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Chondrules are mm-sized spheroidal igneous components of chondritic meteorites. They consist of olivine and orthopyroxene set in a glassy mesostasis with varying minor amounts of metals, sulfieds, oxides and carbon phases.
Metal additive manufacturing (AM) processes have been demonstrated to be effective at reducing costs and lead times associated with complex components for space flight applications. Laser powderbed fusion (L-PBF) is a commonly used AM technology due to the ability to produce complex parts with fine feature resolution in a wide variety of alloys and applications. L-PBF, like many other manufacturing processes, can produce minor flaws in parts when in nominal operation as well as process-escape defects when process abnormalities occur. The effects of the flaws and methods of detecting the flaws are a subject of interest to understand the difficulties in detecting these flaws with current technology and how much risk the flaws or defects pose to potential flight parts. Using a RoboMet.3D automated serial sectioning system, seeded defects as well as minor process flaws can be imaged and reconstructed in three dimensions to compare to non-destructive evaluation (NDE) techniques, such as x-ray computed tomography (CT), neutron CT, and in-situ monitoring. The RoboMet automates the metallography process by automatically grinding, polishing, and imaging samples in a single system and providing the control data for NDE comparisons to know the real size of defects built into coupons. These comparisons provide an understanding behind the technological limitations of the NDE techniques for different alloys. The same serial sectioning methods have also been utilized to characterize the surfaces of parts to reconstruct the surfaces and take measurements of internal features not easily examined with non-destructive methods. Using the RoboMet, fine lattice structures built with L-PBF have been characterized to determine the actual thicknesses of struts and density of the lattice structures. These structures have been used as finer build supports for the L-PBF process, designs for fine catalysts, and other design considerations for small components. The RoboMet data helps to inform the modeling and design efforts around these fine components.
Thermal Interface Materials (TIMs) are critical components in spacecraft thermal management systems, where thermal performance is strongly influenced by vacuum conditions, interface contact resistance, and layered metallic joint behavior. However, manufacturer-reported thermal conductivity values are often derived under idealized conditions and may not accurately represent performance within operational aerospace applications. To address this limitation, the Testbed for Advanced Interface Materials in Vacuum (TAIMV) was developed as a modular vacuum-compatible thermal conductivity characterization platform capable of evaluating aerospace-relevant TIM configurations under both ambient and high-vacuum environments. The testbed was derived from the ASTM C1044-16 guarded hot plate methodology and incorporates interchangeable layers of stainless steel coupon geometries, independently controlled main and guard heaters, embedded resistance temperature detectors (RTDs), thermocouples, multi-layer insulation (MLI), and a temperature-controlled cold plate to characterize through-thickness thermal gradients across layered interfaces. In the current configuration, interface compression is limited to the nominal contact pressure generated by the experimental stack assembly. Initial experimental campaigns were conducted at ambient pressure and below 1×10-5 torr for vacuum cases using multiple interface materials including Braycote 601EF and Krytox-based greases across a range of thermal operating conditions. In parallel, a coupled numerical Python thermal model was developed to predict temperature distribution throughout the stack while accounting for conduction, radiation, and parasitic heat transfer pathways and effective interface resistance effects. Experimental measurements and numerical predictions showed consistent thermal trends across multiple operating conditions and environmental states. Results also revealed measurable differences between ambient and vacuum thermal behavior, demonstrating the importance of interface resistance, parasitic heat transfer mechanisms, and stack geometry in determining effective thermal performance within layered thermal interfaces. The presented work establishes a foundation for future thermal model correlation efforts and expanded characterization of aerospace thermal interface materials under representative environmental conditions. Future work will focus on the integration of a load cell system to enable controlled pressure-dependent characterization of thermal interface materials under compressive loading. This capability will allow investigation of the influence of contact pressure on effective thermal conductivity, interface resistance, and thermal performance within layered aerospace thermal interfaces under representative operational conditions.
Nanotechnology is the art and science of building materials and devices at the ultimate level of finesse: atom by atom. Our nation's space program has needs for miniaturization of components, minimization of weight and maximization of performance, and nanotechnology will help us get there. MSFC - Engineering Directorate (ED) is committed to developing nanotechnology that will enable MSFC missions in space transportation, space science and space optics manufacturing. MSFC-ED has a dedicated group of technologists who are currently developing high pay-off nanotechnology concepts. This poster presentation will outline some of the concepts being developed at this time including, nanophase structural materials, carbon nanotube reinforced metal and polymer matrix composites, nanotube temperature sensors and aerogels. The poster will outline these concepts and discuss associated technical challenges in turning these concepts into real components and systems.
