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Iterating on a Design – Further Developments in the Evolution of the Ballistic Limit Equations for the Mars Sample Return Project

The goal of the Mars Sample Return–Capture, Containment, and Return System Project is to retrieve samples launched from the Martian surface and return them to Earth for detailed analysis. An important part of this project is the design of the system’s micrometeoroid protection system, which protects the Earth Entry System and the collected samples during their journey back to Earth. As mission parameters and the micrometeoroid and orbital debris threat became better understood, the design of the micrometeoroid protection system evolved. A key element used in the shield development process is the ballistic limit equation, which is an equation that is used to determine whether or not a particular structural element or system will end up in a failed state as a result of a specified impact. As the design of the Earth Entry System and the micrometeoroid protection system evolved, a new set of ballistic limit equations was needed to better predict and assess the performance of developing shield system designs in anticipation of possible damage from micrometeoroid and orbital debris particle impacts. This paper provides a summary of how a set of initial BLEs were either extended or modified so that the resulting equations were better suited to new types of target configurations being considered, as well as how additional ballistic limit equations were developed where none previously existed.

William P Schonberg↗

Design and Testing of a Prototype Lunar or Planetary Surface Landing Research Vehicle (LPSLRV)

This handbook describes a two-semester senior design course sponsored by the NASA Office of Education, the Exploration Systems Mission Directorate (ESMD), and the NASA Space Grant Consortium. The course was developed and implemented by the Mechanical and Aerospace Engineering Department (MAE) at Utah State University. The course final outcome is a packaged senior design course that can be readily incorporated into the instructional curriculum at universities across the country. The course materials adhere to the standards of the Accreditation Board for Engineering and Technology (ABET), and is constructed to be relevant to key research areas identified by ESMD. The design project challenged students to apply systems engineering concepts to define research and training requirements for a terrestrial-based lunar landing simulator. This project developed a flying prototype for a Lunar or Planetary Surface Landing Research Vehicle (LPSRV). Per NASA specifications the concept accounts for reduced lunar gravity, and allows the terminal stage of lunar descent to be flown either by remote pilot or autonomously. This free-flying platform was designed to be sufficiently-flexible to allow both sensor evaluation and pilot training. This handbook outlines the course materials, describes the systems engineering processes developed to facilitate design fabrication, integration, and testing. This handbook presents sufficient details of the final design configuration to allow an independent group to reproduce the design. The design evolution and details regarding the verification testing used to characterize the system are presented in a separate project final design report. Details of the experimental apparatus used for system characterization may be found in Appendix F, G, and I of that report. A brief summary of the ground testing and systems verification is also included in Appendix A of this report. Details of the flight tests will be documented in a separate flight test report. This flight test report serves as a complement to the course handbook presented here. This project was extremely ambitious, and achieving all of the design and test objectives was a daunting task. The schedule ran slightly longer than a single academic year with the complete design closure not occurring until early April. Integration and verification testing spilled over into late May and the first flight did not occur until mid to late June. The academic year at Utah State University ended on May 8, 2010. Following the end of the academic year, testing and integration was performed by the faculty advisor, paid research assistants, and volunteer student help

Murphy, Gloria A.↗

Formal Methods Case Studies for DO-333

RTCA DO-333, Formal Methods Supplement to DO-178C and DO-278A provides guidance for software developers wishing to use formal methods in the certification of airborne systems and air traffic management systems. The supplement identifies the modifications and additions to DO-178C and DO-278A objectives, activities, and software life cycle data that should be addressed when formal methods are used as part of the software development process. This report presents three case studies describing the use of different classes of formal methods to satisfy certification objectives for a common avionics example - a dual-channel Flight Guidance System. The three case studies illustrate the use of theorem proving, model checking, and abstract interpretation. The material presented is not intended to represent a complete certification effort. Rather, the purpose is to illustrate how formal methods can be used in a realistic avionics software development project, with a focus on the evidence produced that could be used to satisfy the verification objectives found in Section 6 of DO-178C.

