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The fabrication of large segmented optics requires a polishing process that can correct the figure of a surface to within a short distance from its edges-typically, a few millimeters. The work here is to develop QED's Magnetorheological Finishing (MRF) precision polishing process to minimize residual edge effects.
The planned Mars Science Laboratory mission requires inlet funnels for channeling unconsolidated powdered samples from the sampling and sieving mechanisms into instrument test cells, which are required to reduce cross-contamination of the samples and to minimize residue left in the funnels after each sample transport. To these ends, a solid-state shaking mechanism has been created that requires low power and is lightweight, but is sturdy enough to survive launch vibration. The funnel mechanism is driven by asymmetrically mounted, piezoelectric flexure actuators that are out of the load path so that they do not support the funnel mass. Each actuator is a titanium, flextensional piezoelectric device driven by a piezoelectric stack. The stack has Invar endcaps with a half-spherical recess. The Invar is used to counteract the change in stress as the actuators are cooled to Mars ambient temperatures. A ball screw is threaded through the actuator frame into the recess to apply pre-stress, and to trap the piezoelectric stack and endcaps in flexure. During the vibration cycle of the flextensional actuator frame, the compression in the piezoelectric stack may decrease to the point that it is unstressed; however, because the ball joint cannot pull, tension in the piezoelectric stack cannot be produced. The actuators are offset at 120 . In this flight design, redundancy is required, so three actuators are used though only one is needed to assist in the movement. The funnel is supported at three contact points offset to the hexapod support contacts. The actuator surface that does not contact the ring is free to expand. Two other configurations can be used to mechanically tune the vibration. The free end can be designed to drive a fixed mass, or can be used to drive a free mass to excite impacts (see figure). Tests on this funnel mechanism show a high density of resonance modes between 1 and 20 kHz. A subset of these between 9 and 12 kHz was used to drive the CheMin actuators at 7 V peak to peak. These actuators could be driven by a single resonance, or swept through a frequency range to decrease the possibility that a portion of the funnel surface was not coincident with a nodal line (line of no displacement). The frequency of actuation can be electrically controlled and monitored and can also be mechanically tuned by the addition of tuning mass on the free end of the actuator. The devices are solid-state and can be designed with no macroscopically moving parts. This design has been tested in a vacuum at both Mars and Earth ambient temperatures ranging from 30 to 25 C
The advantages of using higher order, interpolatory basis functions are examined in the analysis of transverse electric (TE) plane wave scattering by homogeneous, dielectric cylinders. A boundary-element/finite-element (BEM/FEM) hybrid formulation is employed in which the interior dielectric region is modeled with the vector Helmholtz equation, and a radiation boundary condition is supplied by an Electric Field Integral Equation (EFIE). An efficient method of handling the singular self-term arising in the EFIE is presented. The iterative solution of the partially dense system of equations is obtained using the Quasi-Minimal Residual (QMR) algorithm with an Incomplete LU Threshold (ILUT) preconditioner. Numerical results are shown for the case of an incident wave impinging upon a square dielectric cylinder. The convergence of the solution is shown versus the number of unknowns as a function of the completeness order of the basis functions.
The development and verification of the Charring Ablating Thermal Protection Implicit System Solver is presented. This work concentrates on the derivation and verification of the stationary grid terms in the equations that govern three-dimensional heat and mass transfer for charring thermal protection systems including pyrolysis gas flow through the porous char layer. The governing equations are discretized according to the Galerkin finite element method with first and second order implicit time integrators. The governing equations are fully coupled and are solved in parallel via Newton's method, while the fully implicit linear system is solved with the Generalized Minimal Residual method. Verification results from exact solutions and the Method of Manufactured Solutions are presented to show spatial and temporal orders of accuracy as well as nonlinear convergence rates.
A computer program solves the Navier- Stokes equations governing the flow of a viscous, compressible fluid in an axisymmetric or two-dimensional (2D) setting. To obtain solutions more accurate than those generated by prior such programs that utilize regular and/or fixed computational meshes, this program utilizes unstructured (that is, irregular triangular) computational meshes that are automatically adapted to solutions. The adaptation can refine to regions of high change in gradient or can be driven by a novel residual minimization technique. Starting from an initial mesh and a corresponding data structure, the adaptation of the mesh is controlled by use of minimization functional. Other improvements over prior such programs include the following: (1) Boundary conditions are imposed weakly; that is, following initial specification of solution values at boundary nodes, these values are relaxed in time by means of the same formulations as those used for interior nodes. (2) Eigenvalues are limited in order to suppress expansion shocks. (3) An upwind fluctuation-splitting distribution scheme applied to inviscid flux requires fewer operations and produces less artificial dissipation than does a finite-volume scheme, leading to greater accuracy of solutions.
