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NASA NTRS1999

Fabrication of Large YBCO Superconducting Disks

We have undertaken fabrication of large bulk items to develop a repeatable process and to provide test articles in laboratory experiments investigating reported coupling of electromagnetic fields with the local gravity field in the presence of rotating superconducting disks. A successful process was developed which resulted in fabrication of 30 cm diameter annular disks. The disks were fabricated of the superconductor YBa2Cu3O(7-x). Various material parameters of the disks were measured.

Koczor, Ronald J.↗

NASA NTRS1997

Optical Fabrication and Measurement AXAF and CIRS

This paper presents a final report on Optical Fabrication and Measurement AXAF (Advanced X-Ray Astrophysics Facility) and CIRS (Composite Infrared Spectrometer) from July 12, 1994 to August 16, 1996.. This paper includes specific tasks to be performed. The tasks are as follows: 1) Preparation and Characterization of Zerodur Glass Samples; 2) Develop and Fabricate AXAF and CIRS Metrology Tooling; 3) Update AXAF Technical Data Base; and 4) Perform Fabrication Related Metrology Tasks for CIRS. This paper also includes final activities from the July, 1996 report to August 1996.

Engelhaupt, Darell↗

NASA NTRS1999

Fabrication and Testing of Ceramic Matrix Composite Rocket Propulsion Components

The National Aeronautics and Space Administration (NASA) is pursuing using ceramic matrix composites (CMC) as primary structural components for advanced rocket engines. This endeavor is due to the requirement of increasing safety by two orders of magnitude and reducing costs from $10,000/lb to $1,000/lb both within ten years. Out year goals are even more aggressive. Safety gains, through using CMCS, will be realized by increasing temperature margins, tolerance for extreme thermal transients, and damping capability of components and systems, by using components with lower weight and thermal conductivity, etc. Gains in cost reduction, through using CMCS, are anticipated by enabling higher performance systems, using lighter weight components and systems, enabling 100 mission reusability without system refurbishment, greatly reducing cooling requirements and erosion rates, selecting safe fabrication processes that are ideally cost competitive with metal processes at low volume production, etc. This philosophy contrasts the previous philosophy of rocket engine development focused largely on achieving the highest performance with metals and ablatives -- cost and safety were not the focal point of the initial design. Rocket engine components currently being pursued, largely C/SiC and SiC/SiC, include blisks or rotors, 10 foot by 8 foot nozzle ramps, gas generators, thrust chambers, and upperstage nozzles. The Simplex Turbopump CMC blisk effort has just successfully completed a 4.5 year development and test program. The other components mentioned are in the design or fabrication stage. Although the temperature limits of the CMC materials are not quantified in a realistic environment yet, CMC materials are projected to be the only way to achieve significant safety risks mitigation and cost reductions simultaneously. We, the end-users, material fabricators, technology facilitators, and government organizations are charged with developing and demonstrating a much safer and a lot less costly Earth-to-Orbit full-scale propulsion system by 2005.

Effinger, Michael↗

NASA NTRS2000

p-n Junction Diodes Fabricated on Si-Si/Ge Heteroepitaxial Films

A set of photolithographic masks was designed for the fabrication of diodes in the Si-Si/Ge material system. Fabrication was performed on samples obtained from two different wafers: (1) a complete HBT structure with an n (Si emitter), p (Si/Ge base), and an n/n+ (Si collector/sub-collector) deposited epitaxially (MBE) on a high resistivity p-Si substrate, (2) an HBT structure where epitaxial growth was terminated after the p-type base (Si/Ge) layer deposition. Two different process runs were attempted for the fabrication of Si-Si/Ge (n-p) and Si/Ge-Si (p-n) junction diodes formed between the emitter-base and base-collector layers, respectively, of the Si-Si/Ge-Si HBT structure. One of the processes employed a plasma etching step to expose the p-layer in the structure (1) and to expose the e-layer in structure (2). The Contact metallization used for these diodes was a Cu-based metallization scheme that was developed during the first year of the grant. The plasma-etched base-collector diodes on structure (2) exhibited well-behaved diode-like characteristics. However, the plasma-etched emitter-base diodes demonstrated back-to-back diode characteristics. These back-to back characteristics were probably due to complete etching of the base-layer, yielding a p-n-p diode. The deep implantation process yielded rectifying diodes with asymmetric forward and reverse characteristics. The ideality factor of these diodes were between 1.6 -2.1, indicating that the quality of the MBE grown epitaxial films was not sufficiently high, and also incomplete annealing of the implantation damage. Further study will be conducted on CVD grown films, which are expected to have higher epitaxial quality.

