Automated Magnetic Susceptibility Analysis
Microprocessor-controlled susceptometer measures cryogenic temperature dependence of ac magnetic susceptibility of small cylindrical samples.
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Microprocessor-controlled susceptometer measures cryogenic temperature dependence of ac magnetic susceptibility of small cylindrical samples.
A few Charpy samples containing a transverse EB weld at the V-notch location were produced. Three tensile specimens containing a transverse weld were also produced. These samples were tested at cryogenic temperatures. The welded Charpy samples resulted in average impact values of 20 ft-lb. This average value is as good as the NASA test samples with the base metal. The tensile specimens broke at slightly higher loads than had been calculated. The Charpy specimens did not come up to the prescribed level of 25 ft-lb. The results of the specimen tests are presented.
Design and fabrication cost drivers for cryogenic transonic wind tunnel models are defined. The major cost factors for wind tunnel models are model complexity, tolerances, surface finishes, materials, material validation, and model inspection. The cryogenic temperatures require the use of materials with relatively high fracture toughness but at the same time high strength. Some of these materials are very difficult to machine, requiring extensive machine hours which can add significantly to the manufacturing costs. Some additional engineering costs are incurred to certify the materials through mechanical tests and nondestructive evaluation techniques, which are not normally required with conventional models. When instrumentation such as accelerometers and electronically scanned pressure modules is required, temperature control of these devices needs to be incorporated into the design, which requires added effort. Additional thermal analyses and subsystem tests may be necessary, which also adds to the design costs. The largest driver to the design costs is potentially the additional static and dynamic analyses required to insure structural integrity of the model and support system.
The development of an iron-base alloy that combines the normally divergent properties of high toughness and high strength at cryogenic temperatures is discussed. Specifically, alloy properties were sought which at -196 C would exhibit a fracture toughness of 220 MPa-m(1/2) with a corresponding yield strength of 1.4 GPa (200 ksi). Early work showed that high toughness could be achieved in Fe-12Ni alloys containing reactive metal additions such as Al, Nb, Ti, and V. Further research emphasized strengthening of these tough alloys by thermomechanical processing and the addition of Cu. Results showed that high strength and high toughness could be achieved in a single alloy at temperatures as low as -196 C. An alloy with composition Fe-12Ni-9.5Al-2Cu exhibited a yield strength of 1.65 GPa with a corresponding fracture toughness of 220 MPa-m(1/2) at -196 C. Strengthening due to Cu additions to the Fe-12Ni base alloys results primarily from precipitation of Cu-rich epsilon particles approximately 20 nm in diameter. Strengthening mechanisms are discussed in terms of an elastic modulus hardening model and are supported by transimission electron microscopy examinations of selected test specimens.
Pressure measurements on the National Transonic Facility models will be made using electronically scanned pressure instrumentation. The system consists of pressure modules, a pressure calibration standard, and a system controller. The pressure modules, which must be operated above -18 C, will be housed in model-integrated designed thermally controlled containers. The Pathfinder 1 192-channel pressure package is described. Recent and planned developments to reduce the pressure module's volume per channel ratio are discussed, including the 48-channel module and a proposed 32-channel module that would be 2.54 by 2.54 by 8.13 cm. Pressure transducers capable of operating at cryogenic temperatures for dynamic and static pressure measurements are discussed.
An analysis and optimization of a mirror-actuator system for large excursion/high-frequency chopping is developed. The results of this analysis, combined with laboratory measurements of a prototype actuator operating at cryogenic temperatures, allow performance predictions to be made for a real system utilizing this technology.
The Ti-5Al-2.5Sn extremely low interstitial alloy employed in the large castings which form the critical attachment fittings of the Space Shuttle External Tank was selected because of its high fracture resistance at cryogenic temperatures. Casting was selected over alternative fabrication methods because of its lower cost and adaptability to design changes, although it was found necessary to weld-repair surface and subsurface casting defects in order to reduce the scrap rate and maintain the inherent cost advantage of the castings. Hot Isostatic Pressing was experimentally found to heal the surface and internal defects of the castings, but did not improve tensile or fracture properties and was therefore rejected as a production technique. Production castings are instead weld-repaired, without any mechanical property degradation.
A research program for the development of a 10.6 micron HgCdTe photodiode/GaAs field effect transistor amplifier package for use at cryogenic temperatures (77k). The photodiode/amplifier module achieved a noise equivalent power per unit bandwidth of 5.7 times 10 to the 20th power W/Hz at 2.0 GHz. The heterodyne sensitivity of the HgCdTe photodiode was improved by designing and building a low noise GaAs field effect transistor amplifier operating at 77K. The Johnson noise of the amplifier was reduced at 77K, and thus resulted in an increased photodiode heterodyne sensitivity.
