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All sourcesNASA NTRSDOE OSTI
NASA NTRS2023

Shock- and Corrosion-Resistant Bearings for Space Mechanisms

Nickel-titanium (NiTi) alloys are an emerging class of materials for rolling element bearing applications that require superior corrosion resistance and/or high load capability. Certain space mechanisms fall into one or both of those categories. Often, due to size and mass considerations, space mechanism systems are limited in torque margin and necessarily require small, precision-instrument bearings with very little frictional drag (i.e., low torque). In addition, space mechanism bearings must survive launch conditions without suffering raceway dents known as brinnelling, which would increase operating torque and reduce overall smoothness. Consequently, a bearing material or design that reduces or eliminates brinnelling under high contact stress conditions would represent a beneficial technology advancement. One specific alloy, nickel-titanium-hafnium (NiTi-Hf), under development for several years at the NASA Glenn Research Center as a bearing material, has the potential to mitigate concerns about brinnelling under extreme load conditions due to its unusually high elastic strain capability. In the present work, a sample of small precision bearings produced with three different ball materials (steel, ceramic, and NiTi-Hf) is subjected to a range of load conditions sufficient to dent the races. The dent depth as a function of load is compared and demonstrates that NiTi-Hf has the potential to increase bearing load capacity from the perspective of brinnelling under severe load conditions; additional testing of full NiTi-Hf bearings demonstrates corrosion resistance superior to that of 440C bearings.

Bearings↗
NASA NTRSDate not supplied

Space Environmental Effects on Additively Manufactured (AM) Parts on MISSE-9/10

The Materials on International Space Station Experiment (MISSE) experiments have made a continuous presence on the ISS and allowed for testing of performance and durability of materials exposed to the Low Earth Orbit (LEO) space environment. Additive Manufacturing (AM) has been included on several MISSE flights, and many companies (Made in Space and Stratasys) and NASA centers wanted to test various AM material samples. The goal of studying Space Environmental Effects on AM Parts with MISSE 9/10 was to fly promising metal and polymer AM material samples (dogbones) that could have future manufacturing capabilities in space and conduct post-flight analysis of these materials via mechanical and optical properties. On these flights, MISSE-9 contained three Inconel and 12 polymer samples and MISSE-10 included three Inconel and 16 polymer samples. Before flying to the ISS, all the samples underwent thermal vacuum bakeout (at 60°C for 24 hours and 10-6 torr). After bakeout, control and flight experiments were weighed, and optical properties were taken. Optical properties such as solar absorptance and infrared emittance were taken on the control samples and the flight samples (preflight and postflight). To understand more about the mechanical properties of the AM samples, tensile testing was conducted on the samples to determine the yield and ultimate tensile strength of the dogbone samples against the control. Lastly, the torque on the fasteners securing the dogbone samples were loosened and measured using a torque wrench, and they were compared to their preflight torque specification required. Optical properties and masses were recorded before flight, and the postflight results were recorded and collected in June 2022 to study the effects. With the postflight analysis, NASA engineers can now better characterize how UV radiation and thermal cycling affect the material properties.

