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A list of the present state of knowledge in materials processing is presented. The fluid behavior in a low gravity environment is summarized. Materials processing in the Space Transportation System facility is discussed. Prospects for space commercialization are reported.
A compact color schlieren system designed for field measurement of materials processing parameters has been built and tested in a microgravity environment. Improvements in the color filter design and a compact optical arrangement allowed the system described here to retain the traditional advantages of schlieren, such as simplicity, sensitivity, and ease of data interpretation. Testing was accomplished by successfully flying the instrument on a series of parabolic trajectories on the NASA KC-135 microgravity simulation aircraft. A variety of samples of interest in materials processing were examined. Although the present system was designed for aircraft use, the technique is well suited to space flight experimentation. A major goal of this effort was to accommodate the main optical system within a volume approximately equal to that of a Space Shuttle middeck locker. Future plans include the development of an automated space-qualified facility for use on the Shuttle and Space Station.
The paper reviews the evolution of the U.S. Materials Processing In Space Program, current materials processing in space program, and future programs. The discussion covers a summary of significant findings from previous flight experiments, a current assessment of the attractive areas for future experimentation, and a synopsis of the experiments accepted for future Space Processing Application Rocket (SPAR) and Spacelab flights. The ultimate goal is to develop a viable commercial interest in using space (1) to perform research for improving industrial technology or developing new products; (2) to prepare research quantities of material to serve as paradigms for comparing current earth-based technologies; (3) to manufacture limited quantities of a unique product to test market potential, or to fulfill a limited but compelling need; and (4) to produce materials in space of adequate quantity and value to be economically self-sufficient.
The Microgravity and Materials Processing Facility (MMPF) of the Space Station is examined. The MMPF is designed to accommodate individual experiments and associated hardware and is to be housed in the Manufacturing and Technology Laboratory Module. The objectives of the microgravity and materials processing study and the user, experiment/equipment, MMPF system requirements, and programmatics and planning development tasks of the study are described. Consideration is given to the acceleration environment, on-orbit sample preparation and analysis, mission-time-line analyses, and payload complement trades. Diagrams of the MMPF are presented.
This CP contains the extended abstracts and presentation figures of 36 papers presented at the PPM and Other Propulsion R&T Conference. The focus of the research described in these presentations is on materials and structures technologies that are parts of the various projects within the NASA Aeronautics Propulsion Systems Research and Technology Base Program. These projects include Physics and Process Modeling; Smart, Green Engine; Fast, Quiet Engine; High Temperature Engine Materials Program; and Hybrid Hyperspeed Propulsion. Also presented were research results from the Rotorcraft Systems Program and work supported by the NASA Lewis Director's Discretionary Fund. Authors from NASA Lewis Research Center, industry, and universities conducted research in the following areas: material processing, material characterization, modeling, life, applied life models, design techniques, vibration control, mechanical components, and tribology. Key issues, research accomplishments, and future directions are summarized in this publication.
The use of an expert system for the control of materials processing experiments in a facility such as the Space Station provides a number of attractive features for insuring that certain critical process parameters can be used to optimize the productivity of the materials processing experiments. The proposed approach to implementation of an expert system utilizes a knowledge base of desired process characteristics which will provide the desired results. The knowledge base for each experiment will be created in conjunction with the scientific investigator in charge of the experiment. Improvements to the knowledge base will be expanded to include self learning sessions in ground based experiments in order to teach the expert system how to respond to perturbations in the process and update the knowledge base on what process change should be implemented in order to reach the desired end product. Design considerations using an on-line real time expert system such as PICON is studied. The types of experiments evaluated include several types of solidification experiments which will be performed on the Space Station.
Attention is given to the Materials, Processes, and Environmental Engineering Network (MPEEN), which was developed as a central holding facility for materials testing information generated by the Materials and Processes Laboratory of NASA-Marshall. It contains information from other NASA centers and outside agencies, and also includes the NASA Environmental Information System (NEIS) and Failure Analysis Information System (FAIS) data. The data base is NEIS, which is accessible through MPEEN. Environmental concerns are addressed regarding materials identified by the NASA Operational Environment Team (NOET) to be hazardous to the environment. The data base also contains the usage and performance characteristics of these materials.
The Space Shuttle Discovery STS-64 mission carried the first American autonomous robot into space, the Robot Operated Materials Processing System (ROMPS). On this mission ROMPS was the only Hitchhiker experiment and had a unique opportunity to utilize all Hitchhiker space carrier capabilities. ROMPS conducted rapid thermal processing of the one hundred semiconductor material samples to study how micro gravity affects the resulting material properties. The experiment was designed, built and operated by a small GSFC team in cooperation with industry and university based principal investigators who provided the material samples and data interpretation. ROMPS' success presents some valuable lessons in such cooperation, as well as in the utilization of the Hitchhiker carrier for complex applications. The motivation of this paper is to share these lessons with the scientific community interested in attached payload experiments. ROMPS has a versatile and intelligent material processing control data system. This paper uses the ROMPS data system as the guiding thread to present the ROMPS mission experience. It presents an overview of the ROMPS experiment followed by considerations of the flight and ground data subsystems and their architecture, data products generation during mission operations, and post mission data utilization. It then presents the lessons learned from the development and operation of the ROMPS data system as well as those learned during post-flight data processing.
