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Douglas Juanarena, a former NASA Langley instrument design engineer, found a solution to the problem of long, repetitive tunnel runs needed to measure airflow pressures. Electronically scanned pressure (ESP) replaced mechanical systems with electronic sensors. Juanarena licensed the NASA-patented technology and now manufactures ESP modules for research centers, aerospace companies, etc.
New facilities and test techniques afford research aerodynamicists many opportunities to investigate complex aerodynamic phenomena. For example, NASA Langley Research Center's National Transonic Facility (NTF) can hold Mach number, Reynolds number, dynamic pressure, stagnation temperature and stagnation pressure constant during testing. This is important because the wing twist associated with model construction may mask important Reynolds number effects associated with the flight vehicle. Beyond this, the NTF's ability to vary Reynolds number allows for important research into the study of boundary layer transition. The capabilities of facilities such as the NTF coupled with test techniques such as temperature sensitive paint yield data that can be applied not only to vehicle design but also to validation of computational methods. Development of Luminescent Paint Technology for acquiring pressure and temperature measurements began in the mid-1980s. While pressure sensitive luminescent paints (PSP) were being developed to acquire data for aerodynamic performance and loads, temperature sensitive luminescent paints (TSP) have been used for a much broader range of applications. For example, TSP has been used to acquire surface temperature data to determine the heating due to rotating parts in various types of mechanical systems. It has been used to determine the heating pattern(s) on circuit boards. And, it has been used in boundary layer analysis and applied to the validation of full-scale flight performance predictions. That is, data acquired on the same model can be used to develop trends from off design to full scale flight Reynolds number, e.g. to show the progression of boundary layer transition. A discussion of issues related to successfully setting-up TSP tests and using TSP systems for boundary layer studies is included in this paper, as well as results from a variety of TSP tests. TSP images included in this paper are all grey-scale so that similar to pictures from sublimating chemical tests areas of laminar flow appear "lighter," or white, and areas of turbulent flow appear "darker."
The objective of this research is to develop micro-opto-mechanical system (MOMS)-based sensors for time- and space-resolved measurements of flow properties in aerodynamics applications. The measurement technique we propose uses optical resonances in dielectric micro-spheres that can be excited by radiation tunneling from optical fibers. It exploits the tunneling-induced and morphology-dependent shifts in the resonant frequencies. The shift in the resonant frequency is dependent on the size, shape, and index of refraction of the micro-sphere. A physical change in the environment surrounding a micro-bead can change one or more of these properties of the sphere thereby causing a shift in frequency of resonance. The change of the resonance frequency can be detected with high resolution by scanning a frequency-tunable laser that is coupled into the fiber and observing the transmission spectrum at the output of the fiber. It is expected that, in the future, the measurement concept will lead to a system of distributed micro-sensors providing spatial data resolved in time and space. The present project focuses on the development and demonstration of temperature sensors using the morphology-dependent optical resonances although in the latter part of the work, we will also develop a pressure sensor. During the period covered in this report, the optical and electronic equipment necessary for the experimental work was assembled and the experimental setup was designed for the single sensor temperature measurements. Software was developed for real-time tracking of the optical resonance shifts. Some preliminary experiments were also carried out to detect temperature using a single bead in a water bath.
A nozzle body and assembly for delivering atomized fuel to a combustion chamber. The nozzle body is rotatably mounted onto a substrate. One or more curvilinear fuel delivery channels are in flow communication with an internal fuel distribution cavity formed in the nozzle body. Passage of pressurized fuel through the nozzle body causes the nozzle body to rotate. Components of the nozzle assembly are formed of silicon carbide having surfaces etched by deep reactive ion etching utilizing MEMS (micro-electro-mechanical systems) technology. A fuel premix chamber is carried on the substrate in flow communication with a supply passage in the nozzle body.
