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NASA NTRS2009

Diamond Machining of an Off-Axis Biconic Aspherical Mirror

Two diamond-machining methods have been developed as part of an effort to design and fabricate an off-axis, biconic ellipsoidal, concave aluminum mirror for an infrared spectrometer at the Kitt Peak National Observatory. Beyond this initial application, the methods can be expected to enable satisfaction of requirements for future instrument mirrors having increasingly complex (including asymmetrical), precise shapes that, heretofore, could not readily be fabricated by diamond machining or, in some cases, could not be fabricated at all. In the initial application, the mirror is prescribed, in terms of Cartesian coordinates x and y, by aperture dimensions of 94 by 76 mm, placements of -2 mm off axis in x and 227 mm off axis in y, an x radius of curvature of 377 mm, a y radius of curvature of 407 mm, an x conic constant of 0.078, and a y conic constant of 0.127. The aspect ratio of the mirror blank is about 6. One common, "diamond machining" process uses single-point diamond turning (SPDT). However, it is impossible to generate the required off-axis, biconic ellipsoidal shape by conventional SPDT because (1) rotational symmetry is an essential element of conventional SPDT and (2) the present off-axis biconic mirror shape lacks rotational symmetry. Following conventional practice, it would be necessary to make this mirror from a glass blank by computer-controlled polishing, which costs more than diamond machining and yields a mirror that is more difficult to mount to a metal bench. One of the two present diamond machining methods involves the use of an SPDT machine equipped with a fast tool servo (FTS). The SPDT machine is programmed to follow the rotationally symmetric asphere that best fits the desired off-axis, biconic ellipsoidal surface. The FTS is actuated in synchronism with the rotation of the SPDT machine to generate the difference between the desired surface and the best-fit rotationally symmetric asphere. In order to minimize the required stroke of the FTS, the blanks were positioned at a large off-axis distance and angle, and the axis of the FTS was not parallel to the axis of the spindle of the SPDT machine. The spindle was rotated at a speed of 120 rpm, and the maximum FTS speed was 8.2 mm/s.

Ohl, Raymond G.↗

NASA NTRS1986

Two-dimensional nonsteady viscous flow simulation on the Navier-Stokes computer miniNode

The needs of large-scale scientific computation are outpacing the growth in performance of mainframe supercomputers. In particular, problems in fluid mechanics involving complex flow simulations require far more speed and capacity than that provided by current and proposed Class VI supercomputers. To address this concern, the Navier-Stokes Computer (NSC) was developed. The NSC is a parallel-processing machine, comprised of individual Nodes, each comparable in performance to current supercomputers. The global architecture is that of a hypercube, and a 128-Node NSC has been designed. New architectural features, such as a reconfigurable many-function ALU pipeline and a multifunction memory-ALU switch, have provided the capability to efficiently implement a wide range of algorithms. Efficient algorithms typically involve numerically intensive tasks, which often include conditional operations. These operations may be efficiently implemented on the NSC without, in general, sacrificing vector-processing speed. To illustrate the architecture, programming, and several of the capabilities of the NSC, the simulation of two-dimensional, nonsteady viscous flows on a prototype Node, called the miniNode, is presented.

Nosenchuck, Daniel M.↗

NASA NTRS1994

JTEC Panel report on microelectromechanical systems in Japan

This report summarizes recent activities in the development of microelectromechanical systems (MEMS) in Japan. For the purposes of this study, 'MEMS' means batch-fabricated miniature devices that convert physical parameters to or from electrical signals and that depend on mechanical structures or parameters in important ways for their operation. The report covers advanced materials and process technology; sensors and sensing microstructures; microactuators and actuation mechanisms; sensor-circuit integration and system partitioning; advanced packaging, microassembly, and testing technologies; and MEMS design techniques, applications, and infrastructure. The panel found that Japanese industry is emphasizing approaches to MEMS that are similar to those taken by U.S. industry (i.e., approaches based on silicon integrated-circuit technology); these efforts are comparable in their level of development to those in the United States. However, the ten-year, $250 million, MITI-sponsored program in micromachines emphasizes the miniaturization of more traditional (nonlithographic) machining processes, an area in which there is no comparable U.S. effort. Packaging technology and applications for batch-fabricated MEMS devices is considered a major challenge in both countries. The panel concluded that these and other issues will require global leadership and international cooperation to realize the benefits of MEMS in a timely way.