The silicon substrate carrier was created so that a large-area array (in this case 62,000+ elements of a microshutter array) and a variety of discrete passive and active devices could be mounted on a single board, similar to a printed circuit board. However, the density and number of interconnects far exceeds the capabilities of printed circuit board technology. To overcome this hurdle, a method was developed to fabricate this carrier out of silicon and implement silicon integrated circuit (IC) technology. This method achieves a large number of high-density metal interconnects; a 100-percent yield over a 6-in. (approximately equal to 15-cm) diameter wafer (one unit per wafer); a rigid, thermally compatible structure (all components and operating conditions) to cryogenic temperatures; re-workability and component replaceability, if required; and the ability to precisely cut large-area holes through the substrate. A method that would employ indium bump technology along with wafer-scale integration onto a silicon carrier was also developed. By establishing a silicon-based version of a printed circuit board, the objectives could be met with one solution. The silicon substrate would be 2 mm thick to survive the environmental loads of a launch. More than 2,300 metal traces and over 1,500 individual wire bonds are required. To mate the microshutter array to the silicon substrate, more than 10,000 indium bumps are required. A window was cut in the substrate to allow the light signal to pass through the substrate and reach the microshutter array. The substrate was also the receptacle for multiple unpackaged IC die wire-bonded directly to the substrate (thus conserving space over conventionally packaged die). Unique features of this technology include the implementation of a 2-mmthick silicon wafer to withstand extreme mechanical loads (from a rocket launch); integrated polysilicon resistor heaters directly on the substrate; the precise formation of an open aperture (approximately equal to 3x3cm) without any crack propagation; implementation of IR transmission blocking techniques; and compatibility with indium bump bonding. Although designed for the microshutter arrays for the NIRSpec instrument on the James Webb Space Telescope, these substrates can be linked to microshutter applications in the photomask generation and stepper equipment used to make ICs and microelectromechanical system (MEMS) devices.
Wettability of microfog streams of high temperature lubricants on static metal surface
The primary reason for use of composites is to save structural weight. A well designed composite aircraft structure will usually save 25-30 percent of a well designed metal structure. The weight savings then translates into improved performance of the aircraft in measures of greater payload, increased flying range or improved efficiency - less use of fuel. Composite materials offer technical advantages. Key technical advantages that composites offer are high stiffness, tailored strength capability, fatigue resistance, and corrosion resistance. Low thermal expansion properties produce dimensionally stable structures over a wide range of temperature. Specialty resin 'char' forming characteristics in a fire environment offer potential fire barrier application and safer aircraft. The materials and processes of composite fabrication offer the potential for lower cost structures in the near future. The application of composite materials to aircraft are discussed.
The goal of doubling thrust-to-weight ratio for gas turbine engines has placed significant demands on engine component materials. Operating temperatures for static seals in the transition duct and turbine sections for instance, may well reach 2000 F within the next ten years. At these temperatures conventional age-hardenable superalloys lose their high strength via overaging and eventual dissolution of the gamma precipitate, and are well above their oxidation stability limit. Conventional solid-solution-strengthened alloys offer metallurgical stability, but suffer from rapid oxidation and little useful load bearing strength. Ceramic materials can theoretically be used at these temperatures, but manufacturing processes are in the developmental stages.
Friction stir welding (FSW) is a solid state process that pan be used to join materials without melting. The process was invented by The Welding Institute (TWI), Cambridge, England. Friction stir welding exhibits several advantages over fusion welding in that it produces welds with fewer defects and higher joint efficiency and is capable of joining alloys that are generally considered non-weldable with a fusion weld process. In 1994, NASA-Marshall began collaborating with TWI to transform FSW from a laboratory curiosity to a viable metal joining process suitable for manufacturing hardware. While teamed with TWI, NASA-Marshall began its own FSW research and development effort to investigate possible aerospace applications for the FSW process. The work involved nearly all aspects of FSW development, including process modeling, scale-up issues, applications to advanced materials and development of tooling to use FSW on components of the Space Shuttle with particular emphasis on aluminum tanks. The friction stir welding process involves spinning a pin-tool at an appropriate speed, plunging it into the base metal pieces to be joined, and then translating it along the joint of the work pieces. In aluminum alloys the rotating speed typically ranges from 200 to 400 revolutions per minute and the translation speed is approximately two to five inches per minute. The pin-tool is inserted at a small lead angle from the axis normal to the work piece and requires significant loading along the axis of the tool. An anvil or reaction structure is required behind the welded material to react the load along the axis of the pin tool. The process requires no external heat input, filler material, protective shielding gas or inert atmosphere typical of fusion weld processes. The FSW solid-state weld process has resulted in aluminum welds with significantly higher strengths, higher joint efficiencies and fewer defects than fusion welds used to join similar alloys.
