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NASA NTRSDate not supplied

AM Powder Flowability Capabilities at NASA Marshall Space Flight Center (MSFC)

Additive Manufacturing (AM) powder flowability is critical to metal 3D printing, because the more fluid the powder is, the better powder spreads. AM Powder Flowability Capabilities at NASA MSFC studies density, flow, particle size distribution, and morphology for programs such as Moon-to-Mars Planetary Autonomous Construction Technology (MMPACT), ASTM Proficiency Testing for AM and Powder Metallurgy, and MSFC’s AM team. Examining and measuring powder characteristics is essential for improving flowability of AM powder and ensuring lot-to-lot consistency, which will help to prevent defects in manufactured parts. The Contamination Control Team (CCT) uses several methods to characterize AM powder. Optical particle size distribution and morphology analyses determine particle parameters including size, circularity, convexity, and dimensions. The Carney and Hall Flowmeter Funnel measures time it takes powder to flow through a funnel to compare relative flowability (free-flowing and non-free-flowing). In addition to this, the device utilizes a density cup which determines apparent density. Lastly, the Revolution Powder Analyzer measures dynamic powder flowability and behavior over time via digital imaging. Using the CCT’s lab, the team has produced ASTM Powder Proficiency Testing results with flow rates, apparent density, particle size distribution, and tap density on titanium-based and nickel-based powder and compared data with other companies/labs. Morphology data was also collected for various regolith simulant powder for the MMPACT program. Lastly, the CCT used morphology data to examine the flowability of Inconel 718 powder for Selective Laser Melting (SLM) and Directed Energy Deposition (DED) printers at MSFC. The CCT’s essential work in studying and enabling AM powder characterization has helped and will continue to help study new and refined powders in the AM industry.

Additive Manufacturing↗
NASA NTRS2001

Friction Stir Welding Development at NASA, Marshall Space Flight Center

Friction stir welding (FSW) is a solid state process that pan be used to join materials without melting. The process was invented by The Welding Institute (TWI), Cambridge, England. Friction stir welding exhibits several advantages over fusion welding in that it produces welds with fewer defects and higher joint efficiency and is capable of joining alloys that are generally considered non-weldable with a fusion weld process. In 1994, NASA-Marshall began collaborating with TWI to transform FSW from a laboratory curiosity to a viable metal joining process suitable for manufacturing hardware. While teamed with TWI, NASA-Marshall began its own FSW research and development effort to investigate possible aerospace applications for the FSW process. The work involved nearly all aspects of FSW development, including process modeling, scale-up issues, applications to advanced materials and development of tooling to use FSW on components of the Space Shuttle with particular emphasis on aluminum tanks. The friction stir welding process involves spinning a pin-tool at an appropriate speed, plunging it into the base metal pieces to be joined, and then translating it along the joint of the work pieces. In aluminum alloys the rotating speed typically ranges from 200 to 400 revolutions per minute and the translation speed is approximately two to five inches per minute. The pin-tool is inserted at a small lead angle from the axis normal to the work piece and requires significant loading along the axis of the tool. An anvil or reaction structure is required behind the welded material to react the load along the axis of the pin tool. The process requires no external heat input, filler material, protective shielding gas or inert atmosphere typical of fusion weld processes. The FSW solid-state weld process has resulted in aluminum welds with significantly higher strengths, higher joint efficiencies and fewer defects than fusion welds used to join similar alloys.

McGill, Preston↗
NASA NTRS2009

Implementation of an Online Database for Chemical Propulsion Systems

The Johns Hopkins University, Chemical Propulsion Information Analysis Center (CPIAC) has been working closely with NASA Goddard Space Flight Center (GSFC); NASA Marshall Space Flight Center (MSFC); the University of Alabama at Huntsville (UAH); The Johns Hopkins University, Applied Physics Laboratory (APL); and NASA Jet Propulsion Laboratory (JPL) to capture satellite and spacecraft propulsion system information for an online database tool. The Spacecraft Chemical Propulsion Database (SCPD) is a new online central repository containing general and detailed system and component information on a variety of spacecraft propulsion systems. This paper only uses data that have been approved for public release with unlimited distribution. The data, supporting documentation, and ability to produce reports on demand, enable a researcher using SCPD to compare spacecraft easily, generate information for trade studies and mass estimates, and learn from the experiences of others through what has already been done. This paper outlines the layout and advantages of SCPD, including a simple example application with a few chemical propulsion systems from various NASA spacecraft.

