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NASA NTRS2013

Common Practice Lightning Strike Protection Characterization Technique to Quantify Damage Mechanisms on Composite Substrates

To support FAA certification airworthiness standards, composite substrates are subjected to lightning direct-effect electrical waveforms to determine performance characteristics of the lightning strike protection (LSP) conductive layers used to protect composite substrates. Test results collected from independent LSP studies are often incomparable due to variability in test procedures & applied practices at different organizations, which impairs performance correlations between different LSP data sets. Under a NASA supported contract, The Boeing Company developed technical procedures and documentation as guidance in order to facilitate a test method for conducting universal common practice lightning strike protection test procedures. The procedures obtain conformity in future lightning strike protection evaluations to allow meaningful performance correlations across data sets. This universal common practice guidance provides the manufacturing specifications to fabricate carbon fiber reinforced plastic (CFRP) test panels, including finish, grounding configuration, and acceptable methods for pretest nondestructive inspection (NDI) and posttest destructive inspection. The test operations guidance elaborates on the provisions contained in SAE ARP5416 to address inconsistencies in the generation of damage protection performance data, so as to provide for maximum achievable correlation across capable lab facilities. In addition, the guidance details a direct effects test bed design to aid in quantification of the multi-physical phenomena surrounding a lightning direct attachment supporting validation data requirements for the development of predictive computational modeling. The lightning test bed is designed to accommodate a repeatable installation procedure to secure the test panel and eliminate test installation uncertainty. It also facilitates a means to capture the electrical waveform parameters in 2 dimensions, along with the mechanical displacement and thermal heating parameters which occur during lightning attachment. Following guidance defined in the universal common practice LSP test documents, protected and unprotected CFRP panels were evaluated at 20, 40 and 100KAmps. This report presents analyzed data demonstrating the scientific usefulness of the common practice approach. Descriptions of the common practice CFRP test articles, LSP test bed fixture, and monitoring techniques to capture the electrical, mechanical and thermal parameters during lightning attachment are presented here. Two methods of measuring the electrical currents were evaluated, inductive current probes and a newly developed fiberoptic sensor. Two mechanical displacement methods were also examined, optical laser measurement sensors and a digital imaging correlation camera system. Recommendations are provided to help users implement the common practice test approach and obtain LSP test characterizations comparable across data sets.

Szatkowski, George N.↗

NASA NTRS2013

Apparatus and Process for Controlled Nanomanufacturing Using Catalyst Retaining Structures

An apparatus and method for the controlled fabrication of nanostructures using catalyst retaining structures is disclosed. The apparatus includes one or more modified force microscopes having a nanotube attached to the tip portion of the microscopes. An electric current is passed from the nanotube to a catalyst layer of a substrate, thereby causing a localized chemical reaction to occur in a resist layer adjacent the catalyst layer. The region of the resist layer where the chemical reaction occurred is etched, thereby exposing a catalyst particle or particles in the catalyst layer surrounded by a wall of unetched resist material. Subsequent chemical vapor deposition causes growth of a nanostructure to occur upward through the wall of unetched resist material having controlled characteristics of height and diameter and, for parallel systems, number density.

Nguyen, Cattien↗

NASA NTRS2014

Measurement and Control of Oxygen Partial Pressure in an Electrostatic Levitator

Recently the NASA Marshall Space Flight Center electrostatic levitation (ESL) laboratory has been upgraded to include an oxygen control system. This system allows the oxygen partial pressure within the vacuum chamber to be measured and controlled, at elevated temperatures, theoretically in the range from 10(exp -36) to 10(exp 0) bar. The role of active surface agents in liquid metals is fairly well known; however, published surface tension data typically has large scatter, which has been hypothesized to be caused by the presence of oxygen. The surface tension of metals is affected by even a small amount of adsorption of oxygen. It has even been shown that oxygen partial pressures may need to be as low as 10(exp -24) bar to avoid oxidation. While electrostatic levitation is done under high vacuum, oxide films or dissolved oxygen may have significant effects on materials properties, such as surface tension and viscosity. Therefore, the ability to measure and control the oxygen partial pressure within the chamber is highly desirable. The oxygen control system installed at MSFC contains a potentiometric sensor, which measures the oxygen partial pressure, and an oxygen ion pump. In the pump, a pulse-width modulated electric current is applied to yttrium-stabilized zirconia, resulting in oxygen transfer into or out of the system. Also part of the system is a control unit, which consists of temperature controllers for the sensor and pump, PID-based current loop for the ion pump, and a control algorithm. This system can be used to study the effects of oxygen on the thermophysical properties of metals, ceramics, glasses, and alloys. It can also be used to provide more accurate measurements by processing the samples at very low oxygen partial pressures. The oxygen control system will be explained in more detail and an overview of its use and limitations in an electrostatic levitator will be described. Some preliminary measurements have been made, and the results to date will be provided.

