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All sourcesNASA NTRSDOE OSTI
NASA NTRS1986

Development of sensor augmented robotic weld systems for aerospace propulsion system fabrication

In order to meet stringent performance goals for power and reuseability, the Space Shuttle Main Engine was designed with many complex, difficult welded joints that provide maximum strength and minimum weight. To this end, the SSME requires 370 meters of welded joints. Automation of some welds has improved welding productivity significantly over manual welding. Application has previously been limited by accessibility constraints, requirements for complex process control, low production volumes, high part variability, and stringent quality requirements. Development of robots for welding in this application requires that a unique set of constraints be addressed. This paper shows how robotic welding can enhance production of aerospace components by addressing their specific requirements. A development program at the Marshall Space Flight Center combining industrial robots with state-of-the-art sensor systems and computer simulation is providing technology for the automation of welds in Space Shuttle Main Engine production.

Jones, C. S.↗
NASA NTRS1988

Optimization of low gravity materials processing experiments using expert systems

The use of an expert system for the control of materials processing experiments in a facility such as the Space Station provides a number of attractive features for insuring that certain critical process parameters can be used to optimize the productivity of the materials processing experiments. The proposed approach to implementation of an expert system utilizes a knowledge base of desired process characteristics which will provide the desired results. The knowledge base for each experiment will be created in conjunction with the scientific investigator in charge of the experiment. Improvements to the knowledge base will be expanded to include self learning sessions in ground based experiments in order to teach the expert system how to respond to perturbations in the process and update the knowledge base on what process change should be implemented in order to reach the desired end product. Design considerations using an on-line real time expert system such as PICON is studied. The types of experiments evaluated include several types of solidification experiments which will be performed on the Space Station.

Workman, Gary L.↗
NASA NTRS1999

Space Weathering in the Fine Size Fractions of Lunar Soils: Soil Maturity Effects

The effects of space weathering on the optical properties of lunar materials have been well documented. These effects include a reddened continuum slope, lowered albedo, and attenuated absorption features in reflectance spectra of lunar soils as compared to finely comminuted rocks from the same Apollo sites. However, the regolith processes that cause these effects are not well known, nor is the petrographic setting of the products of these processes fully understood. A Lunar Soil Characterization Consortium has been formed with the purpose of systematically integrating chemical and mineralogical data with the optical properties of lunar soils. Understanding space-weathering effects is critical in order to fully integrate the lunar sample collection with remotely-sensed data from recent robotic missions (e.g., Lunar Prospector, Clementine, and Galileo) We have shown that depositional processes (condensation of impact-derived vapors, sputter deposits, accreted impact material, e.g., splash glass, spherules, etc.) are a major factor in the modification of the optical surfaces of lunar regolith materials. In mature soils, it is the size and distribution of the nanophase metal in the soil grains that has the major effect on optical properties. In this report, we compare and contrast the space-weathering effects in an immature and a mature soil with similar elemental compositions. For this study, we analyzed <10 micron sieve fractions of two Apollo 17 soils, 79221 (mature, Is/FeO = 81) and 71061 (immature, Is/FeO = 14). Details of the sieving procedures and allocation scheme are given else where. The results of other detailed chemical, mineralogical, and spectroscopic analyses of these soil samples are reported elsewhere. A representative sample of each soil was embedded in low-viscosity epoxy, and thin sections (about 70nm thick) were obtained through ultra microtomy. The thin sections used for these analyses typically contained cross sections of up to 500 individual grains. The thin sections were studied using a JEOL 2010 transmission electron microscope (TEM) equipped with a thin window energy-dispersive X-ray (EDX) spectrometer. An individual thin section was selected from each soil, and for each grain in the section we determined (1) the elemental composition by EDX; (2) whether the grain was crystalline or glassy using electron diffraction and darkfield imaging; (3) the presence or absence of rims and accreted material; and (4) the distribution of nanophase Fe where present. Most of the categories are self-evident; however, we divide the agglutinate derived material into agglutinitic glass (glass with approximately the same composition as the bulk soil that contains nanophase Fe with or without vesicles) and agglutinate fragments, which are composed of crystalline grains and agglutinitic glass. Lithic fragments are defined as polymineralic grains with no glass. Pyroxene grains have been divided into high- and low-Ca groups. As expected, there are a number of differences in the petrography of the <10-microns fractions of 79221 and 71061 given the great difference in their respective maturities, but we focus here on two major distinctions: agglutinate content and the number of grains with micropatina. Slightly over 50% of the particles in 79221 consist of agglutinitic glass and agglutinate fragments, while the remainder are predominantly crystalline mineral grains. The agglutinic glass particles contain abundant nanophase Fe and vesicles. Angular particles are rare, with most showing smooth, rounded exteriors, Of the mineral grains analyzed thus far, over 90% of the grains have amorphous rims that contain nanophase Fe (these rims are believed to have formed by vapor deposition and irradiation effects). The nanophase Fe in these rims probably accounts for a significant fraction of the increase in Is/FeO measured in these size fractions. In addition to the rims, the majority of particles also show abundant accreted material in the form of glass splashes and spherules that also contain nanophase Fe. In stark contrast, the surfaces of the mineral grains in the 71061 sample are relatively prisitine, as only about 14% of the mineral grains in the sample exhibited amorphous rims. Furthermore, the mineral particles are more angular and show greater surface roughness than in the mature sample. Accreted material on particle surfaces is rare. Agglutinitic material is a major component of the 71061 sample; however, nanophase Fe and vesicles are not as well developed as in the 79221 sample. It is now recognized that nanophase Fe is probably the main agent in modifying the optical properties of lunar soil grains. The most important result of this study is the observation that in the fine size fractions of mature soils, nearly every grain has nanophase Fe within 100 run of the particle surface. (Additional Information contained in original)