The abundances of the actinide elements in the cosmic rays can provide critical constraints on the major sites of their acceleration. Using recent calculations of the r-process yields in core collapse supernovae, we have determined the actinide abundances averaged over various assumed time intervals for their supernova generation and their cosmic-ray acceleration. Using standard Galactic chemical evolution models, we have also determined the expected actinide abundances in the present interstellar medium. From these two components, we have calculated the U/Th and other actinide abundances expected in the supernova-active cores of superbubbles, as a function of their ages and mean metallicity resulting from dilution with interstellar cloud debris. Then, using observations of the fractions of Galactic supernovae that occur in superbubbles and in the rest of the interstellar medium, we calculate the expected actinide abundances in cosmic rays accelerated by Galactic supernovae. We find that the current measurements of actinide/Pt-group and preliminary estimates of the UPuCm/Th ratio in cosmic rays are all consistent with the expected values if superbubble cores have mean metallicities of around 3 times solar. Such metallicities are quite comparable to the superbubble core metallicities inferred from other cosmic-ray observations. Future, more precise measurements of these ratios with experiments such as ECCO are needed to provide a better measure of the mean source metallicity sampled by the local Galactic cosmic rays. Measurements of the cosmic- ray actinide abundances have been favorably compared with the protosolar ratio, inferred from present solar system abundances, to infer that the cosmic rays are accelerated from the general interstellar medium. We suggest, however, that such an inference is not valid because the expected actinide abundances in the present interstellar medium are very different from the protosolar values, which sampled the interstellar medium 4.5 Gyr ago and included an additional fresh ejecta component from a neighboring supernova.
The aim of this experiment was to test the optical behavior of 20 components and coatings subjected to space exposure. Most of them are commonly used for their reflective or transmittive properties in spaceborne optics. They consist in several kind of metallic and dielectric mirrors designed for the 0.12 to 10 microns spectrum, UV, and NIR bandpass filters, visible, and IR antireflecting coatings, visible/IR dichroic beam splitters, and visible beam splitter. The coatings were deposited on various substrates such as glasses, germanium, magnesium fluoride, quartz, zinc selenide, and kanigened aluminum. Several coating materials were used such as Al, Ag, Au, MgF2, LaF3, ThF3, ThF4, SiO2, TiO2, ZrO2, Al2O3, MgO, Ge, and ZnSe. Five samples of each component were manufactured. Two flight samples were mounted in such a way that one was directly exposed to space and the other looking backwards. The same arrangement was used for the spare samples stored on ground in a box identical to the flight one and they were kept under vacuum during the LDEF mission. Finally, one set of reference components was stocked in a sealed box under a dry nitrogen atmosphere. By comparing the preflight and postflight optical performances of the five samples of each component, it is possible to detect the degradations due to the space exposure.
We investigated the metal-rich chondrite Sierra Gorda (SG) 009, a member of the new G chondrite grouplet (also including NWA 5492, GRO 95551). G chondrites contain 23% metal, very reduced silicates, and rare oxidized mineral phases (Mg-chromite, FeO-rich pyroxene). G chondrites are not related to CH-CB chondrites, based on bulk O, C and N isotopic compositions, mineralogy and geochemistry. G chondrites have no fine-grained matrix or matrix lumps enclosing hydrated material typical for CH-CB chondrites. G chondrites’ average metal compositions are similar to H chondrites. Siderophile and lithophile geochemistry indicate sulfidization and fractionation of the SG 009 metal and silicates, unlike NWA 5492 and GRO 05551. The G chondrites have average O isotopic compositions DELTA 17O >0 ‰ ranging between bulk enstatite (E) and ordinary (O) chondrites. An Al-rich chondrule from SG 009 has DELTA 17O <0 ‰ indicating some heterogeneity in oxygen isotopic composition of G chondrite components. SG 009’s bulk carbon and nitrogen isotopic compositions correspond to E and O chondrites. Neon isotopic composition reflects a mixture of cosmogenic and solar components, and cosmic ray exposure age of SG 009 is typical for O, E, and R chondrites. G chondrites are closely related to O, E, and R chondrites and may represent a unique metal-rich parent asteroid containing primitive and fractionated material from the inner Solar System. Oxidizing and reducing conditions during SG 009 formation may be connected with a chemical micro-environment and possibly could indicate that G chondrites may have formed by a planetesimal collision resulting in the lack of matrix.