In a collaboration between NASA GSFC and GWU, a low-cost, surface instrument is being developed that can continuously monitor key carbon cycle gases in the atmospheric column: carbon dioxide (CO2) and methane (CH4). The instrument is based on a miniaturized, laser heterodyne radiometer (LHR) using near infrared (NIR) telecom lasers. Despite relatively weak absorption line strengths in this spectral region, spectrallyresolved atmospheric column absorptions for these two molecules fall in the range of 60-80% and thus sensitive and precise measurements of column concentrations are possible. In the last year, the instrument was deployed for field measurements at Park Falls, Wisconsin; Castle Airport near Atwater, California; and at the NOAA Mauna Loa Observatory in Hawaii. For each subsequent campaign, improvement in the figures of merit for the instrument has been observed. In the latest work the absorbance noise is approaching 0.002 optical density (OD) noise on a 1.8 OD signal. An overview of the measurement campaigns and the data retrieval algorithm for the calculation of column concentrations will be presented. For light transmission through the atmosphere, it is necessary to account for variation of pressure, temperature, composition, and refractive index through the atmosphere that are all functions of latitude, longitude, time of day, altitude, etc. For temperature, pressure, and humidity profiles with altitude we use the Modern-Era Retrospective Analysis for Research and Applications (MERRA) data. Spectral simulation is accomplished by integrating short-path segments along the trajectory using the SpecSyn spectral simulation suite developed at GW. Column concentrations are extracted by minimizing residuals between observed and modeled spectrum using the Nelder-Mead simplex algorithm. We will also present an assessment of uncertainty in the reported concentrations from assumptions made in the meteorological data, LHR instrument and tracker noise, and radio frequency bandwidth and describe additional future goals in instrument development and deployment target
To perform in-situ measurements on Mars or other planetary bodies many instruments require powder produced using some sampling technique (drilling/coring) or sample processing technique (core crushing) to be placed in measurement cells. This usually requires filling a small sample cell using an inlet funnel. In order to minimize cross contamination with future samples and ensure the sample is transferred from the funnel to the test cell with minimal residual powder the funnel is shaken. The shaking assists gravity by fluidizing the powder and restoring flow of the material. In order to counter cross contamination or potential clogging due to settling during autonomous handling a piezoelectric shaking mechanism was designed for the deposition of sample fines in instrument inlet funnels. This device was designed to be lightweight, consume low power and demonstrated to be a resilient solid state actuator that can be mechanically and electrically tuned to shake the inlet funnel. In the final design configuration tested under nominal Mars Ambient conditions the funnel mechanism is driven by three symmetrically mounted piezoelectric flexure actuators that are out of the funnel support load path. The frequency of the actuation can be electrically controlled and monitored and mechanically tuned by the addition of tuning mass on the free end of the actuator. Unlike conventional electromagnetic motors these devices are solid state and can be designed with no macroscopically moving parts. This paper will discuss the design and testing results of these shaking mechanisms.
Launch lock and release mechanisms constitute a common space business, however, some science missions due to very challenging functional and performance requirements need the development and testing of dedicated systems. In the LISA Pathfinder mission, a gold-coated 2-kg test mass must be injected into a nearly pure geodesic trajectory with a minimal residual velocity with respect to the spacecraft. This task is performed by the Grabbing Positioning and Release Mechanism, which has been tested on-ground to provide the required qualification. In this paper, we describe the test method that analyzes the main contributions to the mechanism performance and focuses on the critical parameters affecting the residual test mass velocity at the injection into the geodesic trajectory. The test results are also presented and discussed.
In order to fully utilize silicon carbide-based ceramics and ceramic matrix composites (CMCs) for aerospace and ground based applications, advanced joining and integration technologies are critically needed for achieving large, complex shaped, and integrated components. Careful material selection of joining inter-layers needs to consider chemical and thermal compatibilities with the parent materials that are being joined. Also, optimization needs to be conducted to select the proper processing conditions for achieving robust joints that are well adhered, strong, uniform, crack free, and have minimal residual stresses. NASA GRC developed pressureless and pressure aided approaches for joining ceramics and CMCs include brazing, diffusion bonding, refractory eutectic phase joining, and Single-step Elevated Temperature (SET) Joining. For joining ceramics and CMCs to metals, several brazes have been utilized. Brazing approaches for joining ceramics and metals have also included tailored brazes with multiple interlayers and particle additions. An overview of the joining approaches will be provided. In addition, processing-microstructure-property relationships will be discussed.