SanSoucie, Michael P.↗

NASA NTRS2014

Development and Validation of Linear Alternator Models for the Advanced Stirling Convertor

Two models of the linear alternator of the Advanced Stirling Convertor (ASC) have been developed using the Sage 1-D modeling software package. The first model relates the piston motion to electric current by means of a motor constant. The second uses electromagnetic model components to model the magnetic circuit of the alternator. The models are tuned and validated using test data and compared against each other. Results show both models can be tuned to achieve results within 7% of ASC test data under normal operating conditions. Using Sage enables the creation of a complete ASC model to be developed and simulations completed quickly compared to more complex multi-dimensional models. These models allow for better insight into overall Stirling convertor performance, aid with Stirling power system modeling, and in the future support NASA mission planning for Stirling-based power systems.

Linear Alternators↗

NASA NTRS2013

The Force-Free Magnetosphere of a Rotating Black Hole

We revisit the Blandford-Znajek process and solve the fundamental equation that governs the structure of the steady-state force-free magnetosphere around a Kerr black hole. The solution depends on the distributions of the magnetic field angular velocity and the poloidal electric current. These are not arbitrary. They are determined self-consistently by requiring that magnetic field lines cross smoothly the two singular surfaces of the problem: the inner "light surface" located inside the ergosphere and the outer "light surface" which is the generalization of the pulsar light cylinder.We find the solution for the simplest possible magnetic field configuration, the split monopole, through a numerical iterative relaxation method analogous to the one that yields the structure of the steady-state axisymmetric force-free pulsar magnetosphere. We obtain the rate of electromagnetic extraction of energy and confirm the results of Blandford and Znajek and of previous time-dependent simulations. Furthermore, we discuss the physical applicability of magnetic field configurations that do not cross both "light surfaces."

Contopoulos, Ioannis↗

NASA NTRS2015

Development and Validation of Linear Alternator Models for the Advanced Stirling Convertor

Two models of the linear alternator of the Advanced Stirling Convertor (ASC) have been developed using the Sage 1-D modeling software package. The first model relates the piston motion to electric current by means of a motor constant. The second uses electromagnetic model components to model the magnetic circuit of the alternator. The models are tuned and validated using test data and also compared against each other. Results show both models can be tuned to achieve results within 7 of ASC test data under normal operating conditions. Using Sage enables the creation of a complete ASC model to be developed and simulations completed quickly compared to more complex multi-dimensional models. These models allow for better insight into overall Stirling convertor performance, aid with Stirling power system modeling, and in the future support NASA mission planning for Stirling-based power systems.