David B. Owen, II↗
NASA NTRS2004

Range Commanders Council Meteorology Group 88th Meeting: NASA Marshall Space Flight Center Task Report, 2004

Supported Return-to-Flight activities by providing surface climate data from Kennedy Space Center used primarily for ice and dew formation studies, and upper air wind analysis primarily used for ascent loads analyses. The MSFC Environments Group's Terrestrial and Planetary Environments Team documented Space Shuttle day-of-launch support activities by publishing a document in support of SSP Return-to-Flight activities entitled "Space Shuttle Program Flight Operations Support". The team also formalized the Shuttle Natural Environments Technical Panel and chaired the first special session of the SSP Natural Environments Panel meeting at KSC, November 4-7,2003.58 participants from NASA, DOD and other government agencies from across the country attended the meeting.

Roberts, Barry C.↗
NASA NTRS1983

Statistical analysis of turbulence data from the NASA Marshall Space Flight Center atmospheric boundary layer tower array facility

Statistical properties of atmospheric turbulence near the Earth's surface are presented. Emphasis is placed on the probability density distribution two point spatial correlation, length scale, and two point and single point spectrum. Comparison of the data with isotropic homogeneous models is made. In general, agreement with the models is poor. For the design of aircraft during operations in the lower levels associated with approach, takeoff, and terrain following, it appears necessary to improve existing models or develop new nonisotropic turbulence models.

Frost, W.↗
NASA NTRS1985

Cooperative VAS program with NASA Marshall Space Flight Center

The importance of mesoscale moisture information in the forecasting of weather events is discussed. A test is being prepared with the March 6, 1982 Vertical Atmospheric Sounder/Atmospheric Variability Experiment (VAS/AVE) case study to be run on the sub-synoptic scale model (SSM). Model intracomparison of three carefully designed simulations should isolate the role of mesoscale information in the initial conditions for both mositure and vertical motion. Three simulations will be made for the period 1200Z 6 March to 0000Z 7 March starting with the regular synoptic time data of 1200Z. The distinction between the three cases arises from data manipulation at 1800Z midway through the forecast period: (1) Control Case: no alterations at 1800Z. (2) Moisture Information Suppression: at 1800Z the model simulation field for water vapor, which by this time contains considerable mesoscale structure, is replaced by a smoothed version from which the mesoscale structure has been eliminated. No other variables are structure altered. (3) Vertical Motion Information Suppression: at 1800Z the model is subjected to a dead start procedure which primarily imposes a nondivergent constraint of the horizontal motion field field suppressing vertical motion. The main effect is to eliminate the mesoscale component. Comparison of results for the 1800Z to 0000Z time period will give the information desired.

Houghton, D. D.↗
NASA NTRS1987

NASA Marshall Space Flight Center atomic oxygen investigations

An overview of the MSFC atomic oxygen investigations is provided, including descriptions of flight studies, ground-based testing, contractual efforts, and future focus. Summary results of flight experiments on STS-5, STS-8, and STS 41-G are presented. The development of the MSFC Atomic Oxygen Resistive Monitor for the upcoming EOIM-3 (Evaluation of Oxygen Interaction with Materials 3) flight experiment is reviewed. Materials characterization work and ground-based testing are described. Contractual efforts, such as the development of atomic oxygen resistant coatings for the space station, are discussed. Future emphasis is placed on ground-based testing via the development and operation of a state-of-the-art atomic oxygen simulation system and on the continuation of flight studies in support of multi-programs.