Cofer, Darren↗

A smoke generator system for aerodynamic flight research

A smoke generator system was developed for in-flight vortex flow studies on the F-18 high alpha research vehicle (HARV). The development process included conceptual design, a survey of existing systems, component testing, detailed design, fabrication, and functional flight testing. Housed in the forebody of the aircraft, the final system consists of multiple pyrotechnic smoke cartridges which can be fired simultaneously or in sequence. The smoke produced is ducted to desired locations on the aircraft surface. The smoke generator system (SGS) has been used successfully to identify vortex core and core breakdown locations as functions of flight condition. Although developed for a specific vehicle, this concept may be useful for other aerodynamic flight research which requires the visualization of local flows.

Richwine, David M.↗

A methodology for collecting valid software engineering data

An effective data collection method for evaluating software development methodologies and for studying the software development process is described. The method uses goal-directed data collection to evaluate methodologies with respect to the claims made for them. Such claims are used as a basis for defining the goals of the data collection, establishing a list of questions of interest to be answered by data analysis, defining a set of data categorization schemes, and designing a data collection form. The data to be collected are based on the changes made to the software during development, and are obtained when the changes are made. To insure accuracy of the data, validation is performed concurrently with software development and data collection. Validation is based on interviews with those people supplying the data. Results from using the methodology show that data validation is a necessary part of change data collection. Without it, as much as 50% of the data may be erroneous. Feasibility of the data collection methodology was demonstrated by applying it to five different projects in two different environments. The application showed that the methodology was both feasible and useful.

Basili, Victor R.↗

Development of the Flight Tether for ProSEDS

The Propulsive Small Expendable Deployer System (ProSEDS) space experiment will demonstrate the use of an electrodynamic tether propulsion system to generate thrust in space by decreasing the orbital altitude of a Delta 11 Expendable Launch Vehicle second stage. ProSEDS will use the flight-proven Small Expendable Deployer System to deploy a newly designed and developed tether which will provide tether generated drag thrust of approx. 0.4 N. The development and production of very long tethers with specific properties for performance and survivability will be required to enable future tether missions. The ProSEDS tether design and the development process may provide some lessons learned for these future missions. The ProSEDS system requirements drove the design of the tether to have three different sections of tether each serving a specialized purpose. The tether is a total of 15 kilometers long: 10 kilometers of a non-conductive Dyneema lead tether; 5 km of CCOR conductive coated wire; and 220 meters of insulated wire with a protective Kevlar overbraid. Production and joining of long tether lengths involved many development efforts. Extensive testing of tether materials including ground deployment of the full-length ProSEDS tether was conducted to validate the tether design and performance before flight.

Curtis, Leslie↗

Towards an Enhanced Droplet Activation Scheme for Multi-Moment Bulk Microphysics Schemes