Linear Alternators↗

NASA NTRS2016

Tethered Space Satellite-1 (TSS-1): Wound About a Bolt

In the early 1990's US and Italian scientists collaborated to study the electrodynamics on a long tether between two satellites as it moved through the electrically charged portion of Earth's atmosphere called the ionosphere. Potential uses for the electrical current induced in the long wire include power and thrust generation for a satellite, momentum exchange, artificial gravity, deployment of sensors or antennas, and gravity-gradient stabilization. The Tethered Space Satellite (TSS) was a first-of-its-kind experiment with long tethers in space. It consisted of a satellite with science experiments attached to a 12.5 mile long, very thin (0.10 inch diameter) copper wire assembly wound around a spool in the deployer reel mechanism. The whole mechanism sits on a pallet that is installed into the Shuttle bay. At an altitude of 160 nautical miles above earth, the satellite would be deplodeployed from the Shuttle bay by raising it on a boom facing away from Earth. Once cleared of the bay, the deployer mechanism would slowly feed out the 12-plus miles of tether. Scientific data would be collected throughout the operation, after which the satellite would be reeled back in. A receiver spool to catch the 12.5 mile tether as it was being unwound by the deployer reel mechanism was set up to do the system-level test of deployer real mechanism prior to installing the loaded pallet into the Shuttle bay. The system level tests were required before the pallet could be installed into the Space Shuttle cargo bay. A few months before flight, the system level tests, including unreeling and reeling the tether, were completed at Kennedy Space Center (KSC) and the TSS payload was installed onto the Spacelab pallet. Some of this testing equipment was then shipped back to the contractor, Martin Marietta. Integration with the Shuttle began. Systems-level load analyses, which cannot be run until all information about each payload is finalized, was run in parallel with the physical integration of the hardware into the Shuttle payload bay. An analysis, called Coupled loads analysis, incorporates any updates to the model due to system level tests of all the different payloads, and any changes that were found during integration. Engineering analysis examines the worst case scenarios for the loads the hardware will see. The two times during the mission where the dynamic loads are the worst were 1) the first 10-second portion of Shuttle lift off, and 2) a 2-second time during landing when the landing gears hit the ground. The coupled loads analysis using the final verification loads showed that a single bolt attaching the deployer reel mechanism to the support structure had a "negative margin" - which is an indication that it might fail - during touch down. Hardware certification rules do not allow for hardware to fly with negative margins. A structural failure of one payload could have serious or catastrophic consequences to other payloads, or may significantly damage the Orbiter. The issue had to be resolved before the flight.

O'Connor, Brian↗

NASA NTRS2016

Tethered Space Satellite-1 (TSS-1): Technical Roundabouts

In the early 1990's US and Italian scientists collaborated to study the electrodynamics of dragging a satellite on a tether through the electrically charged portion of Earth's atmosphere called the ionosphere. An electrical current induced in the long wire could be used for power and thrust generation for a satellite. Other tether uses include momentum exchange, artificial gravity, deployment of sensors or antennas, and gravity-gradient stabilization for satellites. Before the Tethered Space Satellite (TSS-1), no long tether had ever been flown, so many questions existed on how it would actually behave. The TSS consisted of a satellite with science experiments attached to a 12.5 mile long, very thin (0.10 inch diameter) copper wire assembly wound around a spool in the deployer reel mechanism. With the Space Shuttle at an altitude of 160 nautical miles above earth, the satellite was to be deployed by raising it from the Shuttle bay on a boom facing away from Earth. Once cleared of the bay, the deployer mechanism was to slowly feed out the 12-plus miles of tether. Scientific data would be collected throughout the operation, after which the satellite would be reeled back in. Pre-flight testing system level tests involved setting up a tether receiver to catch the 12.5 mile tether onto another reel as it was being unwound by the deployer reel mechanism. Testing only the reel mechanism is straightforward. This test becomes more complicated when the TSS is mounted on the flight pallet at Kennedy Space Center (KSC). The system level tests must be passed before the pallet can be installed into the Space Shuttle cargo bay. A few months before flight, the TSS payload had been integrated onto the Spacelab pallet and system level tests, including unreeling and reeling the tether, had been successfully completed. Some of this testing equipment was then shipped back to the contractor Martin Marietta. Systems-level load analyses, which cannot be run until all information about each payload is finalized, was run in parallel with the physical integration of the hardware into the Shuttle payload bay. The coupled loads analysis, as it is called, incorporates any updates to the model due to system level tests, and any changes that were found during integration. The coupled loads analysis revealed that a single bolt attaching the deployer reel mechanism to the support structure had a "negative margin" - which is an indication that it might fail during operation. Hardware certification rules do not allow for hardware to fly with negative margins, so this issue had to be resolved before the flight. Since there is conservatism in engineering analysis, there is an option to "waive" the margin requirement, and fly the experiment as is. On the other hand, a structural failure of one payload could have serious or catastrophic consequences to other payloads and possibly the mission. Minor design changes or fixes might be feasible within the payload bay prior to launch. Any major design changes that required the spooling test to validate the hardware, or for the pallet to be removed, would cause TSS not to be ready for the Shuttle launch.