Source record↗
NASA NTRS1990

The NASA, Marshall Space Flight Center drop tube user's manual

A comprehensive description of the structural and instrumentation hardware and the experimental capabilities of the 105-meter Marshall Space Flight Center Drop Tube Facility is given. This document is to serve as a guide to the investigator who wishes to perform materials processing experiments in the Drop Tube. Particular attention is given to the Tube's hardware to which an investigator must interface to perform experiments. This hardware consists of the permanent structural hardware (with such items as vacuum flanges), and the experimental hardware (with the furnaces and the sample insertion devices). Two furnaces, an electron-beam and an electromagnetic levitator, are currently used to melt metallic samples in a process environment that can range from 10(exp -6) Torr to 1 atmosphere. Details of these furnaces, the processing environment gases/vacuum, the electrical power, and data acquisition capabilities are specified to allow an investigator to design his/her experiment to maximize successful results and to reduce experimental setup time on the Tube. Various devices used to catch samples while inflicting minimum damage and to enhance turnaround time between experiments are described. Enough information is provided to allow an investigator who wishes to build his/her own furnace or sample catch devices to easily interface it to the Tube. The experimental instrumentation and data acquisition systems used to perform pre-drop and in-flight measurements of the melting and solidification process are also detailed. Typical experimental results are presented as an indicator of the type of data that is provided by the Drop Tube Facility. A summary bibliography of past Drop Tube experiments is provided, and an appendix explaining the noncontact temperature determination of free-falling drops is provided. This document is to be revised occasionally as improvements to the Facility are made and as the summary bibliography grows.

Rathz, Thomas J.↗
NASA NTRS1991

NASA Marshall Space Flight Center solar observatory report, January - June 1991

Given here is a summary of the solar vector magnetic field, H-alpha, and white-light observations made at the NASA/Marshall Space Flight Center (MSFC) Solar Observatory during its daily periods of operation. The MSFC Solar Observatory facilities consist of the Solar Magnetograph, an f/13, 30-cm Cassegrain system with a 3.5-cm image of the Sun, housed on top of a 12.8-meter tower; a 12.5-cm Razdow H-alpha telescope housed at the base of the tower; an 18-cm Questar telescope with a full aperture white-light filter mounted at the base of the tower; a 30-cm Cassegrain telescope located in a second metal dome; and a 16.5-cm H-alpha telescope mounted on side of the Solar Vector Magnetograph. A concrete block building provides office space, a darkroom for developing film and performing optical testing, a workshop, video displays, and a computer facility for data reduction.

Smith, James E.↗
NASA NTRS1991

NASA. Marshall Space Flight Center Hydrostatic Bearing Activities

The basic approach for analyzing hydrostatic bearing flows at the Marshall Space Flight Center (MSFC) is briefly discussed. The Hydrostatic Bearing Team has responsibility for assessing and evaluating flow codes; evaluating friction, ignition, and galling effects; evaluating wear; and performing tests. The Office of Aerospace and Exploration Technology Turbomachinery Seals Tasks consist of tests and analysis. The MSFC in-house analyses utilize one-dimensional bulk-flow codes. Computational fluid dynamics (CFD) analysis is used to enhance understanding of bearing flow physics or to perform parametric analysis that are outside the bulk flow database. As long as the bulk flow codes are accurate enough for most needs, they will be utilized accordingly and will be supported by CFD analysis on an as-needed basis.

Benjamin, Theodore G.↗
NASA NTRS1992

NASA Marshall Space Flight Center Solar Observatory report, July - December 1991

A summary is given of the solar vector magnetic field, H-alpha, and white light observations made at the NASA/Marshall Space Flight Center (MSFC) Solar Observatory during its daily periods of observation. The MSFC Solar Observatory facilities consist of the Solar Magnetograph, an f-13, 30 cm Cassegrain system with a 3.5 cm image of the Sun housed on top of a 12.8 meter tower, a 12.5 cm Razdow H-alpha telescope housed at the base of the tower, an 18 cm Questar telescope with a full aperture white-light filter mounted at the base of the tower, a 30 cm Cassegrain telescope located in a second metal dome, and a 16.5 cm H-alpha telescope mounted on the side of the Solar Vector Magnetograph. A concrete block building provides office space, a darkroom for developing film and performing optical testing, a workshop, video displays, and a computer facility for data reduction.

Smith, James E.↗
NASA NTRS1992

Battery and cell testing at NASA. Marshall Space Flight Center

An overview covering the ten cell/battery tests ongoing at MSFC are presented. The presentation is not intended to give specific test results on any test. The purpose and related program that applies to each test is acknowledged. Except for the Combined Release and Radiation Effects Satellite (CRRES), all are energy-stored and retrieval devices at low earth orbit (LEO) cycles.