Initial droplet spectra produced upon activation impact the ensuing chain of microphysical processes andtherefore play a crucial role in cloud evolution. This work re-examines dependencies of newly formed clouddroplet size distribution (CDSD) characteristics on environmental and aerosol properties via parcel model simulationsthat serve as the basis for a multi-moment bulk microphysics droplet activation scheme suitable for acloud-resolving model (CRM). It is found that applying a fixed size threshold to define activated droplets versusemploying physical considerations can lead to erroneous activation and overly broad CDSDs for high aerosolconcentration and weak updraft conditions. Aerosol distributions characterized by larger median sizes and/orincreased solubility can result in greater activated droplet numbers, whereas impacts of these parameters onCDSD spectral width depend on both aerosol number concentration and updraft velocity. An expansion of theactivation scheme to include CDSD spectral width is proposed to aid efforts to extend high-order momentprediction to cloud droplet categories in CRMs as well as better represent variability in the activation process onthe cloud scale.simulations to investigate the regime dependence of the relative dispersion(d)1 of newly activated CDSDs, where d is the ratio of dropletradius standard deviation (σ) to the mean radius (r ). C16 demonstratedthat increasing Na resulted in increasing (decreasing) d values via reducedcondensational narrowing (spectral broadening) rates within theAL (UL) regime, with d values peaking in the TR regime. Their findingssuggest a similar regime dependence for d as R09 noted for Nc and helpexplain reportedly conflicting relationships between Na and CDSDspectral characteristics (cf. Hudson and Noble, 2014; Liu et al., 2014),although the applicability of these results within bulk microphysicalschemes was not addressed.Simulating aerosol-cloud interactions with CRMs employing bulkmicrophysics requires that the scheme minimally predict two CDSDparameters, namely mass and number concentrations, and represent thedroplet activation process. Various activation schemes aim to determineNc from aerosol and environmental properties and include analyticalexpressions (e.g., Abdul-Razzak et al., 1998; Morrison et al., 2005) aswell as lookup tables (LUTs) based on detailed parcel model calculations(e.g., Saleeby and Cotton, 2004, hereafter SC04; Segal and Khain,2006; Thompson and Eidhammer, 2014). Expressions to diagnose CDSDspectral width from Nc (Grabowski, 1998; Liu et al., 2006; Morrison andGrabowski, 2007) or cloud water content (Geoffroy et al., 2010) havealso been developed, although more robust methods to obtain CDSDspectral width upon activation are presently lacking. This latter point isrelevant for triple-moment (3 M) bulk microphysics that aim to predictdistribution spectral width alongside number and mass concentrations(e.g., Loftus et al., 2014; Milbrandt and Yau, 2005).The current work extends the findings of C16 to the current LUTbasedaerosol activation scheme used in the Regional AtmosphericModeling System (RAMS) (Cotton et al., 2003; SC04; Saleeby and vanden Heever, 2013, hereafter SvdH13) and additionally examinesaerosol size and solubility impacts on newly activated CDSD properties.Because early cloud development processes such as condensationalgrowth, evaporation, and droplet self-collection depend on and impactCDSD spectral width (Hudson and Yum, 1997; Seifert and Beheng 2001;Lu and Seinfeld, 2006; Igel and van den Heever, 2017), an expansion ofthe activation LUTs to include CDSD spectral width is proposed as apreliminary step for extending 3M prediction to CDSDs in CRMs forimproved simulations of aerosol-cloud interactions.2. MethodologyThe current RAMS two-moment microphysics module determinesthe fractional number of aerosol particles that activate to cloud dropletsfrom five-dimensional LUTs based on model predicted air temperature(T), w, Na, and the geometric