Materials on International Space Station Experimen↗
NASA NTRSDate not supplied

TRIDENT Drill Validation at Mars and Lunar Analog Field Sites

Drilling on Earth is typically a human-intensive activity. Drilling on other planets is further complicated by the lack of prior local field surveys of their target area, hence blindly drilling into uncertain target rocks. Field conditions on the Moon or Mars are also different than for shallow drilling on Earth: lower temperatures and pressures, less power available, low masses (hence less weight-on-bit). Given the cost of transport from Earth, no drilling muds or working fluids are likely to be available to carry away cuttings. And impact-gardened regolith and dust vary mechanically and texturally from most terrestrial soils. The Regolith and Ice Drill for Exploration of New Terrains (TRIDENT) is a rotary-percussive 1m-class drill from Honeybee Robotics. It is low-power (rotary and percussive actuators are 200 W each) and lightweight (<20 kg) with the maximum weight on bit limited to 200 N. TRIDENT has been manifested for the Volatiles Investigating Polar Exploration Rover (VIPER) and PRIME-1 lunar south pole missions in 2024, has previously been field tested at a hot, dry analog site in the Atacama Desert, and in lunar conditions in thermal vacuum chamber tests. TRIDENT was also part of the 2019 Icebreaker Mars Discovery proposal, as well as in the Mars Life Explorer concept. During ARADS tests, drill control and fault recovery automation software enabled hands-off operations of a rover-mounted TRIDENT drill. TRIDENT Drill Analog Site Validation: Past TRIDENT tests in thermal vacuum (TVAC) chambers targeted containers of manufactured lunar simulants with added volatiles. 2022 TRIDENT ambient testing at NASA Ames drilled into cemented lunar simulant materials. Low cuttings-permeability led to cuttings buildup, and drill choking and binding was observed. The Atacama analog site in ARADS had desiccated unconsolidated sediments that did not challenge the TRIDENT design. However, lunar polar regolith is expected to be diverse and heterogeneous with varying clast sizes, with abundant impactites and perhaps subsurface ice deposits. Neither the simulants nor Atacama testing had completely covered the TRIDENT-targeted field characteristics, motivating further analog tests prior to the planned lunar missions. To gain more insight into the behavior of the TRIDENT hardware in diverse impactites and subsurface ice, and to verify the software automation in that environment, in August 2023 TRIDENT was brought to Haughton Crater, a field analog site in the Canadian Arctic. In September 2023 the same drill was brought to the Bishop Tuff in southern California to verify whether drilling binding behaviors previously seen in lunar simulant testing would be observed in naturally occurring fine-grained massive layers. The ~22 Ma Haughton Crater impact structure is located at 75 ̊22’ N, 89 ̊41’ W, on northwestern Devon Island, Nunavut, Canada. Numerous deposits of pale-grey crater-fill polymictic impact-melt breccia are found within the crater with a typical thickness reaching ~125 m or greater and covering ~60 km -2 . An approximately 600m-thick permafrost layer is also present with ice typically found within 0.5-0.6m of the surface. The volcanic tableland north of Bishop, CA exposes densely welded tuff laid down during the eruption that created the Long Valley Caldera at approximately 0.76 Ma. Extensional faults and the Owens River gorge expose cross-sections across the plateau. The area is viewed as an analog site for Mars features believed to be of pyroclastic origin. Results: Haughton Crater.Drilling tests were conducted 8-13 August 2023 at a previously undisturbed area separated 5-10 m from past years’ Drill Hill test sites (75.4208, -089.7613). In six days, TRIDENT drilled 8 holes to nearly 1 m depth each, totaling 7.80 m. The active layer/ice boundary was at ~67 cm depth, with a total of approximately 2.4 m drilled into ice or ice-cemented impact breccia. During drilling, five drill fault states were observed and successfully recovered. Holes 23-1, 4 and 7 were drilled under manual control, using Honeybee’s Thorax user interface. Holes 23-5, 6, and 8 were drilled with the Ames IBexec automated drilling control software. TRIDENT was observed to have little difficulty in the thawed uncemented impact breccia above the active layer boundary, but required percussion to make slower headway in the ice-cemented breccia. In Hole 23-7 (Fig.1), drilling slowed down in a massive unit just above the active-layer boundary (perhaps a large rock extending into the ice-cementation?), with only 7cm progress made in 27 minutes of high auger torque and constant percussion, leading to a choking fault and then a binding fault. A similar pattern had been observed in TRIDENT Rio Tinto test data from 2017 [6] as well as in the 2022laboratory tests.Bishop Tuff.A team from NASA Ames and the US Geological Survey deployed the same TRIDENT drill to Bishop Sites 1B and 1C (37.4203, -118.4289; 37.4265, -118.4215) on 13-16 September 2023, on the Bishop Tuff plateau. A third drill site was used 17-18 September 2023(37.4598, -118.3667) in an abandoned pumice mine. Four holes (totaling 2.5m depth) were drilled into the fine-grained, meters-thick tuff units at Sites 1B and 1C, and a further two boreholes (totaling 1.98m depth) were made at the pumice site. Drill behavior in the tuff below 10 cm depth was similar to that seen at 65-74 cm depth in Haughton Hole 23-7 (Fig. 1) and that seen in the 2022 lab simulant drilling. Drill safety torque limits were exceeded multiple times resulting in drill stops downhole. These freezes then required external added torques (with a pipe wrench) to resume rotation, to unstick the drill for withdrawal. To prevent this choking and binding behavior we found that more-frequent cuttings removal was necessary, e.g., reducing the “drill bite” size from the nominal 10 cm to 2 cm per bite --bringing the auger up to the surface more frequently, as seen in Bishop Site 1C Hole 2 (Fig.2). This permitted slow progress without drill binding and without external interventions. Conversely, TRIDENT drilling in the more porous pumice target material showed no cuttings buildup issue, and single bites as large as 40 cm were demonstrated. Discussion: We observed that TRIDENT easily penetrated unconsolidated heterogeneous soils (both above the active layer boundary at Haughton and previously in the Atacama). Cemented or consolidated targets that were cuttings-permeable (icy impact breccia, pumice) required more energy applied and percussion. However, in non-cuttings-permeable targets (welded microporous tuff, cemented simulants, boulder) TRIDENT was observed to be prone to excessive cuttings accumulation leading to choking/binding faults and stalling. The wedge cutting bit, used by TRIDENT in field tests and in its flight versions, pulverizes the target rock and creates fine cuttings that ideally are transported up the auger spirals for removal. In porous, fractured or vesicular target materials (such as at the Bishop pumice site) a significant portion of the cuttings are pushed aside, but for non-fractured, microporous targets the cuttings remain in the borehole and accumulate. Rock powder is relatively incompressible as a working fluid at only 100-200N downward force (TRIDENT limits) and hence eventual drilling progress slows or stops. Our recommended strategy for improving TRIDENT cuttings removal in massive target units with low cuttings-permeability is to reduce TRIDENT bite sizes when encountering these units, from 10cm to as little as 1-2cm, to effectively bail the accumulating cuttings. This approach was demonstrated to reduce choking and allowed slow progress to continue in cuttings-impermeable microporous target units (viz. the Bishop tuff in our September 2023 tests or cemented simulants in 2022 ambient tests).