Whitt, Tom↗
NASA NTRS1992

A status of the activities of the NASA. Marshall Space Flight Center Combustion Devices Technology Team

The Consortium for Computational Fluid Dynamics (CFD) Applications in Propulsion Technology was established to focus on computational fluid dynamics applications in propulsion. Specific areas of effort include developing the CFD technology required to address rocket propulsion issues, validating the technology, and applying the validated technology to design problems. The Combustion Devices Technology Team was formed to implement the above objectives in the broad area of combustion driven flows. In an effort to bring CFD to bear in the design environment, the team has focused its efforts on the Space Transportation Main Engine nozzle. The main emphasis has been on the film cooling scheme used to cool the nozzle wall. Benchmark problems have been chosen to validate CFD film cooling capabilities. CFD simulations of the subscale nozzle have been made. Also, CFD predictions of the base flow resulting from this type of nozzle have been made. The status of these calculations is presented along with future plans. Information is given in viewgraph form.

Tucker, Kevin↗
NASA NTRS1987

CFD activities at NASA. Marshall Space Flight Center (validation)

Computational fluid dynamics objectives are presented for Marshall Space Flight Center. Topics covered include: codes in use, applications to hardware development, and the Center's benchmark plan for the future. All results are presented in viewgraph format.

Schutzenhofer, Luke A.↗
NASA NTRS2001

Structural Dynamics Experimental Activities in Ultra-Lightweight and Inflatable Space Structures

This paper reports recently completed structural dynamics experimental activities with new ultralightweight and inflatable space structures (a.k.a., "Gossamer" spacecraft) at NASA Langley Research Center, NASA Marshall Space Flight Center, and NASA Goddard Space Flight Center. Nine aspects of this work are covered, as follows: 1) inflated, rigidized tubes, 2) active control experiments, 3) photogrammetry, 4) laser vibrometry, 5) modal tests of inflatable structures, 6) in-vacuum modal tests, 7) tensioned membranes, 8) deployment tests, and 9) flight experiment support. Structural dynamics will play a major role in the design and eventual in-space deployment and performance of Gossamer spacecraft, and experimental R&D work such as this is required now to validate new analytical prediction methods. The activities discussed in the paper are pathfinder accomplishments, conducted on unique components and prototypes of future spacecraft systems.

Pappa, Richard S.↗
NASA NTRS2001

Structural Dynamics Experimental Activities in Ultra-Lightweight and Inflatable Space Structures

This paper reports recently completed structural dynamics experimental activities with new ultra-lightweight and inflatable space structures (a.k.a., "Gossamer" spacecraft) at NASA Langley Research Center, NASA Marshall Space Flight Center, and NASA Goddard Space Flight Center. Nine aspects of this work are covered: 1) inflated, rigidized tubes, 2) active control experiments, 3) photogrammetry, 4) laser vibrometry, 5) modal tests of inflatable structures, 6) in-vacuum modal tests, 7) tensioned membranes, 8) deployment tests, and 9) flight experiment support. Structural dynamics will play a major role in the design and eventually in-space deployment and performance of Gossamer spacecraft. Experimental research and development such as this is required to validate new analysis methods. The activities discussed in the paper are pathfinder accomplishments. conducted on unique components and prototypes of future spacecraft systems.

Pappa, Richard S.↗
NASA NTRS2001

Friction Stir Welding Development at NASA-Marshall Space Flight Center

This paper presents an overview of friction stir welding (FSW) process development and applications at Marshall Space Flight Center (MSFC). FSW process development started as a laboratory curiosity but soon found support from many users. The FSW process advanced very quickly and has found many applications both within and outside the aerospace industry. It is currently being adapted for joining key elements of the Space Shuttle External Tank for improved producibility and reliability. FSW process modeling is done to better understand and improve the process. Special tools have been developed to weld variable thickness materials including thin and thick materials. FSW is now being applied to higher temperature materials such as copper and to advanced materials such as metal matrix composites. FSW technology is being successfully transferred from MSFC laboratory to shop floors of many commercial companies.

Bhat, Biliyar N.↗