The Infrared Multi-Object Spectrometer (IRMOS) is a facility instrument for the Kitt Peak National Observatory 4 and 2.1 meter telescopes. IRMOS is a near-IR (0.8 - 2.5 micron) spectrometer with low- to mid-resolving power (R = 300 - 3000). IRMOS produces simultaneous spectra of approximately 100 objects in its 2.8 x 2.0 arc-min field of view using a commercial Micro Electro-Mechanical Systems (MEMS) Digital Micro-mirror Device (DMD) from Texas Instruments. The IRMOS optical design consists of two imaging subsystems. The focal reducer images the focal plane of the telescope onto the DMD field stop, and the spectrograph images the DMD onto the detector. We describe ambient breadboard subsystem alignment and imaging performance of each stage independently, and the ambient and cryogenic imaging performance of the fully assembled instrument. Interferometric measurements of subsystem wavefront error serve to venfy alignment, and are accomplished using a commercial, modified Twyman-Green laser unequal path interferometer. Image testing provides further verification of the optomechanical alignment method and a measurement of near-angle scattered light due to mirror small-scale surface error. Image testing is performed at multiple field points. A mercury-argon pencil lamp provides spectral lines at 546.1 nm and 1550 nm, and a CCD camera and IR camera are used as detectors. We use commercial optical modeling software to predict the point-spread function and its effect on instrument slit transmission and resolution. Our breadboard test results validate this prediction. We conclude with an instrument performance prediction for first light.
An independent twelve degree-of-freedom simulation of the X-43A separation trajectory was created with the Program to Optimize Simulated trajectories (POST II). This simulation modeled the multi-body dynamics of the X-43A and its booster and included the effect of two pyrotechnically actuated pistons used to push the vehicles apart as well as aerodynamic interaction forces and moments between the two vehicles. The simulation was developed to validate trajectory studies conducted with a 14 degree-of-freedom simulation created early in the program using the Automatic Dynamic Analysis of Mechanics Systems (ADAMS) simulation software. The POST simulation was less detailed than the official ADAMS-based simulation used by the Project, but was simpler, more concise and ran faster, while providing similar results. The increase in speed provided by the POST simulation provided the Project with an alternate analysis tool. This tool was ideal for performing separation control logic trade studies that required the running of numerous Monte Carlo trajectories.
The Infrared Multi-Object Spectrometer (IRMOS) is a principle investigator class instrument for the Kitt Peak National Observatory 4 and 2.1 meter telescopes. IRMOS is a near-IR (0.8 - 2.5 micron) spectrometer with low-to mid-resolving power (R = 300 - 3000). IRMOS produces simultaneous spectra of approximately 100 objects in its 2.8 x 2.0 arc-min field of view (4 m telescope) using a commercial Micro Electro-Mechanical Systems (MEMS) micro-mirror array (MMA) from Texas Instruments. The IRMOS optical design consists of two imaging subsystems. The focal reducer images the focal plane of the telescope onto the MMA field stop, and the spectrograph images the MMA onto the detector. We describe ambient breadboard subsystem alignment and imaging performance of each stage independently, and ambient imaging performance of the fully assembled instrument. Interferometric measurements of subsystem wavefront error serve as a qualitative alignment guide, and are accomplished using a commercial, modified Twyman-Green laser unequal path interferometer. Image testing provides verification of the optomechanical alignment method and a measurement of near-angle scattered light due to mirror small-scale surface error. Image testing is performed at multiple field points. A mercury-argon pencil lamp provides a spectral line at 546.1 nanometers, a blackbody source provides a line at 1550 nanometers, and a CCD camera and IR camera are used as detectors. We use commercial optical modeling software to predict the point-spread function and its effect on instrument slit transmission and resolution. Our breadboard and instrument level test results validate this prediction. We conclude with an instrument performance prediction for cryogenic operation and first light in late 2003.
An electroactive polymer (EAP), high energy electron irradiated poly(vinylidene fluoride-trifluoroethylene) [P(VDFTrFE)] copolymer, based actuation micropump diaphragm (PAMPD) have been developed for air flow control. The displacement strokes and profiles as a function of amplifier and frequency of electric field have been characterized. The volume stroke rates (volume rate) as function of electric field, driving frequency have been theoretically evaluated, too. The PAMPD exhibits high volume rate. It is easily tuned with varying of either amplitude or frequency of the applied electric field. In addition, the performance of the diaphragms were modeled and the agreement between the modeling results and experimental data confirms that the response of the diaphragms follow the design parameters. The results demonstrated that the diaphragm can fit some future aerospace applications to replace the traditional complex mechanical systems, increase the control capability and reduce the weight of the future air dynamic control systems. KEYWORDS: Electroactive polymer (EAP), micropump, diaphragm, actuation, displacement, volume rate, pumping speed, clamping ratio.