NASA's materials processing in space- (MPS) program involves both ground and space-based research and looks to frequent and cost effective access to the space environment for necessary progress. The first generation payloads for research are under active design and development. They will be hosted by the Space Shuttle/Spacelab on Earth orbital flights in the early 1980's. hese missions will focus on the acquisition of materials behavior research data, the potential enhancement of Earth based technology, and the implementation of space based processing for specialized, high value materials. Some materials to be studied in these payloads may provide future breakthroughs for stronger alloys, ultrapure glasses, superior electronic components, and new or better chemicals. An operational 25 kW power system is expected to be operational to support sustained, systematic space processing activity beyond shuttle capability for second generation payload systems for SPACELAB and free flyer missions to study solidification and crystal growth and to process metal/alloys, glasses/ceramics, and chemicals and biologicals.
To promote potential commercial applications of low-g technology, the materials processing and manufacturing in space program is structured to: (1) analyze the scientific principles of gravitational effects on processes used in producing materials; (2) apply the research toward the technology used to control production process (on Earth or in space, as appropriate); and (3) establish the legal and managerial framework for commercial ventures. Presently federally funded NASA research is described as well as agreements for privately funded commercial activity, and a proposed academic participation process. The future scope of the program and related capabilities using ground based facilities, aircraft, sounding rockets, and space shuttles are discussed. Areas of interest described include crystal growth; solidification of metals and alloys; containerless processing; fluids and chemical processes (including biological separation processes); and processing extraterrestrial materials.
Analyses for Experiment M512, Materials Processing Facility (MSFC), to be used for evaluating the performance of the Skylab corollary experiments under preflight, inflight, and post-flight conditions are presented. Experiment contingency plan workaround procedure and malfunction analyses are presented in order to assist in making the experiment operationally successful.
The synergy and linkages between bioregenerative life support systems and the materials produced by in-situ materials processing systems was investigated. Such systems produce a broad spectrum of byproducts such as oxygen, hydrogen, processed soil material, ceramics, refractory, and other materials. Some of these materials may be utilized by bioregenerative systems either directly or with minor modifications. The main focus of this project was to investigate how these materials can be utilized to assist a bioregenerative life support system. Clearly the need to provide a sustainable bioregenerative life support system for long term human habitation of space is significant.
Mathematical and physical modeling of turbulence phenomena in metals processing, electromagnetically driven flows in materials processing, gas-solid reactions, rapid solidification processes, the electroslag casting process, the role of cathodic depolarizers in the corrosion of aluminum in sea water, and predicting viscoelastic flows are described.
This is a report presenting the progress of a research grant funded by NASA for work performed during 1 Oct. 1994 - 31 Sep. 1995. The report deals with the development and investigation of potential use of software for data processing for the Robot Operated Material Processing System (ROMPS). It reports on the progress of data processing of calibration samples processed by ROMPS in space and on earth. First data were retrieved using the I/O software and manually processed using MicroSoft Excel. Then the data retrieval and processing process was automated using a program written in C which is able to read the telemetry data and produce plots of time responses of sample temperatures and other desired variables. LabView was also employed to automatically retrieve and process the telemetry data.
A systems design study to describe the conceptual evolution, the institutional interrelationshiphs, and the basic physical requirements to implement materials processing in space was conducted. Planning for a processing era, rather than hardware design, was emphasized. Product development in space was examined in terms of fluid phenomena, phase separation, and heat and mass transfer. The effect of materials processing on the environment was studied. A concept for modular, unmanned orbiting facilities using the modified external tank of the space shuttle is presented. Organizational and finding structures which would provide for the efficient movement of materials from user to space are discussed.
Ares I Crew Launch Vehicle Upper Stage is designed and developed based on sound systems engineering principles. Systems Engineering starts with Concept of Operations and Mission requirements, which in turn determine the launch system architecture and its performance requirements. The Ares I-Upper Stage is designed and developed to meet these requirements. Designers depend on the support from materials, processes and manufacturing during the design, development and verification of subsystems and components. The requirements relative to reliability, safety, operability and availability are also dependent on materials availability, characterization, process maturation and vendor support. This paper discusses the roles and responsibilities of materials and manufacturing engineering during the various phases of Ares IUS development, including design and analysis, hardware development, test and verification. Emphasis is placed how materials, processes and manufacturing support is integrated over the Upper Stage Project, both horizontally and vertically. In addition, the paper describes the approach used to ensure compliance with materials, processes, and manufacturing requirements during the project cycle, with focus on hardware systems design and development.
NASA research to date on materials processing in space (MPS) has revealed that microgravity conditions to a large degree eliminate normal convection, sedimentation, buoyancy, and deformations due to gravity, and permit the exploration of containerless processing. The goals of current NASA MPS work is to augment the fundamental database on MPS and to foster commercial participation in MPS. Techniques being applied by NASA to fulfill the latter goal are described, including technical exchange, industrial guest investigator and joint endeavor agreements, and tangible market incentives. Guidelines for each type of agreement are summarized.
Multiscale modeling of materials requires simulations of multiple levels of structural hierarchy. The computational efficiency of numerical methods becomes a critical factor for simulating large physical systems with highly desperate length scales. Multigrid methods are known for their superior efficiency in representing/resolving different levels of physical details. The efficiency is achieved by employing interactively different discretizations on different scales (grids). To assist optimization of manufacturing conditions for materials processing with numerous particles (e.g., dispersion of particles, controlling flow viscosity and clusters), a new multigrid algorithm has been developed for a case of multiscale modeling of flows with small particles that have various length scales. The optimal efficiency of the algorithm is crucial for accurate predictions of the effect of processing conditions (e.g., pressure and velocity gradients) on the local flow fields that control the formation of various microstructures or clusters.