Das, K.↗

NASA NTRS2000

Fabrication of Composite Combustion Chamber/Nozzle for Fastrac Engine

The Fastrac Engine developed by the Marshall Space Flight Center for the X-34 vehicle began as a low cost engine development program for a small booster system. One of the key components to reducing the engine cost was the development of an inexpensive combustion chamber/nozzle. Fabrication of a regeneratively cooled thrust chamber and nozzle was considered too expensive and time consuming. In looking for an alternate design concept, the Space Shuttle's Reusable Solid Rocket Motor Project provided an extensive background with ablative composite materials in a combustion environment. An integral combustion chamber/nozzle was designed and fabricated with a silica/phenolic ablative liner and a carbon/epoxy structural overwrap. This paper describes the fabrication process and developmental hurdles overcome for the Fastrac engine one-piece composite combustion chamber/nozzle.

Lawerence, T.↗

NASA NTRS2001

Fabrication of Composite Combustion Chamber/Nozzle for Fastrac Engine

Lawrence, T.↗

NASA NTRS2001

Rare-Earth Oxide (Yb2O3) Selective Emitter Fabrication and Evaluation

This investigation involved the fabrication and evaluation of rare-earth oxide selective emitters. The first goal of this study was to successfully fabricate the selective emitter samples using paper and ceramic materials processing techniques. The resulting microstructure was also analyzed using a Scanning Electron Microscope. All selective emitter samples fabricated for this study were made with ytterbium oxide (Yb2O3). The second goal of this study involved the measurement of the spectral emission and the radiated power of all the selective emitter samples. The final goal of this study involved the direct comparison of the radiated power emitted by the selective emitter samples to that of a standard blackbody at the same temperature and within the same wavelength range.

Jennette, Bryan↗

NASA NTRS2002

Design, Fabrication, Optical Testing, and Performance of Diamond Machined Aspheric Mirrors for Ground-Based Near-IR Astronomy

Challenges in fabrication and testing have historically limited the choice of surfaces available for the design of reflective optical instruments. Spherical and conic mirrors are common, but, for future science instruments, more degrees of freedom are necessary to meet challenging performance and packaging requirements. These instruments will be composed of unusual aspheres located far off-axis with large spherical departure, and some designs will require asymmetric surface profiles. In particular, single-surface astigmatism correction in spectrographs necessitates a toroidal surface, which lacks an axis of rotational symmetry. We describe the design, fabrication, optical testing, and performance of three rotationally symmetric, off-axis, aspheric mirrors and one toroidal, off-axis, biconic camera mirror on aluminum substrates for the Infrared Multi-Object Spectrograph (IRMOS) instrument. IRMOS is a facility instrument for the Kitt Peak National Observatory's Mayall Telescope (3.8 m) and an engineering prototype for a possible design of the Next Generation Space Telescope/Multi-Object Spectrograph. The symmetric mirrors range in aperture from 94x86 mm to 286x269 mm and in f-number from 0.9 to 2.4. They are various off-axis, convex and concave, prolate and oblate ellipsoids. The concave biconic mirror has a 94x76 mm aperture, Rx=377 mm, kx=0.0778, Ry=407 mm, and ky=0.1265 and is decentered. by -2 mm in x and 227 mm in y. The mirrors have an aspect ratio of approximately 4:1. The surface error fabrication tolerances are less than 63.3 nm RMS figure error and less than 10 nm RMS microroughness. The mirrors are attached to the instrument bench via a semi-kinematic, integral flexure mount. We describe mirror design, diamond machining, the results of figure testing using computer-generated holograms, and imaging and scattered light modeling and performance.