By surveying current research of various micro-electro mechanical systems (MEMS) shear stress sensor development efforts we illustrate the wide variety of methods used to test and characterize these sensors. The different methods of testing these sensors make comparison of results difficult in some cases, and also this comparison is further complicated by the different formats used in reporting the results of these tests. The fact that making these comparisons can be so difficult at times clearly illustrates a need for standardized testing and reporting methodologies. This need indicates that the development of a national or international standard for the calibration of MEMS shear stress sensors should be undertaken. As a first step towards the development of this standard, two types of devices are compared and contrasted. The first type device is a laminar flow channel with two different versions considered: the first built with standard manufacturing techniques and the second with advanced precision manufacturing techniques. The second type of device is a new concept for creating a known shear stress consisting of a rotating wheel with the sensor mounted tangentially to the rim and positioned in close proximity to the rim. The shear stress generated by the flow at the sensor position is simply tau = (mu)r(omega)/h, where mu is the viscosity of the ambient gas, r the wheel radius, omega the angular velocity of the wheel, and h the width of the gap between the wheel rim and the sensor. Additionally, issues related to the development of a standard for shear stress calibration are identified and discussed.
At STARSYS, we execute many Firm Fixed Price (FFP) programs for the development of mechanical systems for spacecraft. Contracting this way pre-suppose that we have the ability to establish and hold scope for a system that has yet to be defined. To do FFP, it is critical that we have program managers who are masters at cost control. Fortunately, we have some "masters" in our company. They just seem to have a knack for driving to a financial target. Doesn't matter if the program has contingency or not. Doesn't seem to matter if they use MS Project, Excel spread-sheets, or the back of an envelope. Doesn't even seem to matter whether the program is set up as a financial challenge or a winner.
FEM software available to the Mechanical Systems Analysis and Simulation Branch at Goddard Space Flight Center (GSFC) include: 1) MSC/Nastran; 2) Abaqus; 3) Ansys/Multiphysics; 4) COSMOS/M; 5) 'Home-grown' programs; 6) Pre/post processors such as Patran and FEMAP. This viewgraph presentation provides additional information on MSC/Nastran and Ansys/Multiphysics, and includes screen shots of analyzed equipment, including the Wilkinson Microwave Anistropy Probe, a micro-mirror, a MEMS tunable filter, and a micro-shutter array. The presentation also includes information on the verification of results.
A critical application for the success of the Exploration Mission is developing cost effective means to extract resources from the Moon and Mars needed to support human exploration. Water is the most important resource in this regard, providing a critical life support consumable, the starting product of energy rich propellants, energy storage media (e.g. fuel cells), and a reagent used in virtually all manufacturing processes. Water is adsorbed and chemically bound in Mars soils, ice is present near the Martian surface at high latitudes, and water vapor is a minor atmospheric constituent, but extracting meaningful quantities requires large complex mechanical systems, massive feedstock handling, and large energy inputs. Liquid water aquifers are almost certain to be found at a depth of several kilometers on Mars based on our understanding of the average subsurface thermal gradient, and geological evidence from recent Mars missions suggests liquid water may be present much closer to the surface at some locations. The discovery of hundreds of recent water-carved gullies on Mars indicates liquid water can be found at depths of 200-500 meters in many locations. Drilling to obtain liquid water via pumping is therefore feasible and could lower the cost and improve the return of Mars exploration more than any other ISRU technology on the horizon. On the Moon, water ice may be found in quantity in permanently shadowed regions near the poles.
No significant general-purpose method is currently available to mechanically transform system requirements into a provably equivalent model. The widespread use of such a method represents a necessary step toward high-dependability system engineering for numerous application domains. Current tools and methods that start with a formal model of a system and mechanically produce a provably equivalent implementation are valuable but not sufficient. The "gap" unfilled by such tools and methods is that the formal models cannot be proven to be equivalent to the requirements. We offer a method for mechanically transforming requirements into a provably equivalent formal model that can be used as the basis for code generation and other transformations. This method is unique in offering full mathematical tractability while using notations and techniques that are well known and well trusted. Finally, we describe further application areas we are investigating for use of the approach.