The NASA Marshall Space Flight Center (MSFC) has been leading the development of technologies that will enable the development, fabrication, and flight of the automated X-37 Orbital Vehicle (OV). With the Administration s recent announcement of the Vision for Space Exploration, NASA placed the X-37 OV design on hold while developing detailed requirements for a Crew Exploration Vehicle, but has continued funding the development of high-risk, critical technologies for potential future space exploration vehicle applications. Hot Structure Control Surfaces (HSCS) technology development is one of the high-priority areas being funded at this time. The goal of HSCS research is to mitigate risk by qualifying the lightest possible components that meet the stringent X-37 OV weight and performance requirements, including Shuttle-type reen- try environments with peak temperatures of 2800 OF. The small size of the X-37 OV (25.7-feet long and 14.9-foot wingspan) drives the need for advanced HSCS because the vehicle's two primary aerodynamic surfaces, the flaperons and ruddervators, have thicknesses ranging from approximately 5 in. down to 1 in. Traditional metallic or polymer-matrix composites covered with tile or blanket thermal protection system (TPS) materials cannot be used as there is insufficient volume to fabricate such multi-component structures. Therefore, carbon-carbon (C-C) and carbodsilicon-carbide (C-SiC) composite HSCS structures are being developed in parallel by two teams supporting the X-37 prime contractor (The Boeing Company). The Science Applications International Coy. (SAIC) and Carbon-Carbon Advanced Technologies, Inc. (C-CAT) team is developing the C-C HSCS, while the General Electric Energy Power Systems Composites (GE-PSC) and Materials Research and Design (MRD) team is developing the C-SiC HSCS. These two teams were selected to reduce the high level of risk associated with developing advanced control surface components. They have continued HSCS development work as part of the X-37 critical technology development contract. The SAIC/C-CAT team is using Advanced Carbon-Carbon (ACC) because its fabrication is very similar to the process used for Space Shuttle Reinforced Carbon-Carbon fabrication, including the Sic-based pack cementation conversion coating systems using with both materials. ACC was selected over RCC because it has much higher tension and compressions strengths, and because T-300 fiber is readily available, whereas RCC rayon fiber is no longer manufactured. The GE-PSC/MRD team is using a T-300 fiber-reinforced Sic matrix composite material densified by chemical vapor infiltration. The C-Sic material has an Sic-based environmental barrier coating. Major accomplishments have been made over the past year by both HSCS teams. C-C and C- SiC flaperon subcomponents, which are truncated full-scale versions of flight hardware, have been fabricated and are undergoing testing at the NASA Dryden Flight Research Center, NASA Langley Research Center, and U.S. Air Force Research Laboratory. By the end of 2004, ruddervator subcomponents also will be delivered and tested. As NASA moves forward in realizing the Vision for Space Exploration, it will continue to invest in advanced research and development aimed at making new generations of spacecraft safer, more reliable, and more affordable. The X-37 HSCS effort ultimately will benefit the Agency's vision and mission.