Ohl, Raymond G.↗

NASA NTRS2002

Characterization of 2219 Aluminum Produced by Electron Beam Freeform Fabrication

Researchers at NASA Langley Research Center are developing a new electron beam freeform fabrication (EB F(sup 3)) technique to fabricate metal parts. This process introduces metal wire into a molten pool created by a focused electron beam. Potential aerospace applications for this technology include ground-based fabrication of airframe structures and on-orbit construction and repair of space components and structures. Processing windows for reliably producing high quality 2219 aluminum parts using the EB F(sup 3) technique are being defined. The effects of translation speed, wire feed rate, and beam power on the resulting microstructures and mechanical properties are explored. Tensile properties (ultimate tensile strength, yield strength, and elongation) show little effect over the range of processing conditions tested. Basic processing-microstructure-property correlations are drawn for the EB F(sup 3) process.

Taminger, Karen M. B.↗

NASA NTRS2004

Highlights of the ASPE 2004 Winter Topical Meeting on Free-Form Optics: Design, Fabrication, Metrology, Assembly

We present highlights from the American Society for Precision Engineering's 2004 winter topical meeting entitled Free-Form Optics: Design, Fabrication, Metrology, Assembly. We emphasize those papers that are most relevant to astronomical optics. Optical surfaces that transcend the bounds of rotational symmetry have been implemented in novel optical systems with fantastic results since the release of Polaroid's first instant camera. Despite these successes, free-form optics have found only a few niche applications and have yet to enter the mainstream. The purpose of this meeting is to identify the state of the art of free-form optics design, fabrication, metrology and assembly and to identify the technical and logistical challenges that inhibit their widespread use. Issues that will be addressed include: What are free-form optics? How can optical systems be made better with free-form optics? How can designers use free-form optics? How can free-form optics be fabricated? How can they be measured? How are free-form optical systems assembled? Control of multi-axis systems.

Ohl, Raymond G.↗

NASA NTRS2004

Large-Scale Fabrication of Carbon Nanotube Probe Tips For Atomic Force Microscopy Critical Dimension Imaging Applications

Carbon nanotube (CNT) probe tips for atomic force microscopy (AFM) offer several advantages over Si/Si3N4 probe tips, including improved resolution, shape, and mechanical properties. This viewgraph presentation discusses these advantages, and the drawbacks of existing methods for fabricating CNT probe tips for AFM. The presentation introduces a bottom up wafer scale fabrication method for CNT probe tips which integrates catalyst nanopatterning and nanomaterials synthesis with traditional silicon cantilever microfabrication technology. This method makes mass production of CNT AFM probe tips feasible, and can be applied to the fabrication of other nanodevices with CNT elements.

Ye, Qi Laura↗

NASA NTRS2003

Thermoelectric microdevice fabricated by a MEMS-like electrochemical process

Microelectromechanical systems (MEMS) are the basis of many rapidly growing technologies, because they combine miniature sensors and actuators with communications and electronics at low cost. Commercial MEMS fabrication processes are limited to silicon-based materials or two-dimensional structures. Here we show an inexpensive, electrochemical technique to build MEMS-like structures that contain several different metals and semiconductors with three-dimensional bridging structures. We demonstrate this technique by building a working microthermoelectric device. Using repeated exposure and development of multiple photoresist layers, several different metals and thermoelectric materials are fabricated in a three-dimensional structure. A device containing 126 n-type and p-type (Bi, Sb)2Te3 thermoelectric elements, 20 microm tall and 60 microm in diameter with bridging metal interconnects, was fabricated and cooling demonstrated. Such a device should be of technological importance for precise thermal control when operating as a cooler, and for portable power when operating as a micro power generator.

Evaluation Studies↗

NASA NTRS2004

Wave Propagation in 2-D Granular Matrix and Dust Mitigation of Fabrics for Space Exploration Mission