Stirling technology is being developed to replace RTG s (Radioisotope Thermoelectric Generators), more specifically a stirling convertor, which is a stirling engine coupled to a linear alternator. Over the past three decades, the stirling engine has been designed to perform different functions. Stirling convertors have been designed to decrease fuel consumption in automobiles. They have also been designed for terrestrial and space applications. Currently NASA Glenn is using the convertor for space based applications. A stiring converter is a better means of power for deep space mission and "dusty" mission, like the Mars Rovers, than solar panels because it is not affected by dust. Spirit and Opportunity, two Mars rovers currently navigating the planet, are losing their ability to generate electricity because dust is collecting on their solar panels. Opportunity is losing more energy because its robotic arm has a heater with a switch that can not be turned off. The heater is not needed at night, but yet still runs. This generates a greater loss of electricity and in turn diminishes the performance of the rover. The stirling cycle has the potential to provide very efficient conversion of heat energy to electric a1 energy, more so than RTG's. The stirling engine converts the thermal energy produced by the decaying radioisotope to mechanical energy; the linear alternator converts this into electricity. convertor. Since the early 1990's tests have been performed to maximize the efficiency of the stirling converter. Many months, even years, are dedicated to preparing and performing tests. Currently, two stirling convertors #'s 13 and 14, which were developed by Stirling Technology Company, are on an extended operation test. As of June 7th, the two convertors reached 7,500 hours each of operation. Before the convertors could run unattended, many safety precautions had to be examined. So, special instrumentation and circuits were developed to detect off nominal conditions and also safely shutdown the engines. The test will last for a period of 8000 to 9000 hours. Other types of tests that have been performed are: performance mapping, controller development, launch environment, and vibration emissions testing. Currently, the thermo-mechanical system branch is housing a RG-350, a stirling convertor. The convertor was used in previous tests such as a Hall Thruster test, world s first integrated test of a dynamic power system with electric propulsion. Another test performed was to conclude if free piston stirling convertors can be synchronized for vibration balancing, with no thermodynamic or electrical connections and not cause both to shutdown if one failed. The ability to reduce vibration by synchronizing convertor operation but still be able to operate when one partner fails is pertinent in space and terrestrial applications. The convertor is now being brought back into operation and a controller is in the process of being developed. This convertor will be used as a testbed for new controllers. I worked with Mary Ellen Roth on the electric engineering aspects of the RG-350. My main goal was to enhance the data collection process. I worked on different aspects of the RG-350, with a main focus on the engine controller. I drew a schematic of the wire connections in the engine controller, using PCB Express, so that a plan could be devised to connect the power meter properly between the output of the engine and the engine controller. I measured the power using two different instruments: Valhalla Scientific power meter and Ohio Semitronics power measurement device. The convertor is connected to an Agilent 34970A Data Acquisition/Switch Unit, which allows the user to measure, record, and monitor voltage, current, frequency, and temperature. I assisted in preparing the Data Acquisition for general operation. I also helped test a panel of transducers, which will be placed in the rack that powers and monitors the convertor.
Ceramic materials have a lower density than most metals and are capable of performing at extremely high temperatures. The utility of these materials is obvious; however, the fracture strength of brittle materials is not easily predicted and often varies greatly. Characteristically, brittle materials lack ductility and do not yield as other materials. Ceramics materials are naturally populated with microscopic cracks due to fabrication techniques. Upon application of a load, stress concentration occurs at the root of these cracks and fracture will eventually occur at some not easily predicted strength. In order to use ceramics in any application some design methodology must exist from which a component can be placed into service. This design methodology is CARES/LIFE (Ceramics Analysis and Reliability Evaluation of Structures) which has been developed and refined at NASA over the last several decades. The CARES/LIFE computer program predicts the probability of failure of a ceramic component over its service life. CARES combines finite element results from a commercial FE (finite element) package such as ANSYS and experimental results to compute the abovementioned probability of failure. Over the course of several tests CARES has had great success in predicting the life of various ceramic components and has been used throughout industry. The latest challenge is to verify that CARES is valid for MEMS (Micro-Electro Mechanical Systems). To investigate a series of microtensile specimens were fractured in the laboratory. From this data, material parameters were determined and used to predict a distribution of strength for other specimens that exhibit a known stress concentration. If the prediction matches the experimental results then these parameters can be applied to a desired component outside of the laboratory. During testing nearly half of the tensile Specimens fractured at a location that was not expected and hence not captured in the FE model. It has been my duty to investigate the nature of this phenomenon in hopes of finding a better correlation between theory and empirical results. To investigate I built complete FE models of all of the tensile specimens using ANSYS. It is suspected that some misalignment naturally occurs during testing and thus additional bending stresses are present in the specimens. I modeled this eccentric loading and ran several FE trials using ANSYS/PDS (a probabilistic design system in ANSYS). My objective this summer has been familiarize myself with the CARES/LIFE program in hopes of using it in conjunction with ANSYS to help verify that CARES is applicable to MEMS-scale (greater that 1 micron, less than 1 millimeter) components.