Photolithographic techniques were employed to fabricate small Joule-Thomson refrigerators in laminated substrates. The gas passages of a J-T refrigerator are formed by etching channels as narrow as 50 microns and as shallow as 5 microns in glass plates which are laminated together. Circular refrigerators on the order of 1.5 centimeters in diameter and .75 millimeters thick were produced which cool down to cryogenic temperatures in a few seconds, using Argon or Nitrogen, with no vacuum or radiation insulation. Smaller refrigerators are developed for both faster cooldown and low refrigeration capacity applications. By using this technology, custom refrigerators can be designed to meet specific application requirements.
Three fiber composites (graphite-fiber epoxy, graphite-fiber aluminum, and graphite-fiber magnesium) are evaluated for their possible use in space applications. Using the composite mechanics theories for thermomechanical behavior embodied in the ICAN (Integrated Composites Analyzer) computer code, select composite thermal and mechanical properties are predicted and also their response to cryogenic temperatures, resembling those which occur in space applications. The predicted results are presented in graphical form as a function of the composite's laminate configuration, fiber volume ratio and the selected use temperature. These results are suitable for preliminary design purposes only and should serve as an aid in selecting controlled experiments for obtaining corresponding measured data.
Research concerning the development of pressure instrumentation for the space shuttle main engine is reported. The following specific topics were addressed: (1) transducer design and materials, (2) silicon piezoresistor characterization at cryogenic temperatures, (3) chip mounting characterization, and (4) frequency response optimization.
Research concerning the utilization of silicon piezoresistive strain sensing technology for space shuttle main engine applications is reported. The following specific topics were addressed: (1) transducer design and materials, (2) silicon piezoresistor characterization at cryogenic temperatures, (3) chip mounting characterization, and (4) frequency response optimization.
The advantages of silicon piezoresistive strain sensing technology are being used to achieve the objectives of state of the art pressure sensors for SSME applications. The integration of multiple functions on a single chip is the key attribute being exploited. Progress is reported in transducer packaging and materials; silicon resistor characterization at cryogenic temperatures; chip mounting; and frequency response optimization.
The objective of the research project described is to define and demonstrate methods to advance the state of the art of pressure sensors for the space shuttle main engine (SSME). Silicon piezoresistive technology was utilized in completing tasks: generation and testing of three transducer design concepts for solid state applications; silicon resistor characterization at cryogenic temperatures; experimental chip mounting characterization; frequency response optimization and prototype design and fabrication. Excellent silicon sensor performance was demonstrated at liquid nitrogen temperature. A silicon resistor ion implant dose was customized for SSME temperature requirements. A basic acoustic modeling software program was developed as a design tool to evaluate frequency response characteristics.
The design and performance of a tunable double-half-wave bandpass filter centered at 286 microns (Delta lambda/lambda = 0.16) and operating at cryogenic temperatures (for astronomy applications) are presented. The operating principle is explained, and the fabrication of the device, which comprises two identical mutually coupled Fabry-Perot filters with electroformed Ni-mesh reflectors and is tuned by means of variable spacers, is described. A drawing of the design and graphs of computed and measured performance are provided. Significantly improved bandpass characteristics are obtained relative to the single Fabry-Perot filter.
A model consisting of a rigid wing with an integral, flexible beam support that was cantilever mounted from the wall in the NASA LaRC 0.3-m transonic cryogenic tunnel was used in a flutter analysis study. The wing had a rectangular planform of aspect ratio 1.5 and a 64A010 airfoil. Various considerations and procedures for conducting flutter tests in a cryogenic wind tunnel were evaluated. Flutter onset conditions were established from extrapolated subcritical response measurements. A flutter boundary was determined at cryogenic temperatures over a Mach number M range from 0.5 to 0.9. Flutter was obtained at two different Reynolds numbers R at M = 0.5 (R = 4.4 and 18.4 x 10 to the 6th power) and at M = 0.8 (R = 5.0 and 10.4 x 10 to the 6th power). Flutter analyses using subsonic lifting surface (kernel function) aerodynamics were made over the range of test conditions. To evaluate the Reynolds number effects at M = 0.5 and 0.8, the experimental results were adjusted using analytical trends to account for differences in the model test temperatures and mass ratios. The adjusted experimental results indicate that increasing Reynolds number from 5.0 to 20.0 x 10 to the 6th power decreased the dynamic pressure by 4.0 to 6.5 percent at M = 0.5 and 0.8.
The effect of cooling as a fundamental limit to delay times in IC's was considered. It appears that the delay time should be decreased at cryogenic temperatures.
The results of selected studies that have been conducted by the NASA Langley Research Center in the last three years are presented. The topics presented focus primarily on the ever-important transonic flight regime and include the following: body-freedom flutter of a forward-swept-wing configuration with and without relaxed static stability; instabilities associated with a new tilt-rotor vehicle; effects of winglets, supercritical airfoils, and spanwise curvature on wing flutter; wind-tunnel investigation of a flutter-like oscillation on a high-aspect-ratio flight research wing; results of wind-tunnel demonstration of the NASA decoupler pylon concept for passive suppression of wing/store flutter; and, new flutter testing methods which include testing at cryogenic temperatures for full scale Reynolds number simulation, subcritical response techniques for predicting onset of flutter, and a two-degree-of-freedom mount system for testing side-wall-mounted models.