O'Connor, Brian↗

NASA NTRS2012

High-Temperature Superconductors as Electromagnetic Deployment and Support Structures in Spacecraft

This report, concluding a one-year NIAC Phase I study, describes a new structural and mechanical technique aimed at reducing the mass and increasing the deployed-to-stowed length and volume ratios of spacecraft systems. This technique uses the magnetic fields generated by electrical current passing through coils of high‐temperature superconductors (HTSs) to support spacecraft structures and deploy them to operational configurations from their stowed positions inside a launch vehicle fairing.

Superconductors↗

NASA NTRS2017

Dust and Debris Tolerant Retractable Cover Connector

A debris exclusion and removal apparatus for connectors which have retractable cover configurations which include internal wafers that clean the connectors prior to mating. XXXX connectors. More particularly, embodiments relate to dust tolerant connectors. Some embodiments also relate to an intelligent connector system capable of detecting damage to or faults within a conductor and then rerouting the energy to a non-damaged spare conductor. Discussion Connectors of the present invention may be used to transfer electrical current, fluid, and gas in a wide variety of environments containing dust and other debris, wherein that debris may present substantial challenges. For example, lunar/Martian dust intrusion and/or accumulation in connectors used to transfer oxygen, hydrogen, nitrogen, etc., may lead to larger system failures as well as loss of life in extraterrestrial human exploration endeavors. Additionally, embodiments of the present invention may also be suitable for use where connectors must resist water intrusion, such as terrestrial deep water operations.

Lewis, Mark E.↗

NASA NTRS2017

Testing the Accuracy of Data-Driven MHD Simulations of Active Region Evolution

Models for the evolution of the solar coronal magnetic field are vital for understanding solar activity, yet the best measurements of the magnetic field lie at the photosphere, necessitating the development of coronal models which are "data-driven" at the photosphere. We present an investigation to determine the feasibility and accuracy of such methods. Our validation framework uses a simulation of active region (AR) formation, modeling the emergence of magnetic flux from the convection zone to the corona, as a ground-truth data set, to supply both the photospheric information and to perform the validation of the data-driven method. We focus our investigation on how the accuracy of the data-driven model depends on the temporal frequency of the driving data. The Helioseismic and Magnetic Imager on NASA's Solar Dynamics Observatory produces full-disk vector magnetic field measurements at a 12-minute cadence. Using our framework we show that ARs that emerge over 25 hours can be modeled by the data-driving method with only approximately 1 percent error in the free magnetic energy, assuming the photospheric information is specified every 12 minutes. However, for rapidly evolving features, under-sampling of the dynamics at this cadence leads to a strobe effect, generating large electric currents and incorrect coronal morphology and energies. We derive a sampling condition for the driving cadence based on the evolution of these small-scale features, and show that higher-cadence driving can lead to acceptable errors. Future work will investigate the source of errors associated with deriving plasma variables from the photospheric magnetograms as well as other sources of errors, such as reduced resolution, instrument bias, and noise.

Leake, James E.↗

NASA NTRS2018

Photoacoustic Chemical Detector

A laser vibrometer for measurement of ambient chemical species includes a laser that produces a beam that is split into a reference readout beam and a signal readout beam. A probe laser beam is tuned to an absorption feature of a molecular transition, and generates acoustic signals when incident on a gaseous species via the photo acoustic effect. The scattered acoustic signals are incident on a thin membrane that vibrates. The readout laser beam reflected from the vibrating membrane is mixed with the reference beam at the surface of a photo-EMF detector. Interferrometric fringes are generated at the surface of the photo-EMF detector. Electric current is generated in the photo-EMF detector when the fringes are in motion due to undulations in the signal readout beam imparted by the vibrating membrane. A highly sensitive photo-EMF detector is capable of detecting picoJoules or less laser energy generated by vibrating processes.