Due to the thermal expansion coefficient mismatch (CTE) between the fiber and the matrix, high residual sresses exist in metal matrix composite systems upon cool down from processing temperature to room temperature. An interface material can be placed between the fiber and the matrix to reduce the high tensile residual stresses in the matrix. A computer program was written to minimize the residual stress in the matrix subject to the interface material properties. The decision variables are the interface modulus, thickness and thermal expansion coefficient. The properties of the interface material are optimized such that the average distortion energy in the matrix and the interface is minimized. As a result, the only active variable is the thermal expansion coefficient. The optimum modulus of the interface is always the minimum allowable value and the interface thickness is always the maximum allowable value, independent of the fiber/matrix system. The optimum interface thermal expansion coefficient is always between the values of the fiber and the matrix. Using this analysis, a survey of materials was conducted for use as fiber coatings in some specific composite systems.
The stabilization of the neglected dynamics of the higher modes of vibration in large space structures is studied, and the influence of the structure of the plant noise intensity matrix of the Kalman-Bucy filter on the stability margin of the residual modes is shown. An optimization procedure uses information on the residual modes to minimize spillover of known residual modes while preserving robustness with respect to the unknown dynamics, and the optimum plant noise intensity matrix is selected to maximize the stability margins of the residual modes and to properly place the observer poles. Examples for both centralized and decentralized control are considered.
Failure analysis and testing of a prototype urine monitoring system (UMS) are reported. System performance was characterized by a regression formula developed from volume measurement test data. When the volume measurement test data. When the volume measurement data was imputted to the formula, the standard error of the estimate calculated using the regression formula was found to be within 1.524% of the mean of the mass of the input. System repeatability was found to be somewhat dependent upon the residual volume of the system and the evaporation of fluid from the separator. The evaporation rate was determined to be approximately 1cc/minute. The residual volume in the UMS was determined by measuring the concentration of LiCl in the flush water. Observed results indicated residual levels in the range of 9-10ml, however, results obtained during the flushing efficiency test indicated a residual level of approximately 20ml. It is recommended that the phase separator pumpout time be extended or the design modified to minimize the residual level.
Insect residue contamination on aircraft wings can decrease fuel efficiency in aircraft designed for natural laminar flow. Insect residues can cause a premature transition to turbulent flow, increasing fuel burn and making the aircraft less environmentally friendly. Surfaces, designed to minimize insect residue adhesion, were evaluated through flight testing on a Falcon HU-25C aircraft flown along the coast of Virginia and North Carolina. The surfaces were affixed to the wing leading edge and the aircraft remained at altitudes lower than 1000 feet throughout the flight to assure high insect density. The number of strikes on the engineered surfaces was compared to, and found to be lower than, untreated aluminum control surfaces flown concurrently. Optical profilometry was used to determine insect residue height and areal coverage. Differences in results between flight and laboratory tests suggest the importance of testing in realistic use environments to evaluate the effectiveness of engineered surface designs.
Maintenance of laminar flow under operational flight conditions is being investigated under NASA s Environmentally Responsible Aviation (ERA) Program. Among the challenges with natural laminar flow is the accretion of residues from insect impacts incurred during takeoff or landing. Depending on air speed, temperature, and wing structure, the critical residue height for laminar flow disruption can be as low as 4 microns near the leading edge. In this study, engineered surfaces designed to minimize insect residue adhesion were examined. The coatings studied included chemical compositions containing functional groups typically associated with abhesive (non-stick) surfaces. To reduce surface contact by liquids and enhance abhesion, the engineered surfaces consisted of these coatings doped with particulate additives to generate random surface topography, as well as coatings applied to laser ablated surfaces having precision patterned topographies. Performance evaluation of these surfaces included contact angle goniometry of pristine coatings and profilometry of surfaces after insect impacts were incurred in laboratory scale tests, wind tunnel tests and flight tests. The results illustrate the complexity of designing antifouling surfaces for effective insect contamination mitigation under dynamic conditions and suggest that superhydrophobic surfaces may not be the most effective solution for preventing insect contamination on aircraft wing leading edges.
The fabrication of metal matrix composites poses unique problems to the materials engineer. The large thermal expansion coefficient mismatch between the fiber and matrix leads to high tensile residual stresses at the fiber/matrix interface which could lead to premature matrix cracking during cooldown. Fiber coating could be used to reduce thermal residual stresses. A simple closed-form analysis, based on a three-phase composite cylinder model, was developed to calculate thermal residual stresses in a fiber/interface/matrix system. Guidelines, in the form of simple equations, for the selection of appropriate material properties of the fiber coating, were also derived to minimize thermal residual stresses in the matrix during fabrication.