median radius (rg) and soluble fraction (ε)of the aerosol size distribution (SvdH13). These LUTs are created offlineusing a one-dimensional Lagrangian adiabatic parcel model (Feingoldand Heymsfield, 1992; Heymsfield and Sabin, 1989; SC04) to simulateexplicit droplet activation and initial CDSD growth for a range of ambientatmospheric conditions [T, w] and binned lognormal aerosol sizedistributions given by= ⎡⎣ ⎢− ⎤⎦ ⎥N r Nr π σr rσ( )2 lnexp[ln( / )]2(ln )aggg22 (1)where r is the dry aerosol particle bin radius and σg is the geometricstandard deviation of the distribution. As the parcel model simulationsfocus on the activation process, other processes such as coalescence,sedimentation, and mixing are not considered. Details of the parcelmodel can be found in SC04 and SvdH13, and only a brief description isprovided here. At the onset of parcel model calculations, the initiallydry aerosol particles in all bins first deliquesce and reach theirequilibrium diameters in a sub-saturated environment based on theKöhler equation for solution droplets. The parcel is then lifted at a fixedupward velocity w, and particle growth by vapor diffusion, along withconcurrent changes in the ambient environment, are iteratively computedusing the Variable-coefficient Ordinary Differential Equation(VODE) solver (Brown et al., 1989). The time resolution of these calculationsis determined within the VODE solver, and the frequency atwhich the solver is called is controlled by a longer model time stepbased on fixed upward parcel displacement increments (Δz) at thespecified w (Δt=Δz/w). Model calculations proceed until the parcelreaches a height 50m beyond the level of maximum saturation ratio(Smax) or total parcel displacement exceeds 2 km. Upon model termination,Smax and the fractional number of aerosols (factv) resulting innewly formed cloud droplets, defined as particles having diameters of atleast 2 μm, are cataloged in the LUTs according to the specified T, w, Na,rg, and ε parameter values.A critical point regarding the creation of these LUTs is the use of afixed minimum diameter (Dmin) to define cloud droplets in the parcelmodel, which can produce erroneous CDSD characteristics, particularlywithin the UL regime. For aerosol distributions with large rg valuesunder low SS conditions, for example, deliquesced aerosols within thelarge tail of the distribution can exceed 2 μm in diameter yet remainunactivated as ‘haze’ particles (Levin and Cotton, 2009; McFigganset al., 2006). For this study, aerosol particles activate to cloud dropletsbased on the critical diameter Dcrit as a function of parcel supersaturationratio (Sr) as in R09:D = σ MS RTρ83 ln( ) critsol wr w (2)where σsol is the surface tension of a solution droplet, Mw and ρw are themolar mass and density of liquid water, respectively, and R is theuniversal gas constant. Additionally, at relatively large w values withinthe AL regime, Nc stabilizes shortly after reaching supersaturation.However, parcel ascent and condensational growth continue beyondthe level of Smax, potentially causing additional narrowing of the CDSD.In the current work, model calculations terminate upon reaching Smaxas changes in Nc are negligible with continued ascent (Peng et al., 2007;R09).Parcel model simulations are performed to examine the sensitivitiesof CDSD characteristics to w, Na, rg, and ε, with the ranges for theseparameters listed in Table 1. Aerosols are assumed to be a mix of solubleand insoluble material of equal density, specified by ε, where fullysoluble aerosols correspond to ammonium sulfate with hygroscopicityparameter κ=0.61 (Petters and Kreidenweis, 2007). FollowingSvdH13, aerosol geometric standard deviation is fixed at σg=1.8, andaerosol distributions (Eq. 1) are partitioned into 100 logarithmicallyspacedbins spanning a size range specific to each rg value. For all simulations,Δz=1 m, and initial values of relative humidity, air temperatureand pressure are set to RH=0.99, T=10 °C and p=900 hPa,respectively.