Prasad, Narasimha S.↗

NASA NTRS2018

MMS Examination of FTEs at the Earth's Subsolar Magnetopause

Determining the magnetic field structure, electric currents, and plasma distributions within flux transfer event (FTE)-type flux ropes is critical to the understanding of their origin, evolution, and dynamics. Here the Magnetospheric Multiscale mission's high-resolution magnetic field and plasma measurements are used to identify FTEs in the vicinity of the subsolar magnetopause. The constant-alpha flux rope model is used to identify quasi-force free flux ropes and to infer the size, the core magnetic field strength, the magnetic flux content, and the spacecraft trajectories through these structures. Our statistical analysis determines a mean diameter of 1,700 ± 400 km (~30 ± 9 d(sub i)) and an average magnetic flux content of 100 ± 30 kWb for the quasi-force free FTEs at the Earth's subsolar magnetopause which are smaller than values reported by Cluster at high latitudes. These observed nonlinear size and magnetic flux content distributions of FTEs appear consistent with the plasmoid instability theory, which relies on the merging of neighboring, small-scale FTEs to generate larger structures. The ratio of the perpendicular to parallel components of current density, R(sub J), indicates that our FTEs are magnetically force-free, defined as R(sub J) < 1, in their core regions (<0.6 R(sub flux rope)). Plasma density is shown to be larger in smaller, newly formed FTEs and dropping with increasing FTE size. It is also shown that parallel ion velocity dominates inside FTEs with largest plasma density. Field-aligned flow facilitates the evacuation of plasma inside newly formed FTEs, while their core magnetic field strengthens with increasing FTE size.

Akhavan-Tafti, M.↗

NASA NTRS2018

Laser Beam Expander with Adjustable Collimation

A laser beam expander has at least two negative lenses with adjustable collimation. The amount of required motion can be reduced by an order of magnitude over single negative lens approaches by splitting the input lens in two and adjusting the small remaining air gap between the lenses. The change in collimation may be accomplished by heating/cooling (i.e., thermal), mechanical motion (e.g., motors), electro-optical means (e.g., applying or reducing an electric current), any combination thereof, or any other suitable mechanism.

Ramos-Izquierdo, Luis A.↗

NASA NTRS2019

A Persistent, Large-Scale, and Ordered Electrodynamic Connection Between Saturn and Its Main Rings

Auroral hiss emissions are ubiquitous in planetary magnetospheres, particularly in regions where electric current systems are present. They are generally diagnostic of electrodynamic coupling between conductive bodies, thus making auroral and moon-connected magnetic field lines prime locations for their detection. However, the role of Saturn's rings as a dynamic conductive body has been elusive and of great interest to the community. Cassini's Grand Finale orbits afforded a unique opportunity to directly sample magnetic field lines connected to the main rings. Here we provide strong evidence for the persistent and organized presence of auroral hiss demonstrably associated with the main rings. This is in contrast to recent observations suggesting that Saturn's rings may be barriers to field-aligned currents. Our results provide a new view of Saturn's rings as a dynamic system that is in continuous and ordered electrodynamic coupling with the planet.

Sulaiman, A. H.↗

NASA NTRS2019

Toward Ultralight High Strength Structural Materials via Collapsed Carbon Nanotube Bonding

The growing commercial availability of carbon nanotube (CNT) macro-assemblies such as sheet and yarn is making their use in structural composite components increasingly feasible. However, the mechanical properties of these materials continue to trail those of state-of-the-art carbon fiber composites due to relatively weak inter-tube load transfer. Forming covalent links between adjacent CNTs promises to mitigate this problem, but it has proven difficult in practice to introduce them chemically within densified and aligned CNT materials due to their low permeability. To avoid this limitation, this work explores the combination of pulsed electrical current, temperature, and pressure to introduce inter-CNT bonds. Reactive molecular dynamics simulations identify the most probable locations, configurations, and conditions for inter-nanotube bonds to form. This process is shown to introduce covalent linkages within the CNT material that manifest as improved macroscale mechanical properties. The magnitude of this effect increases with increasing levels of prealignment of the CNT material, promising a new synthesis pathway to ultralight structural materials with specific strengths and stiffnesses exceeding 1 and 100 GPa/(g/cu.cm), respectively.