robotic drilling↗
NASA NTRS2024

Optimal Control Allocation for Distributed Electric Propulsion in a Series/Parallel Partial Hybrid Powertrain

The SUbsonic Single Aft eNgine (SUSAN) Electrofan is a NASA concept jet transport aircraft with a 2040 entry-into-service date. It utilizes electrified aircraft propulsion (EAP) to enable propulsive and aerodynamic benefits to reduce fuel usage, emissions, and cost. The powertrain consists of a single thrust producing, boundary layer-ingesting (BLI) turbofan gas turbine engine (GTE) with generators driving a series/parallel partial hybrid EAP system. The architecture includes 16 underwing contrarotating BLI fans, eight on each side, in a mailslot configuration. The 16 fans run on power extracted from the GTE through four 5 MW motor/generators connected to the Low-Pressure Spool, and a single 1 MW motor/generator on the High-Pressure Spool. The distributed fans can be used by the flight control to augment or replace the rudder function. At top of climb, the power extracted from the GTE for the fans is boosted by batteries. The design provides redundancy, and the capacity for boost means that the fans are designed to be able to provide additional thrust when necessary. These features can be leveraged in case of a fan or generator failure. This paper sets up the optimal control problem of setpoint determination for individual fans in the distributed propulsion system, accounting for electrical string efficiencies, saturations, and failures. The solution minimizes power consumption while maintaining thrust and torque on the airframe for maneuvering. Additionally, thrust that would have been lost due to temporary fan speed or power saturation is optimally redistributed to maintain overall desired thrust and torque on the aircraft. The power extraction range constraints derive from the gas turbine engine design and the small amount of variation allowed for the engine to maintain operability. The problem formulation allows the number and location of fan failures for which the thrust and torque can be maintained to be investigated, which has implications for certification. Simulations of a coordinated turn utilizing the distributed electric propulsion for yaw rate control under different failure scenarios demonstrate the robustness of the powertrain design to failures and help define its limitations.

Distributed Electric Propulsion↗
NASA NTRS1959

Some effects of vibration and rotation on the drift of gyroscopic instruments

It is the purpose of this paper to describe and indicate possible analytical approaches to some of the most significant mechanisms by which vibration induced drifts may occur, and to indicate, where possible, some means of alleviating them. In all cases we will not consider gimbal bearing friction, mass unbalance or other sources of steady extraneous torques on the gyro rotor. The mechanisms to be discussed are: Non-Newtonian viscosity in single degree of freedom (SDF) integrating-rate gyros, nonisoelasticity in SDF gyros, noncommutative effects for SDF stabilized platform, gimbal inertia effects, 2 DF gyros, and spin axis torque coupling in 2 DF gyros. High-frequency elastic resonances are not discussed explicitly in detail, because they are a more familiar problem and one which depends strongly on the details of each particular gyro design.