Wise, Kensall D.↗

NASA NTRS2015

Main Oxidizer Valve Design

A developmental Main Oxidizer Valve (MOV) was designed by NASA-MSFC using additive manufacturing processes. The MOV is a pneumatically actuated poppet valve to control the flow of liquid oxygen to an engine's injector. A compression spring is used to return the valve to the closed state when pneumatic pressure is removed from the valve. The valve internal parts are cylindrical in shape, which lends itself to traditional lathe and milling operations. However, the valve body represents a complicated shape and contains the majority of the mass of the valve. Additive manufacturing techniques were used to produce a part that optimized mass and allowed for design features not practical with traditional machining processes.

Addona, Brad↗

NASA NTRS1994

Neutral ion sources in precision manufacturing

Ion figuring of optical components is a relatively new technology that can alleviate some of the problems associated with traditional contact polishing. Because the technique is non contacting, edge distortions and rib structure print through do not occur. This initial investigation was aimed at determining the effect of ion figuring on surface roughness of previously polished or ductile ground ceramic optical samples. This is the first step in research directed toward the combination of a pre-finishing process (ductile grinding or polishing) with ion figuring to produce finished ceramic mirrors. The second phase of the project is focusing on the development of mathematical algorithms that will deconvolve the ion beam profile from the surface figure errors so that these errors can be successfully removed from the optical components. In the initial phase of the project, multiple, chemical vapor deposited silicon carbide (CVD SiC) samples were polished or ductile ground to specular or near-specular roughness. These samples were then characterized to determine topographic surface information. The surface evaluation consisted of stylus profilometry, interferometry, and optical and scanning electron microscopy. The surfaces, were ion machined to depths from 0-5 microns. The finished surfaces were characterized to evaluate the effects of the ion machining process with respect to the previous processing methods and the pre-existing subsurface damage. The development of the control algorithms for figuring optical components has been completed. These algorithms have been validated with simulations and future experiments have been planned to verify the methods. This paper will present the results of the initial surface finish experiments and the control algorithms simulations.

Fawcett, Steven C.↗

NASA NTRS1989

Effect of grinding on the fatigue life of titanium alloy (5 Al-2.5 Sn) under dry and wet conditions

The principal factors in the performance of aerospace materials are strength-to-weight ratio, fatigue life, fracture toughness, survivability and, of course, reliability. Machining processes and, in particular, grinding under adverse conditions have been found to cause damage to surface integrity and affect the residual stress distribution in the surface and subsurface region. These effects have a direct bearing on the fatigue life. In this investigation the effects of grinding conditions on the fatigue life of Titanium 5 Al-2.5Sn were studied. This alloy is used in ground form in the manufacturing of some critical components in the space shuttle's main engine. It is essential that materials for such applications be properly characterized for use in severe service conditions. Flat sub-size specimens 0.1 inch thick were ground on a surface grinding machine equipped with a variable speed motor at speeds of 2000 to 6000 rpm using SiC wheels of grit sizes 60 and 120. The grinding parameters used in this investigation were chosen from a separate study. The ground specimens were then fatigued at a selected stress and the resulting lives were compared with that of the virgin material. The surfaces of the specimens were examined under a scanning electron microscope, and the roughness and hardness were measured using a standard profilometer and microhardness tester, respectively. The fatigue life of the ground specimens was found to decrease with the increase in speed for both dry and wet conditions. The fatigue life of specimens ground under wet conditions showed a significant increase at the wheel speed of 2000 rpm for both the grit sizes and thereafter decreased with increase profilometry, microhardness measurements and scanning electron microscopic examination.

Rangaswamy, Partha↗

NASA NTRS1993

A pattern recognition system for locating small volvanoes in Magellan SAR images of Venus

The Magellan data set constitutes an example of the large volumes of data that today's instruments can collect, providing more detail of Venus than was previously available from Pioneer Venus, Venera 15/16, or ground-based radar observations put together. However, data analysis technology has not kept pace with data collection and storage technology. Due to the sheer size of the data, complete and comprehensive scientific analysis of such large volumes of image data is no longer feasible without the use of computational aids. Our progress towards developing a pattern recognition system for aiding in the detection and cataloging of small-scale natural features in large collections of images is reported. Combining classical image processing, machine learning, and a graphical user interface, the detection of the 'small-shield' volcanoes (less than 15km in diameter) that constitute the most abundant visible geologic feature in the more that 30,000 synthetic aperture radar (SAR) images of the surface of Venus are initially targeted. Our eventual goal is to provide a general, trainable tool for locating small-scale features where scientists specify what to look for simply by providing examples and attributes of interest to measure. This contrasts with the traditional approach of developing problem specific programs for detecting Specific patterns. The approach and initial results in the specific context of locating small volcanoes is reported. It is estimated, based on extrapolating from previous studies and knowledge of the underlying geologic processes, that there should be on the order of 10(exp 5) to 10(exp 6) of these volcanoes visible in the Magellan data. Identifying and studying these volcanoes is fundamental to a proper understanding of the geologic evolution of Venus. However, locating and parameterizing them in a manual manner is forbiddingly time-consuming. Hence, the development of techniques to partially automate this task were undertaken. The primary constraints for this particular problem are that the method must be reasonably robust and fast. Unlike most geological features, the small volcanoes of Venus can be ascribed to a basic process that produces features with a short list of readily defined characteristics differing significantly from other surface features on Venus. For pattern recognition purposes the relevant criteria include (1) a circular planimetric outline, (2) known diameter frequency distribution from preliminary studies, (3) a limited number of basic morphological shapes, and (4) the common occurrence of a single, circular summit pit at the center of the edifice.