Wave Propagation study is essential to exploring the soil on Mars or Moon and Dust Mitigation is a necessity in terms of crew's health in exploration missions. The study of Dust Mitigation has a significant impact on the crew s health when astronauts track dust back into their living space after exploration trips. We are trying to use piezoelectric fiber to create waves and vibrations at certain critical frequencies and amplitudes so that we can shake the particles off from the astronaut s fabrics. By shaking off the dust and removing it, the astronauts no longer have to worry about breathing in small and possibly hazardous materials, when they are back in their living quarters. The Wave Propagation in 2-D Granular Matrix studies how the individual particles interact with each other when a pressure wave travels through the matrix. This experiment allows us to understand how wave propagates through soils and other materials. By knowing the details about the interactions of particles when they act as a medium for waves, we can better understand how wave propagates through soils and other materials. With this experiment, we can study how less gravity effects the wave propagation and hence device a way to study soils in space and on Moon or Mars. Some scientists treat the medium that waves travel through as a "black box", they did not pay much attention to how individual particles act as wave travels through them. With this data, I believe that we can use it to model ways to measure the properties of different materials such as density and composition. In order to study how the particles interact with each other, I have continued Juan Agui's experiment of the effects of impacts on a 2-D matrix. By controlling the inputs and measuring the outputs of the system, I will be able to study now the particles in that system interact with each other. I will also try to model this with the software called PFC2D in order to obtain theoretical data to compare with the experiment. PFC2D is a program that allows the user to control the number of particle's characteristic, and the environment of the particle. With this I can run simulations that mimic the impulse test. This software uses a language called FISH, probably created by the creator of the software. This means that in order to model anything, one must use the command terminal instead of GUI's. I will also use this program to simulate the Moon/Mars simulate adhering to the fabric for the Dust Mitigation project. My goals for this summer are just to complete preliminary studies of the feasibility of the Shaking Fabric, learn the PFC-2D program, and to complete building and testing the wave propagation experiment.

Thanh, Phi Hung X.↗

NASA NTRS2004

Fabrication of a novel gigabit/second free-space optical interconnect - photodetector characterization and testing and system development

The time when computing power is limited by the copper wire inherent in the computer system and not the speed of the microprocessor is rapidly approaching. With constant advances in computer technology, many researchers believe that in only a few years, optical interconnects will begin to replace copper wires in your Central Processing Unit (CPU). On a more macroscopic scale, the telecommunications industry has already made the switch to optical data transmission as, to date, fiber optic technology is the only reasonable method of reliable, long range data transmission. Within the span of a decade, we will see optical technologies move from the macroscopic world of the telecommunications industry to the microscopic world of the computer chip. Already, the communications industry is marketing commercially available optical links to connect two personal computers, thereby eliminating the need for standard and comparatively slow wired and wireless Ethernet transfers and greatly increasing the distance the computers can be separated. As processing demands continue to increase, the realm of optical communications will continue to move closer to the microprocessor and quite possibly onto the microprocessor itself. A day may come when copper connections are used only to supply power, not transfer data. This summer s work marks some of the beginning stages of a 5 to 10 year, long-term research project to create and study a free-space, 1 Gigabit/sec optical interconnect. The research will result in a novel fabricated, chip-to-chip interconnect consisting of a Vertical Cavity Surface Emitting Laser (VCSEL) Diode linked through free space to a Metal- Semiconductor-Metal (MSM) Photodetector with the possible integration of microlenses for signal focusing and Micro-Electromechanical Systems (MEMS) devices for optical signal steering. The advantages, disadvantages, and practicality of incorporating flip-chip mounting technologies will also be addressed. My work began with the design and construction of a test setup for the experiment and then appropriate characterization of the test system. Specifically, I am involved in the characterization of a commercially available 1550nm wavelength, 5mW diode laser and a study of its modulation bandwidth. Commercially produced photodetectors as well as the incorporation of microwave technology, in the form of RF input and output, are used in the characterization procedure. The next stage involves the use of a probe station and network analyzer to characterize and test a series of photodetectors fabricated on a 2 inch, Indium Gallium Arsenide (InGaAs) wafer in the Branch s microlithography lab. Other project responsibilities include, but are not limited to the incorporation of a transimpedance amplifier to the photodetector circuit; a study of VCSEL technology; bit error rate analysis of an optical interconnect system; and analysis of free space divergence of the VCSEL, optical path length of the interconnect; and any other pertinent optical properties of the one gigabit per second interconnect for fabrication and testing.

Savich, Gregory R.↗

NASA NTRS2004

Subscale Testing of a Ceramic Composite Cooled Panel Led to Its Design and Fabrication for Scramjet Engine Testing

In a partnership between the NASA Glenn Research Center and Pratt & Whitney, a ceramic heat exchanger panel intended for use along the hot-flow-path walls of future reusable launch vehicles was designed, fabricated, and tested. These regeneratively cooled ceramic matrix composite (CMC) panels offer lighter weight, higher operating temperatures, and reduced coolant requirements in comparison to their more traditional metallic counterparts. A maintainable approach to the design was adopted which allowed the panel components to be assembled with high-temperature fasteners rather than by permanent bonding methods. With this approach, the CMC hot face sheet, the coolant containment system, and backside structure were all fabricated separately and could be replaced individually as the need occurred during use. This maintainable design leads to both ease of fabrication and reduced cost.

