass, which will ultimately aid in the broader study of the carbon cycle and climate change. The two 2×8 element Pband antenna arrays required by the system will be separated by a baseline of about 25 m, allowing for interferometry measurements. The wide 100-to- 200-MHz bandwidth dual-polarized beams employed will allow the determination of the amount of biomass and even tree height on the ground. To reduce the size of the patches along the boresight dimension in order to fit them into the available space, two techniques were employed. One technique is to add slots along the edges of each patch where the main electric currents are expected to flow, and the other technique is to bend the central part of the patch away from the ground plane. The latter also facilitates higher mechanical rigidity. The high port isolation of more than 40 dB was achieved by employing a highly symmetrical feed mechanism for each pair of elements: three apertures coupling to the patch elements were placed along the two symmetry lines of the antenna element pair. Two apertures were used in tandem to excite two of the stacked patch elements for one polarization; the other was used to excite one element from one side and the other element from the other side, opposite in phase, taking care of the remaining polarization. The apertures narrow down to a small gap where they are excited by a crossing microstrip line to prevent any asymmetrical excitation of the two sides of the aperture gap, minimizing port-to-port coupling. Using patches that are non-planar leads to higher mechanical rigidity and smaller patch sizes to fit into the available space. Aperture coupling minimizes direct metal-to-metal connections. Using an aperture coupling feed mechanism results in a feed network for two antenna elements with a total of three feed points, plus one simple in-phase combiner to reduce it to two ports. It greatly reduces the complexity of the alternative, but more conventional, way of feeding a pair of two dual-polarized elements with high port isolation.

duToit, Cornelis↗

The Atacama Cosmology Telescope: Beam Measurements and the Microwave Brightness Temperatures of Uranus and Saturn

We describe the measurement of the beam profiles and window functions for the Atacama Cosmology Telescope (ACT), which operated from 2007 to 2010 with kilopixel bolometer arrays centered at 148, 218, and 277 GHz. Maps of Saturn are used to measure the beam shape in each array and for each season of observations. Radial profiles are transformed to Fourier space in a way that preserves the spatial correlations in the beam uncertainty to derive window functions relevant for angular power spectrum analysis. Several corrections are applied to the resulting beam transforms, including an empirical correction measured from the final cosmic microwave background (CMB) survey maps to account for the effects of mild pointing variation and alignment errors. Observations of Uranus made regularly throughout each observing season are used to measure the effects of atmospheric opacity and to monitor deviations in telescope focus over the season. Using the WMAP-based calibration of the ACT maps to the CMB blackbody, we obtain precise measurements of the brightness temperatures of the Uranus and Saturn disks at effective frequencies of 149 and 219 GHz. For Uranus we obtain thermodynamic brightness temperatures T(149/U) = 106.7 +/- 2.2 K and T(219/U) = 100.1 +/- 3.1 K. For Saturn, we model the effects of the ring opacity and emission using a simple model and obtain resulting (unobscured) disk temperatures of T(149/S) = 137.3 +/- 3.2 K and T(219/S) = 137.3 +/- 4.7 K.

Atacama Cosmology Telescope (ACT)↗