Viscous Torque↗
NASA NTRS2000

Role of muscle pulleys in producing eye position-dependence in the angular vestibuloocular reflex: a model-based study

It is well established that the head and eye velocity axes do not always align during compensatory vestibular slow phases. It has been shown that the eye velocity axis systematically tilts away from the head velocity axis in a manner that is dependent on eye-in-head position. The mechanisms responsible for producing these axis tilts are unclear. In this model-based study, we aimed to determine whether muscle pulleys could be involved in bringing about these phenomena. The model presented incorporates semicircular canals, central vestibular pathways, and an ocular motor plant with pulleys. The pulleys were modeled so that they brought about a rotation of the torque axes of the extraocular muscles that was a fraction of the angle of eye deviation from primary position. The degree to which the pulleys rotated the torque axes was altered by means of a pulley coefficient. Model input was head velocity and initial eye position data from passive and active yaw head impulses with fixation at 0 degrees, 20 degrees up and 20 degrees down, obtained from a previous experiment. The optimal pulley coefficient required to fit the data was determined by calculating the mean square error between data and model predictions of torsional eye velocity. For active head impulses, the optimal pulley coefficient varied considerably between subjects. The median optimal pulley coefficient was found to be 0.5, the pulley coefficient required for producing saccades that perfectly obey Listing's law when using a two-dimensional saccadic pulse signal. The model predicted the direction of the axis tilts observed in response to passive head impulses from 50 ms after onset. During passive head impulses, the median optimal pulley coefficient was found to be 0.21, when roll gain was fixed at 0.7. The model did not accurately predict the alignment of the eye and head velocity axes that was observed early in the response to passive head impulses. We found that this alignment could be well predicted if the roll gain of the angular vestibuloocular reflex was modified during the initial period of the response, while pulley coefficient was maintained at 0.5. Hence a roll gain modification allows stabilization of the retinal image without requiring a change in the pulley effect. Our results therefore indicate that the eye position-dependent velocity axis tilts could arise due to the effects of the pulleys and that a roll gain modification in the central vestibular structures may be responsible for countering the pulley effect.

NASA Discipline Neuroscience↗
NASA NTRS1998

Role of vestibular information in initiation of rapid postural responses

Patients with bilateral vestibular loss have difficulty maintaining balance without stepping when standing in tandem, on compliant surfaces, across narrow beams, or on one foot, especially with eyes closed. Normal individuals (with no sensory impairment) maintain balance in these tasks by employing quick, active hip rotation (a "hip strategy"). The absence of a hip strategy in vestibular patients responding to translations of a short support surface has previously been taken as evidence that the use of hip strategy requires an intact vestibular system. However, many tasks requiring hip strategy alter one or a combination of important system characteristics, such as initial state of the body (tandem stance), dynamics (compliant surfaces), or biomechanical limits of stability (narrow beams). Therefore, the balance deficit in these tasks may result from a failure to account for these support surface alterations when planning and executing sensorimotor responses. In this study, we tested the hypothesis that vestibular information is critical to trigger a hip strategy even on an unaltered support surface, which imposes no changes on the system characteristics. We recorded the postural responses of vestibular patients and control subjects with eyes closed to rearward support surface translations of varying velocity, in erect stance on a firm, flat surface. Subjects were instructed to maintain balance without stepping, if possible. Faster translation velocities (25 cm/s or more) produced a consistent pattern of early hip torque (first 400 ms) in control subjects (i.e., a hip strategy). Most of the patients with bilateral vestibular loss responded to the same translation velocities with similar torques. Contrary to our hypothesis, we conclude that vestibular function is not necessary to trigger a hip strategy. We postulate, therefore, that the balance deficit previously observed in vestibular patients during postural tasks that elicit a hip strategy may have been due to the sensorimotor consequences of the system alterations imposed by the postural tasks used in those studies. Preliminary results from two younger patients who lost vestibular function as infants indicate that age, duration of vestibular loss, and/or the timing of the loss may also be factors that can influence the use of hip strategy as a rapid postural response.

NASA Discipline Neuroscience↗
NASA NTRS1967

Circuit increases capability of hysteresis synchronous motor

Frequency and phase detector circuit enables a hysteresis synchronous motor to drive a load of given torque value at a precise speed determined by a stable reference. This technique permits driving larger torque loads with smaller motors and lower power drain.

Markowitz, I. N.↗
NASA NTRS1970

Alignment of oblique rotators

Pulsar slowdown by radiation field torques indicated by alignment torque in magnetized oblique sphere rotating in vacuum

Goldwire, H. C., Jr.↗
NASA NTRS1972

Comparison of conventional and microasperity elastohydrodynamic lubrication of a ballspinning in a nonconforming groove

An analysis was developed for the microasperity elastohydrodynamic lubrication of a ball spinning in a nonconforming groove. This analysis was compared to the conventional elastohydrodynamic analysis of a ball spinning in a nonconforming groove. Rheological models for a di-2-ethylhexyl sebacate, a super-refined naphthenic mineral oil, and a polyphenyl ether (5P4E) were constructed from spinning torque data by using both analyses. The value of the lubricant pressure-viscosity coefficient that makes the data fit the analyses of the fluids differs somewhat from published data. For all three lubricants, an exponential composite model best described the lubricant rheology. Good agreement existed with the experimental and analytical values of torque for both the conventional and microasperity elastohydrodynamic analysis for a spinning ball in a nonconforming groove.