Jaskowiak, Martha H.↗

NASA NTRS2000

Chemical Fabrication Used to Produce Thin-Film Materials for High Power-to- Weight-Ratio Space Photovoltaic Arrays

The key to achieving high specific power (watts per kilogram) space solar arrays is the development of a high-efficiency, thin-film solar cell that can be fabricated directly on a flexible, lightweight, space-qualified durable substrate such as Kapton (DuPont) or other polyimide or suitable polymer film. Cell efficiencies approaching 20 percent at AM0 (air mass zero) are required. Current thin-film cell fabrication approaches are limited by either (1) the ultimate efficiency that can be achieved with the device material and structure or (2) the requirement for high-temperature deposition processes that are incompatible with all presently known flexible polyimide or other polymer substrate materials. Cell fabrication processes must be developed that will produce high-efficiency cells at temperatures below 400 degrees Celsius, and preferably below 300 degress Celsius to minimize the problems associated with the difference between the coefficients of thermal expansion of the substrate and thin-film solar cell and/or the decomposition of the substrate.

Hepp, Aloysius F.↗

NASA NTRS2004

Thin-Film Ceramic Thermocouples Fabricated and Tested

The Sensors and Electronics Technology Branch of the NASA Glenn Research Center is developing thin-film-based sensors for surface measurement in propulsion system research. Thin-film sensors do not require special machining of the components on which they are mounted, and they are considerably thinner than wire- or foil-based sensors. One type of sensor being advanced is the thin-film thermocouple, specifically for applications in high-temperature combustion environments. Ceramics are being demonstrated as having the potential to meet the demands of thin-film thermocouples in advanced aerospace environments. The maximum-use temperature of noble metal thin-film thermocouples, 1500 C (2700 F), may not be adequate for components used in the increasingly harsh conditions of advanced aircraft and next-generation launch vehicles. Ceramic-based thermocouples are known for their high stability and robustness at temperatures exceeding 1500 C, but are typically in the form of bulky rods or probes. As part of ASTP, Glenn's Sensors and Electronics Technology Branch is leading an in-house effort to apply ceramics as thin-film thermocouples for extremely high-temperature applications as part of ASTP. Since the purity of the ceramics is crucial for the stability of the thermocouples, Glenn's Ceramics Branch and Case Western Reserve University are developing high-purity ceramic sputtering targets for fabricating high-temperature sensors. Glenn's Microsystems Fabrication Laboratory, supported by the Akima Corporation, is using these targets to fabricate thermocouple samples for testing. The first of the materials used were chromium silicide (CrSi) and tantalum carbide (TaC). These refractory materials are expected to survive temperatures in excess of 1500 C. Preliminary results indicate that the thermoelectric voltage output of a thin-film CrSi versus TaC thermocouple is 15 times that of the standard type R (platinum-rhodium versus platinum) thermocouple, producing 20 mV with a 200 C temperature gradient. The photograph on the left shows the CrSi-TaC thermocouple in a test fixture at Glenn, and the resulting output signal is shown on the right. The temperature differential across the sample, from the center of the sample inside the oven to the sample mount outside the oven, is measured using a type R thermocouple on the sample.

Wrbanek, John D.↗

NASA NTRS2002

High-Strength Composite Fabric Tested at Structural Benchmark Test Facility

Large sheets of ultrahigh strength fabric were put to the test at NASA Glenn Research Center's Structural Benchmark Test Facility. The material was stretched like a snare drum head until the last ounce of strength was reached, when it burst with a cacophonous release of tension. Along the way, the 3-ft square samples were also pulled, warped, tweaked, pinched, and yanked to predict the material's physical reactions to the many loads that it will experience during its proposed use. The material tested was a unique multi-ply composite fabric, reinforced with fibers that had a tensile strength eight times that of common carbon steel. The fiber plies were oriented at 0 and 90 to provide great membrane stiffness, as well as oriented at 45 to provide an unusually high resistance to shear distortion. The fabric's heritage is in astronaut space suits and other NASA programs.

Krause, David L.↗