Loftus, Adrian M.↗

Restoration Process

In the accompanying photos, a laboratory technician is restoring the once-obliterated serial number of a revolver. The four-photo sequence shows the gradual progression from total invisibility to clear readability. The technician is using a new process developed in an applications engineering project conducted by NASA's Lewis Research Center in conjunction with Chicago State University. Serial numbers and other markings are frequently eliminated from metal objects to prevent tracing ownership of guns, motor vehicles, bicycles, cameras, appliances and jewelry. To restore obliterated numbers, crime laboratory investigators most often employ a chemical etching technique. It is effective, but it may cause metal corrosion and it requires extensive preparatory grinding and polishing. The NASA-Chicago State process is advantageous because it can be applied without variation to any kind of metal, it needs no preparatory work and number recovery can be accomplished without corrosive chemicals; the liquid used is water.

Source record↗

Earth System Model Parameter Adjustment Using a Green's Functions Approach

We demonstrate the practicality and effectiveness of using a Green's functions estimation approach for adjusting uncertain parameters in an Earth system model (ESM). This estimation approach has previously been applied to an intermediate-complexity climate model and to individual ESM components, e.g., ocean, sea ice, or carbon cycle components. Here, the Green's functions approach is applied to a state-of-the-art ESM that comprises a global atmosphere/land configuration of the Goddard Earth Observing System (GEOS) coupled to an ocean and sea ice configuration of the Massachusetts Institute of Technology general circulation model (MITgcm). Horizontal grid spacing is approximately 110 km for GEOS and 37–110 km for MITgcm. In addition to the reference GEOS-MITgcm simulation, we carried out a series of model sensitivity experiments, in which 20 uncertain parameters are perturbed. These “control” parameters can be used to adjust sea ice, microphysics, turbulence, radiation, and surface schemes in the coupled simulation. We defined eight observational targets: sea ice fraction, net surface shortwave radiation, downward longwave radiation, near-surface temperature, sea surface temperature, sea surface salinity, and ocean temperature and salinity at 300 m. We applied the Green's functions approach to optimize the values of the 20 control parameters so as to minimize a weighted least-squares distance between the model and the eight observational targets. The new experiment with the optimized parameters resulted in a total cost reduction of 9 % relative to a simulation that had already been adjusted using other methods. The optimized experiment attained a balanced cost reduction over most of the observational targets. We also report on results from a set of sensitivity experiments that are not used in the final optimized simulation but helped explore options and guided the optimization process. These experiments include an assessment of sensitivity to the number of control parameters and to the selection of observational targets and weights in the cost function. Based on these sensitivity experiments, we selected a specific definition for the cost function. The sensitivity experiments also revealed a decreasing overall cost as the number of control variables was increased. In summary, we recommend using the Green's functions estimation approach as an additional fine-tuning step in the model development process. The method is not a replacement for modelers' experience in choosing and adjusting sensitive model parameters. Instead, it is an additional practical and effective tool for carrying out final adjustments of uncertain ESM parameters.

Green's Function↗

Infrastructure and Process Improvements After LADEE

The purpose of the Lunar Atmosphere Dust Environment Explorer (LADEE) mission was to measure the density, composition and time variability of the lunar dust environment. The successful mission launched Sept 7, 2013 and was de-orbited and impacted the moon's surface on April 17, 2014. The spacecraft had 3 primary science instruments, the Lunar Dust Experiment, Neutral Mass Spectrometer, and the Ultra Violet Spectrometer. The mission also had a Laser Communications payload that set a record download rate of 622 Mbps (megabits per second) from the moon orbit. The goal is to use the LADEE software base for upcoming smallsat missions. The onboard flight software for the mission was developed using a Model-Based Software methodology and agile software development practices. High level models were developed in Simulink, autocoded to C and layered on Core Flight Executive and Core Flight Software, VxWorks and required board support packages. Software package versions were frozen several years ago, and need to be brought to modern standards for future spacecraft missions. We are evaluating alternate Real Time Operating Systems and avionics architectures that comply with CubeSat form-factor and power limitations. In addition, the tool chain for the software development process has been improved. We will discuss the rationale, trades and implementation for the upgrade path after the LADEE mission.

Software Maintenance↗

Friction Stir Welding of GR-Cop 84 for Combustion Chamber Liners

GRCop-84 is a copper-chromium-niobium alloy developed by the Glenn Research Center for liquid rocket engine combustion chamber liners. GRCop-84 exhibits superior properties over conventional copper-base alloys in a liquid hydrogen-oxygen operating environment. The Next Generation Launch Technology program has funded a program to demonstrate scale-up production capabilities of GR-Cop 84 to levels suitable for main combustion chamber production for the prototype rocket engine. This paper describes a novel method of manufacturing the main combustion chamber liner. The process consists of several steps: extrude the GR-Cop 84 powder into billets, roll the billets into plates, bump form the plates into cylinder halves and friction stir weld the halves into a cylinder. The cylinder is then metal spun formed to near net liner dimensions followed by finish machining to the final configuration. This paper describes the friction stir weld process development including tooling and non-destructive inspection techniques, culminating in the successful production of a liner preform completed through spin forming.

Russell, Carolyn K.↗

Coupled Reactor and Engine Nuclear Thermal Propulsion Modeling Methodology

The design and development process of a Nuclear Thermal Propulsion (NTP) system requires extensive multiphysics modeling to couple the neutron physics and thermal feedback effects to determine the reactor’s power shape. Propulsion system performance codes utilize this power shape to determine NTP key performance parameters. While the power shape is heavily dependent on the temperature profile and geometry of the reactor, many analyses either assume a constant power shape, or use neutronics analysis to determine a power shape for a specific reactor configuration. The development of a coupling interface for a propulsion system performance code and a Monte Carlo neutron transport code (OpenMC) allows for the reactor power shape to be calculated in a Picard iteration.