Jensen, Benjamin D.↗

NASA NTRS2021

Cluster after 20 Years of Operations: Science Highlights and Technical Challenges

The Cluster mission was the first constellation using four identical spacecraft to study Sun-Earth connection plasma processes. Using four spacecraft in a tetrahedron shape, it could measure, for the first time, 3D quantities such as electrical currents, plasma gradients or divergence of the electron pressure tensor and 3D structures such as boundaries, surface waves or vortices. Launched in pairs in July and August 2000, on two Soyuz rockets from Baikonur, the four spacecraft have been collecting data continuously for more than 20 years. The mission faced many challenges during the years of operations as some spacecraft subsystems had a lifetime of a few years beyond the initial two-year mission. The major one was to operate without functioning batteries and to successfully pass short and long eclipses, up to 3 h long, without damaging the on-board computers and transmitters and without freezing the fuel. More than 1,000 eclipses have been successfully passed since 2010 using a specially made procedure which switches off the complete spacecraft before entering into eclipse and switches it on when the Sun is again illuminating the solar panels. During 20 years, many discoveries and science results have been published in more than 2,700 scientific papers. A few highlights are presented here, focusing on how varying the spacecraft separation was essential to achieve the science goals of the mission. The Cluster Science Data System and the Cluster archive allows public access to all science data as well as spacecraft ancillary data.

C P Escoubet↗

NASA NTRSDate not supplied

Firmware Architecture of the ARMADAS Bolting Robot

The Automated Reconfigurable Mission Adaptive Digital Assembly Systems (ARMADAS) project, under development at NASA Ames Research Center, has demonstrated on-ground autonomous robotic assembly of extensive digital structures, and it is now moving forward towards in-space demonstration. The ARMADAS system comprises of the operation software, the operation user interface (opsUI), and a swarm of robots. The robotic system consists of a multitude of collaborative agents specifically designed to transport, place and bolt the building blocks, called voxels (volumetric pixels). This paper focuses on the bolting robot, referred to as Mobile Metamaterial Internal Co-Integrator (MMIC-I). MMIC-I is a battery-powered crawling robot. It navigates the structure through extension, contraction and gripping. Two distinct controller boards operate the robot's two symmetric modules, referred to as module A and B. Board A is the master board: it coordinates motion planning and motion primitives execution, hosts the WiFi client, performs periodic self-assessment and system idle check and triggers faults if anomalies are detected. Board B periodically sends a heartbeat to board A, through a wired communication channel that uses the Serial protocol. Additionally, board A's WiFi client receives heartbeat packet requests or motion/bolting commands from a dedicated server board, and acknowledges reception sending back a response heartbeat packet containing information about the overall robot status, e. g. electrical current and voltage values, target and actual angles, operating mode, fault status. Whenever a motion command is sent, the motion planning section of the firmware determines the current robot configuration, using Inertial Measurement Unit readings and the motors Pulse Width Modulation values. Afterwards, it calculates the list of primitives needed to reach the target state, and controls their execution in the proper order. MMIC-I can receive and execute motion and bolting commands only when it is in operational mode. MMIC-I has three operating modes: standby, operational and safed. Standby mode is automatically entered upon startup. While in standby mode, all motors are powered off, and the only accepted commands are the ones relative to a change of mode and heartbeat packet request. Fault detection causes the robot to automatically enter safed or standby mode. Whenever the detected fault occurs within a motion and requires immediate intervention, e. g. an over-current situation, the robot enters safed mode. Safed mode powers off all motors except for the locomotion module, thus preventing the robot from collapsing. Conversely, when the detected fault doesn't require immediate intervention (low battery warning, for instance), the robot enters standby mode after completing the ongoing motion. This paper provides a detailed discussion of MMIC-I's firmware architecture. It accurately describes the implementation approach for each module: sensor data reading, motor control and actuation, WiFi server-client communication, intra-boards Serial communication, operating modes and autonomous fault detection, motion planning, coordination and execution, etc. Moreover, in support of the software description, this paper includes a thorough characterization of MMIC-I's hardware and avionics.

In-space assembly↗