Burl, M. C.↗

NASA NTRS1967

Proposed method of rotary dynamic balancing by laser

Laser method, where high energies of monochromatic light can be precisely collimated to perform welding and machining processes, is proposed for rotary dynamic balancing. The unbalance, as detected with the velocity pickup, would trigger the laser system which would emit high energy pulses directed at the heavy side of the component.

Perkins, W. E.↗

NASA NTRS1971

Advanced thrust chamber designs

A regeneratively cooled thrust chamber has been designed and fabricated, consisting of an inner TD nickel liner which was spin formed, welded, and machined and an outer shell of electroformed nickel. Coolant channels were produced in the outer surface of the inner liner by the electric discharge machining process before electroforming the shell. Accessory manifolds and piping were attached by welding. Manufacturing processes employed are described.

Dietrich, F. J.↗

NASA NTRS1972

Beryllium heat shield technology in the area of thermal protection devices

For future space applications, it is important that thermal protection systems be reusable for space shuttle flights. Beryllium offers a unique combination of properties for use as a heat shield material (stiffness, lightweight, ability to absorb heat). In order to adequately test these properties, it was necessary to fabricate heat shields. The concept used was a two-section test panel 99.1 x 99.1 cm (39 x 39 inch) with each section made of two 0.051 cm (0.020 inch) thick beryllium corrugations brazed together as a mirror image, with titanium (Ti-6Al-4V) used as standoffs to support the panel structure. The work prior to fabrication included brazability of both beryllium and titanium, forming of beryllium and titanium, machining processes involving beryllium and chem-milling beryllium. Sub-scale samples were made of all details before actual fabrication of the large panel. The full scale test panel was hot-formed at 950 K, chem-milled to 0.041 + or - 0.005 cm (0.016 + or - 0.002 inches), trimmed, vacuum brazed, drilled and assembled.

Muhl, A. E.↗

NASA NTRS1972

Thermal Skin fabrication technology

Advanced fabrication techniques applicable to Thermal Skin structures were investigated, including: (1) chemical machining; (2) braze bonding; (3) diffusion bonding; and (4) electron beam welding. Materials investigated were nickel and nickel alloys. Sample Thermal Skin panels were manufactured using the advanced fabrication techniques studied and were structurally tested. Results of the program included: (1) development of improved chemical machining processes for nickel and several nickel alloys; (2) identification of design geometry limits; (3) identification of diffusion bonding requirements; (4) development of a unique diffusion bonding tool; (5) identification of electron beam welding limits; and (6) identification of structural properties of Thermal Skin material.

Milam, T. B.↗

NASA NTRS1972

Automatic classification of soils and vegetation with ERTS-1 data

Preliminary results of a test of a computerized analysis method using ERTS 1 data are presented. The method consisted of a four-spectral-band supervised, maximum likelihood, Gaussian classifier with training statistics derived through a combination of clustering and manual methods. The multivariate analysis method leads to the assignment of each resolution element of the data to one of a preselected set of discrete classes. The data frame was an area over the Texas-Oklahoma border including Lake Texoma. The study suggests that multispectral scanner data coupled with machine processing shows promise for earth surface cover surveys. Futhermore, the processing time is short and consequently the costs are low; a full frame can be analyzed completely within 48 hours.

Landgrebe, D. A.↗

NASA NTRS1973

Evaluate ERTS imagery for mapping and detection of changes of snowcover on land and on glaciers

The author has identified the following significant results. A possibly more accurate method to determine snowcover area change has been tried; snowcover area change over periods of an ERTS-1 cycle are very useful in determining energy balances over regional areas and to determine snow depth as a function of altitude. Also since shadow and cloud cover areas are highlighted this method may be a step toward more complete machine processing.