Jacob Stonehill↗

Origin and development of ablator for Space Shuttle external tank

The Space Shuttle External Tank (ET) represents the largest element of the Space Shuttle transportation system. The ET is the fuel tank which contains cryogenic propellants, including liquid oxygen and liquid hydrogen. The task of providing a suitable Thermal Protection System (TPS) which is mass producible for the ET represented a challenge for the aerospace industry. The difficulties were compounded by stringent insulation and ablation requirements for the materials to maintain their integrity over a wide range of operating temperatures during prelaunch and ascent. Attention is given to the configuration of the Space Shuttle system, the configuration of the external tank, the initial ET TPS concept, TPS materials and processes concepts, design rationale, TPS materials structural considerations, material and processes development, development tests, material/process verification, and flight results.

Ronquillo, L.↗

Concurrent engineering research center

The projects undertaken by The Concurrent Engineering Research Center (CERC) at West Virginia University are reported and summarized. CERC's participation in the Department of Defense's Defense Advanced Research Project relating to technology needed to improve the product development process is described, particularly in the area of advanced weapon systems. The efforts committed to improving collaboration among the diverse and distributed health care providers are reported, along with the research activities for NASA in Independent Software Verification and Validation. CERC also takes part in the electronic respirator certification initiated by The National Institute for Occupational Safety and Health, as well as in the efforts to find a solution to the problem of producing environment-friendly end-products for product developers worldwide. The 3M Fiber Metal Matrix Composite Model Factory Program is discussed. CERC technologies, facilities,and personnel-related issues are described, along with its library and technical services and recent publications.

Callahan, John R.↗

NASA's Composite Overwrap Lessons Learned on 40k Thrust Chamber Assemblies

Filament wound carbon fiber/polymer composite overwraps combined with additively manufactured (AM) copper alloy combustion chambers are a critical part of NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. The composite overwrap is a high strength-to-weight material and allows for significant weight reduction of the high-pressure thrust chamber assembly, reduction of overall cost, and reduced fabrication time while offering structural robustness. Integrated AM/composite overwrap chamber assemblies using 2,000 lbf (2k) and 7,000 lbf (7k) thrust were successfully hot fire tested at NASA Marshall Space Flight Center (MSFC). These assemblies allowed the team to learn lessons related to the design, analysis, and manufacturing of these integrated assemblies. A final goal of the RAMPT project is to design and test a 40,000 lbf (40k) thrust chamber assembly. The40k chamber presented the team several new challenges including an integral inlet port in the main body of the composite overwrap. Through multiple iterations of manufacturing techniques, varied materials, and Non-Destructive Evaluations (NDE), many lessons were learned to obtain a final design solution that would not only allow for the interrupted port inlet but also allow for sufficient material margins for the most critically stressed part of the chamber. This paper will cover the manufacturing techniques exploring fabric designs to help subsidize the coverage in the areas left bare by the inlet port during the filament winding process and custom tooling needed for the final full chamber processing. The original material choice of bismaleimide (BMI) 5250-4 from the 7k chamber performed well for the extreme environment of hot fire testing but proved to be difficult with the increased scale and interrupted port design of the 40kchamber. Discussion in this paper will cover these changes, including evaluation of the design, comparison to the prior 2k and 7k designs, and show the final hardware that will be tested. One primary goal of this work and RAMPT project is to provide this development process and data to industry for infusion into future engine designs.