Allen, C. W.↗
NASA NTRS1972

New circumferential seal design concept using self-acting lift geometries

Seal operating temperatures, leakage (pressurizing gas flow), torque, and wear of a conventional circumferential shaft seal were measured and compared to those of a conventional seal modified to have self-acting lift geometries. Both seal types had a 2.625-in diameter bore and were operated at a sliding velocity of 150 ft/sec with differential pressures ranging from 0 to 100 psi. Results of this investigation show that the self-acting seal operated at lower bulk carbon temperatures with half the torque and approximately one-tenth the wear of the conventional seal. Seal leakage of the self-acting seal was of order of 0.04 scfm for pressures above 60 psi which is well within the accepted range for gas turbine engine applications.

Hady, W. F.↗
NASA NTRS1972

Development of a space qualified high reliability rotary actuator. Volume 1: Technical report

A space-qualified, high reliability, 150 ft-lb rated torque rotary acutator based on the Bendix Dynavector drive concept was developed. This drive is an integrated variable reluctance orbit motor-epicyclic transmission actuator. The performance goals were based on future control moment gyro torquer applications and represent a significant advancement in the torque-to-weight ratio, backlash, inertia and response characteristics of electric rotary drives. The program accomplishments have been in two areas: (1) the development of two high ratio (818:1) actuator configurations (breadboard and flightweight), and (2) the invention of a reliable proximity switch sensor system for self-commutation without use of optical or electrical brush techniques.

Presley, R. W.↗
NASA NTRS1972

Development of a space qualified high reliability rotary actuator for spaceflight use. Volume 2: Appendices to technical report

A space-qualified, high reliability, 150 ft-lb rated torque rotary actuator is described. This drive is an integrated variable reluctance orbit motor-epicyclic transmission actuator. The performance goals were based on future control moment gyrotorquer applications and represent an advancement in the torque-to-weight ratio, backlash, inertia and response characteristics of electric rotary drives. The program accomplishments have been in two areas (1) the development of two high ratio (818:1) actuator configurations (breadboard and flightweight) and (2) the invention of a reliable proximity switch sensor system for self-commutation without use of optical or electrical brush techniques.

Presley, R. W.↗
NASA NTRS1972

Attitude stability and performance of a dual-spin satellite with nutation damping.

Previous work of Anand and al. (1969) on the effect of aerodynamic torques on the steady-state behavior of a slowly spinning satellite without damping is extended to consideration of the effects of external torques and of a nutational damper on the transient and state motions of a satellite. Both the transient and steady-state behaviors are analyzed, and the attitude errors relative to a fixed star are established. The results indicate that, in the case of a particular satellite to be used for charting X-ray emitting sources in the celestial sphere, the effect of a nutational damper on the accuracy of the charting computations is significant.

Anand, D. K.↗
NASA NTRS1973

High pressure space suit glove

The High Pressure Space Suit Glove Program yielded one prototype glove assembly with an operating pressure of 8.0 psi. The following developments are reported: (1) A new layup technique for incorporation of the mini-convolute systems; (2) modification in the mini-convolute construction to assure cycle life at 8.0 psi in excess of 100,000 cycles; (3) the development of a unique non-orthogonal low torque wrist joint; (4) the development of a low torque single axis joint for use in the thumb and finger first metacarpal joints; and (5) a number of approaches to 1st metacarpal joints were fabricated and tested to establish the joint technqiues.

Elkins, W.↗
NASA NTRS1973

Active transmission isolation/rotor loads measurement system

Modifications were incorporated into a helicopter active transmission isolation system to provide the capability of utilizing the system as a rotor force measuring device. These included; (1) isolator redesign to improve operation and minimize friction, (2) installation of pressure transducers in each isolator, and (3) load cells in series with each torque restraint link. Full scale vibration tests performed during this study on a CH-53A helicopter airframe verified that these modifications do not degrade the systems wide band isolation characteristics. Bench tests performed on each isolator unit indicated that steady and transient loads can be measured to within 1 percent of applied load. Individual isolator vibratory load measurement accuracy was determined to be 4 percent. Load measurement accuracy was found to be independent of variations in all basic isolator operating characteristics. Full scale system load calibration tests on the CH-53A airframe established the feasibility of simultaneously providing wide band vibration isolation and accurate measurement of rotor loads. Principal rotor loads (lift, propulsive force, and torque) were measured to within 2 percent of applied load.

Kenigsberg, I. J.↗