Meier, M. F.↗

NASA NTRS1973

Evaluation and comparison of ERTS measurements of major crops and soil associations for selected sites in the central United States

The author has identified the following significant results. The most significant result was the use of the temporal overlay technique where the computer was used to overlay ERTS-1 data from three different dates (9 Oct., 14 Nov., 2 Dec.). The registration of MSS digital data from different dates was estimated to be accurate within one half resolution element. The temporal overlay capability provides a significant advance in machine-processing of MSS data. It is no longer essential to go through the tedious exercise of locating ground observation sites on the digital data from each ERTS-1 overpass. Once the address of a ground observation site has been located on a digital tape from any ERTS-1 overpass, the overlay technique can be used to locate the same address on a digital tape of MSS data from any other ERTS-1 pass over the same area. The temporal overlay technique also adds a valuable dimension for identifying and mapping changes in vegetation, water, and other dynamic surface features.

Baumgardner, M. F.↗

NASA NTRS1973

Identification and Mapping of Soils, Vegetation, and Water Resources of Lynn County, Texas, by Computer Analysis of ERTS MSS Data

Results of the analysis and interpretation of ERTS multispectral data obtained over Lynn County, Texas, are presented. The test site was chosen because it embodies a variety of problems associated with the development and management of agricultural resources in the Southern Great Plains. Lynn County is one of ten counties in a larger test site centering around Lubbock, Texas. The purpose of this study is to examine the utility of ERTS data in identifying, characterizing, and mapping soils, vegetation, and water resources in this semiarid region. Successful application of multispectral remote sensing and machine-processing techniques to arid and seminarid land-management problems will provide valuable new tools for the more than one-third of the world's lands lying in arid-semiarid regions.

Baumgardner, M. F.↗

NASA NTRS1973

Land Use and Mapping

From the standpoint of technology, the most encouraging thing about ERTS has been the level of land-use identification. Land-use detail has exceeded the expectations of the Interagency Steering Committee and the requirements of land-use classification proposed by the Department of Interior. Whereas in the latter instance it was anticipated that only nine classes of land use would probably be identifiable, in fact some 14 to 18 classes have been identified. The success in the level of land-use identification results primarily from the various attributes of the ERTS system. These include the ability to provide repetitive coverage, and in particular seasonal coverage; the ability to image in four bands of the electromagnetic spectrum (green, red, and two near-infrared), which allows for manipulation of various combinations of bands; and the provision by the ERTS system of computer-compatible tapes for machine processing of data. Furthermore, the resolution of ERTS imagery has been better than expected. Although there is some question as to its exact resolving power, it is safe to say objects as small as 100 meters (300 feet) in diameter have been identified. Linear features as narrow as 16 meters (50 feet) can be detected (Figure 1).

Lindgren, D. T.↗

NASA NTRS1973

Utilization of ERTS-1 data to monitor and classify eutrophication of inland lakes

The author has identified the following significant results. Significant findings are: (1) one-acre lakes and one-acre islands are detectable; (2)removal of atmospheric parameters derived from RPMI measurements show test lakes to have reflectances of 3.1 to 5.5% in band 4 and 0.3 to 2.3% in band 5; (3) failure to remove reflectance caused by atmosphere results in errors up to 500% in computing lake reflectance from ERTS-1 data; (4) in band 4, up to seven reflectance levels were observed in test lakes; (5) reflectance patterns have been displayed on a color-coded TV monitor and on computer-generated gray scales; (6) deep and shallow water can be separated by a trained photointerpreter and automatic machine processing, with estimates of water depth possible in some cases; (7) RPMI provides direct spectral signature measurements of lakes and lake features such as algal scums and floating plants; (8) a method is reported for obtaining lake color, as estimated by Forel-Ule standards, from ERTS-1 data; (9) a strong correlation between browner water color, diminishing water transparency; and (10) classifying lake eutrophication by observation of surface scums or macrophytes in shallow water seems straightforward.

Rogers, R. H.↗

NASA NTRS1972

Conjugate point determination for multitemporal data overlay

The machine processing is discussed of spatially variant multitemporal data such as imagery obtained at different times which requires that these data be in geometrical registration so that the analysis processor may obtain the datum for a specified ground resolution element in each of the sets of imagery being utilized for analysis. Misregistration between corresponding subsets of imagery contains both a displacement and a geometrical distortion component. Search techniques utilizing the moduli of the Fourier Transforms are developed for estimating the coefficients of geometrical distortion components of this model. Following the correction of these distortion components, the displacement is located by the crosscorrelation of a template obtained from one set of data, termed the reference, with the second, or background data. This template, derived for the optimum discrimination of the reference data embedded in the background, is determined by the solution of a system of equations involving the reference data and the covariance matrix of these data.

Emmert, R. A.↗