Filament Wound↗

Proven and Robust Ground Support Systems - GSFC Success and Lessons Learned

Over the past fifteen years, Goddard Space Flight Center has developed several successful science missions in-house: the Wilkinson Microwave Anisotropy Probe (WMAP), the Imager for Magnetopause-to-Aurora Global Exploration (IMAGE), the Earth Observing 1 (EO-1) [1], and the Space Technology 5 (ST-5)[2] missions, several Small Explorers, and several balloon missions. Currently in development are the Solar Dynamics Observatory (SDO) [3] and the Lunar Reconnaissance Orbiter (LRO)[4]. What is not well known is that these missions have been supported during spacecraft and/or instrument integration and test, flight software development, and mission operations by two in house satellite Telemetry and Command (T & C) Systems, the Integrated Test and Operations System (ITOS) and the Advanced Spacecraft Integration and System Test (ASIST). The advantages of an in-house satellite Telemetry and Command system are primarily in the flexibility of management and maintenance - the developers are considered a part of the mission team, get involved early in the development process of the spacecraft and mission operations-control center, and provide on-site, on-call support that goes beyond Help Desk and simple software fixes. On the other hand, care must be taken to ensure that the system remains generic enough for cost effective re-use from one mission to the next. The software is designed such that many features are user-configurable. Where user-configurable options were impractical, features were designed so as to be easy for the development team to modify. Adding support for a new ground message header, for example, is a one-day effort because of the software framework on which that code rests. This paper will discuss the many features of the Goddard satellite Telemetry and Command systems that have contributed to the success of the missions listed above. These features include flexible user interfaces, distributed parallel commanding and telemetry decommutation, a procedure language, the interfaces and tools needed for a high degree of automation, and instantly accessible archives of spacecraft telemetry. It will discuss some of the problems overcome during development, including secure commanding over networks or the Internet, constellation support for the three satellites that comprise the ST-5 mission, and geographically distributed telemetry end users.

Pfarr, Barbara↗

Ensemble Eclipse: A Process for Prefab Development Environment for the Ensemble Project

This software simplifies the process of having to set up an Eclipse IDE programming environment for the members of the cross-NASA center project, Ensemble. It achieves this by assembling all the necessary add-ons and custom tools/preferences. This software is unique in that it allows developers in the Ensemble Project (approximately 20 to 40 at any time) across multiple NASA centers to set up a development environment almost instantly and work on Ensemble software. The software automatically has the source code repositories and other vital information and settings included. The Eclipse IDE is an open-source development framework. The NASA (Ensemble-specific) version of the software includes Ensemble-specific plug-ins as well as settings for the Ensemble project. This software saves developers the time and hassle of setting up a programming environment, making sure that everything is set up in the correct manner for Ensemble development. Existing software (i.e., standard Eclipse) requires an intensive setup process that is both time-consuming and error prone. This software is built once by a single user and tested, allowing other developers to simply download and use the software

Wallick, Michael N.↗

Mechanistic Models of Friction Stir Welding

Friction stir welding is a welding process developed at The Welding Institute (TWI) in England. The method uses very large strain plastic deformation of the material to join two pieces of metal together. The material is deformed using a tool which is forced between the two pieces which rotates causing a bond. Beyond this, very little is actually known although many people working in the field are willing to speculate on the detailed mechanisms involved. Some measurements made using sacrificial thermocouples at the weld joint indicate that the maximum temperature during the weld process is on the order of 370C - well below the melting temperature of the material. However, at this temperature, the material properties are highly temperature dependent, and the yield stress is approximately an order of magnitude less at this temperature than it is at room temperature. As expected, there are many interpretations of the physical mechanisms occurring during the weld process. Although there is very little published concerned with FSW, some of the anecdotal theories will be described. One describes the primary mechanism as frictional heating at the front of the tool caused by slip between the tool and the material. At elevated temperatures, the weld material becomes soft and deforms around the tool but not essentially altered by the tool rotation, similar to an extrusion. As the material meets again at the rear of the tool, the temperatures and pressures are sufficient to cause the material to bond. All other structures seen are secondary and unimportant. Another theory examined last summer at NASA's Marshall Space Flight Center (MSFC) was that there was no slip between the tool and the material resulting in a rotating mass of plastic weld material traveling at a variety of angular velocities - the greatest at the tool surface diminishing to zero at the outer edge of the plastic mass surrounding the tool. This conceptual model was followed by simplified calculations which showed that the balance of moments through the weld plug was not possible under steady state conditions and realistic temperature profiles. This led to some consideration of a quasi-steady oscillating process. Later when force measurements became available some models were modified and new ones were proposed.

Stewart, Michael B.↗