Molecular Rayleigh scattering offers a means to measure gas flow parameters including density, temperature, and velocity. No seeding of the flow is necessary. The Rayleigh scattered power is proportional to the gas density, the spectral width is related to the gas temperature, and the shift in the frequency of the spectral peak is proportional to one component of the fluid velocity. Velocity measurements based on Rayleigh scattering are more suitable for high-speed flow, where the bulk fluid velocity is on the order of, or larger than, the molecular thermal velocities. Use of ultraviolet wavelengths for Rayleigh scattering diagnostics is attractive for two reasons. First, the Rayleigh scattering cross section is proportional to the inverse 4th power of the wavelength. And second, the reflectivity of metallic surfaces is generally less than it is at longer wavelengths. This is of particular interest in confined flow situations, such as in small wind tunnels and aircraft engine components, where the stray laser light scattered from the windows and internal surfaces in the test facility limits the application of Rayleigh scattering diagnostics. In this work at the NASA Lewis Research Center, molecular Rayleigh scattering of the 266-nm fourth harmonic of a pulsed, injection seeded Nd:YAG (neodymium:yttriumaluminum- garnet) laser was used to measure velocity in a supersonic free air jet with a 9.3- mm exit diameter. The frequency of the Rayleigh scattered light was analyzed with a planar mirror Fabry-Perot interferometer used in a static imaging mode, with the images recorded on a cooled, high-quantum-efficiency charge-coupled discharge (CCD) camera. In addition, some unshifted light from the same laser pulse was imaged through the interferometer to generate a reference. Data were obtained with single laser pulses at velocities up to Mach 1.3. The measured velocities were in good agreement with velocities calculated from isentropic flow relations. Our conclusion from this study was that ultraviolet Rayleigh scattering is preferable in confined flow situations because of the increase in the ratio of Rayleigh scattering signal to stray laser light. On the other hand, in open flows, such as free jets and larger wind tunnels where stray laser light can be controlled, visible Rayleigh scattering is preferable.
Weight savings in the range from 25 to 35 percent could be achieved on Space Shuttle orbiter components and the thermal protection system (TPS) by employing a suitable graphite/polyimide (Gr/Pi) composite material system as a substitute for the baseline aluminum structural material. Predicted weight savings are based on the superior strength and stiffness-to-density ratios of Gr/Pi composite material over metallic counterparts. Specific strength and stiffness properties of Celion/Larc-160 composite laminates are compared with aluminum and titanium alloys. Aspects of materials and processes development are discussed, taking into account Celion/Larc-160 composite cure cycle and tooling evolution, complex shaped component process development, mechanical and physical properties testing and results, and structural element design fabrication, testing, and results. Attention is given to a demonstration of materials and processing technology, and a Celion/Larc-160 materials and processes summary is presented.
Sources of the interior noise level of typical light aircraft are identified for stationary conditions on the ground and in flight. In addition, the relationship between the exterior near- and far-field noise around an aircraft and the interior noise field is examined. The sound transmission paths of a light aircraft fuselage are investigated, and the relative effectiveness of several components of the fuselage for sound attenuation is assessed. The fuselage furnishes an acoustic attenuation of about 20 dB; windows and metallic areas appear to transmit approximately equal amounts of sound energy.
A method is being developed to obtain creep data on foil gage metals at elevated temperatures using an automated data acquisition system in conjunction with a mechanically counter balanced extensometer. The automated system components include the Hewlett-Packard (HP) 9845A desktop computer, the HP 3455A digital voltmeter and the HP 3495A scanner. Software for test monitoring and data collection was developed; data manipulation, including curve plotting was done with a HP regression analysis software package. Initial creep tests were conducted on .003 in. thick foil specimens of Ti-6A1-4V at temperatures of 800 F and 1000 F and at stress levels of 25 ksi and 45 ksi. For comparison, duplicate tests were run on .049 in. thick specimens sheet of the same alloy. During testing, the furnace and specimen temperature, bridge voltage, strain and load output were automatically monitored and recorded at predetermined intervals. Using the HP regression analysis program, recorded strain output was plotted as a function of time. These resultant creep curves indicate that, under similar conditions of temperature and stress, foil gage specimens exhibit a higher creep rate than sheet specimens.
Boundary conditions involving higher order derivatives are presented by simulating surfaces whose reflection coefficients are known analytically, numerically, or experimentally. Procedures for determining the coefficients of the derivatives are discussed, along with the effect of displacing the surface where the boundary conditions are applied. Provided the coefficients satisfy a duality relation, equivalent forms of the boundary conditions involving tangential field components are deduced, and these provide the natural extension to non-planar surfaces. As an illustration, the simulation of metal-backed uniform and three-layer dielectric coatings is given. It is shown that fourth order conditions are capable of providing an accurate simulation for the uniform coating at least a quarter of a wavelength in thickness. Provided, though, some compromise in accuracy is acceptable, it is also shown that a third order condition may be sufficient for practical purposes when simulating uniform coatings.