Fundamental research into the feasibility of microrockets for primary propulsion and attitude control for far-term micro/integrated spacecraft is being performed. These rockets would be fabricated using microelectrical and mechanical systems (MEMS) technology. The enabling technology is being developed at the Massachusetts Institute of Technology (MIT). The NASA/MIT program leverages a very large Army Research Office and Defense Advanced Research Projects Agency (DARPA) program for the development of microturbine technology. The microrocket motor is complete with regenerative cooling, turbopumps, and control valves etched onto the same chip. They would be fabricated in large numbers in parallel using semiconductor manufacturing techniques. The technology may lead to the development of microsatellites as fully integrated MEMS devices that could be mass produced at a fraction of the cost of current satellites.
Material parameters govern many of the design decisions in any engineering task. When two materials are in contact and microscopically small, relative motions (either vibratory or creeping) occur, and fretting fatigue can result. Fretting fatigue is a material response influenced by the materials in contact as well as by such variables as loading and vibratory conditions. Fretting produces fresh, clean interacting surfaces and induces adhesion, galling, and wear in the contact zone. Time, money, and materials are unnecessarily wasted when galling and wear result in excessive fretting fatigue that leads to poorly performing, unreliable mechanical systems. Fretting fatigue is a complex problem of significant interest to aircraft engine manufacturers. It can occur in a variety of engine components. Numerous approaches, depending on the component and the operating conditions, have been taken to address the fretting problems. The components of interest in this investigation were the low-pressure turbine blades and disks. The blades in this case were titanium aluminide, Ti-48Al-2Cr- 2Nb, and the disk was a nickel-base superalloy, Inconel 718 (IN 718). A concern for these airfoils is the fretting in fitted interfaces at the dovetail where the blade and disk are connected. Careful design can reduce fretting in most cases, but not completely eliminate it, because the airfoils frequently have a skewed (angled) blade-disk dovetail attachment, which leads to a complex stress state. Furthermore, the local stress state becomes more complex when the influence of the metal-metal contact and the edge of contact are considered.
Atmospheric entry probes present a unique opportunity for performing quantitative analysis of extra-terrestrial atmospheres in cases where remote sensing alone may not be sufficient and measurements with balloons or aircraft is not practical. An entry probe can provide a complete vertical profile of atmospheric parameters including chemical composition, which cannot be obtained with most other techniques. There are, however, unique challenges associated with building instruments for an entry probe, as compared to orbiters, landers, or rovers. Conditions during atmospheric entry are extreme, there are inherent time constraints due to the short duration of the experiment, and the instrument experiences rapid environmental changes in temperature and pressure as it descends. In addition, there are resource limitations, i.e. mass, power, size and bandwidth. Finally, the demands on the instrument design are determined in large part by conditions (pressure, temperature, composition) unique to the particular body under study, and as a result there is no one-size-fits-all instrument for an atmospheric probe. Many of these requirements can be more easily met by miniaturizing the probe instrument. Our experience building mass spectrometers for atmospheric entry probes leads us to believe that the time is right for a fundamental change in the way spaceflight mass spectrometers are built. The emergence over the past twenty years of Micro-electro- mechanical Systems (MEMS), utilizing lithographic semiconductor fabrication techniques to produce instrument systems in miniature, holds great promise for application to spaceflight mass spectrometry. A highly miniaturized, high performance and low-power mass spectrometer would be an enormous benefit to future entry probe missions, allowing, for example, parallel measurements (e.g., multiple simultaneous gas chromatographic analyses and direct atmospheric leaks.) Such an instrument would also enable mass spectrometry on board small multiple entry probes. In the development of a MEMS Mass Spectrometer, the challenge facing us is to move beyond the proof-of-concept, where research dollars tend to focus, and carry out the detailed work of developing a high performance mass spectrometer system on a chip which meets the unique technical requirements for an atmospheric entry probe described above.