This research reports the findings of a Landsat Next expert review panel that evaluated the use of narrow shortwave infrared (SWIR) reflectance bands to measure ligno-cellulose absorption features centered near 2100 and 2300 nm, with the objective of measuring and mapping non-photosynthetic vegetation (NPV), crop residue cover, and the adoption of conservation tillage practices within agricultural landscapes. Results could also apply to detection of NPV in pasture, grazing lands, and non-agricultural settings. Currently, there are no satellite data sources that provide narrowband or hyperspectral SWIR imagery at sufficient volume to map NPV at a regional scale. The Landsat Next mission, currently under design and expected to launch in the late 2020’s, provides the opportunity for achieving increased SWIR sampling and spectral resolution with the adoption of new sensor technology. This study employed hyperspectral data collected from 916 agricultural field locations with varying fractional NPV, fractional green vegetation, and surface moisture contents. These spectra were processed to generate narrow bands with centers at 2040, 2100, 2210, 2260, and 2230 nm, at various bandwidths, that were subsequently used to derive 13 NPV spectral indices from each spectrum. For crop residues with minimal green vegetation cover, two-band indices derived from 2210 and 2260 nm bands were top performers for measuring NPV (R^(2) = 0.81, RMSE = 0.13) using bandwidths of 30 to 50 nm, and the addition of a third band at 2100 nm increased resistance to atmospheric correction residuals and improved mission continuity with Landsat 8 Operational Land Imager Band 7. For prediction of NPV over a full range of green vegetation cover, the Cellulose Absorption Index, derived from 2040, 2100, and 2210 nm bands, was top performer (R^(2) = 0.77, RMSE = 0.17), but required a narrow (≤20 nm) bandwidth at 2040 nm to avoid interference from atmospheric carbon dioxide absorption. In comparison, broadband NPV indices utilizing Landsat 8 bands centered at 1610 and 2200 nm performed poorly in measuring fractional NPV (R^(2) = 0.44), with significantly increased interference from green vegetation
The fabrication of metal matrix composites poses unique problems to the materials engineer. The large thermal expansion coefficient (CTE) mismatch between the fiber and matrix leads to high tensile residual stresses at the fiber/matrix (F/M) interface which could lead to premature matrix cracking during cooldown. Fiber coatings could be used to reduce thermal residual stresses. A simple closed form analysis, based on a three phase composite cylinder model, was developed to calculate thermal residual stresses in a fiber/interphase/matrix system. Parametric studies showed that the tensile thermal residual stresses at the F/M interface were very sensitive to the CTE and thickness of the interphase layer. The modulus of the layer had only a moderate effect on tensile residual stresses. For a silicon carbide titanium aluminide composite, the tangential stresses were 20 to 30 pct. larger than the axial stresses, over a wide range of interphase layer properties, indicating a tendency to form radial matrix cracks during cooldown. Guidelines for the selection of appropriate material properties of the fiber coating were also derived in order to minimize thermal residual stresses in the matrix during fabrication.
The objective of this work was the development of efficient, user-friendly computer codes for optimizing fabrication-induced residual stresses in metal matrix composites through the use of homogeneous and heterogeneous interfacial layer architectures and processing parameter variation. To satisfy this objective, three major computer codes have been developed and delivered to the NASA-Lewis Research Center, namely MCCM, OPTCOMP, and OPTCOMP2. MCCM is a general research-oriented code for investigating the effects of microstructural details, such as layered morphology of SCS-6 SiC fibers and multiple homogeneous interfacial layers, on the inelastic response of unidirectional metal matrix composites under axisymmetric thermomechanical loading. OPTCOMP and OPTCOMP2 combine the major analysis module resident in MCCM with a commercially-available optimization algorithm and are driven by user-friendly interfaces which facilitate input data construction and program execution. OPTCOMP enables the user to identify those dimensions, geometric arrangements and thermoelastoplastic properties of homogeneous interfacial layers that minimize thermal residual stresses for the specified set of constraints. OPTCOMP2 provides additional flexibility in the residual stress optimization through variation of the processing parameters (time, temperature, external pressure and axial load) as well as the microstructure of the interfacial region which is treated as a heterogeneous two-phase composite. Overviews of the capabilities of these codes are provided together with a summary of results that addresses the effects of various microstructural details of the fiber, interfacial layers and matrix region on the optimization of fabrication-induced residual stresses in metal matrix composites.