Keller, L. P.↗
NASA NTRS2002

Microstructural Studies of Space Weathering Effects in Lunar Materials

Space weathering is a term used to include all of the processes which act on material exposed at the surface of a planetary or small body. In the case of the moon, it includes a variety of processes which have formed the lunar regolith, caused the maturation of lunar soils, and formed patina on rock surfaces. The processes include micrometeorite impact and reworking, implantation of solar wind and flare particles, radiation damage and chemical effects from solar particles and cosmic rays, interactions with the lunar atmosphere, and sputtering erosion and deposition. Space weathering effects collectively result in a reddened continuum slope, lowered albedo, and attenuated absorption features in reflectance spectra of lunar soils as compared to finely comminuted rocks from the same Apollo sites. However, the regolith processes that cause these effects are not well known, nor is the petrographic setting of the products of these processes fully understood. An interesting confluence of events occurred in the early 1990s. First, came the discovery of vapor deposited coatings on lunar regolith grains by Keller and McKay, who showed that amorphous coatings from 50-100 nm thick containing fine-grained Fe metal (1-10 nm in diameter) were common in the fine size fraction of several mature lunar soils. The other discovery was the recognition that the optical properties of lunar soils were dominated by fine grain sized material (less than 45 micrometer fraction) by Pieters and coworkers. These discoveries led to coordinated studies that looked at the mineralogy, chemistry, and optical properties of lunar soils as function of composition, maturity, and grain size fraction. One of the major revelations from these studies was the recognition that much of the nanophase Fe metal is surface-correlated especially in the finest size fractions, and that it was this nanophase Fe that dominated the optical properties of the soil.

Keller, L. P.↗
NASA NTRS2013

Processing of KaRIn/SWOT Data

The Surface Water and Ocean Topography (SWOT) mission [1] is part of NASA’s Decadal Survey Program, and prepared jointly by NASA’s Jet Propulsion Laboratory (JPL), the French space agency (CNES), and the Canadian space agency (CSA). Launch is currently foreseen in 2020. The principal instrument KaRIn (Ka-band Radar Interferometer) would be a bistatic SAR system operating at Kaband, with 200 MHz bandwidth, covering 50 km wide near-nadir swaths (1-4° incidence) on both sides of the satellite track. The nominal payload also would include a conventional Ku/C-band nadir altimeter, a water vapor radiometer, and a precise orbit determination suite. Moreover, additional near-nadir channels from KaRIn to reduce the gap between the nominal swaths may be considered. The main mission goals would be to improve the spatio-temporal coverage of the oceans with respect to today’s nadir-looking altimeters (such as the Jason series), by providing measurements on a 1 km2 grid with virtually complete coverage up to ±78° latitude, while keeping a height precision of 1-2 cm, and to extend the altimetry measurements to continental water surfaces, including lakes, reservoirs and wetlands bigger than 250x250 m2 and rivers down to a width of 100 m (50 m as a goal), with a height precision of the order of 10 cm, represented with a horizontal point spacing of about 50 m. The fine scale of the measurements, with continuous acquisition over both oceans and continents, will result in huge data volumes, starting at the spacecraft and flowing through all links of the ground system. Furthermore, the centimetric height accuracy required means that all aspects of the processing must be considered carefully. In this article we give an overview of the foreseen data products and data processing chains for KaRIn on SWOT. Some particularly challenging processing steps are (will be) described in more detail.

Desroches, Damien↗
NASA NTRS1992

Realization of high quality production schedules: Structuring quality factors via iteration of user specification processes

This paper describes an architecture for realizing high quality production schedules. Although quality is one of the most important aspects of production scheduling, it is difficult, even for a user, to specify precisely. However, it is also true that the decision as to whether a scheduler is good or bad can only be made by the user. This paper proposes the following: (1) the quality of a schedule can be represented in the form of quality factors, i.e. constraints and objectives of the domain, and their structure; (2) quality factors and their structure can be used for decision making at local decision points during the scheduling process; and (3) that they can be defined via iteration of user specification processes.

Hamazaki, Takashi↗
NASA NTRS2008

SAGE II Measurements of Stratospheric Aerosol Properties at Non-Volcanic Levels

Since 2000, stratospheric aerosol levels have been relatively stable and at the lowest levels observed in the historical record. Given the challenges of making satellite measurements of aerosol properties at these levels, we have performed a study of the sensitivity of the product to the major components of the processing algorithm used in the production of SAGE II aerosol extinction measurements and the retrieval process that produces the operational surface area density (SAD) product. We find that the aerosol extinction measurements, particularly at 1020 nm, remain robust and reliable at the observed aerosol levels. On the other hand, during background periods, the SAD operational product has an uncertainty of at least a factor of 2 during due to the lack of sensitivity to particles with radii less than 100 nm.

Thomason, Larry W.↗
NASA NTRS1977

Low cost silicon solar array project silicon materials task: Establishment of the feasibility of a process capable of low-cost, high volume production of silane (step 1) and the pyrolysis of silane to semiconductor-grade silicon (step 2)

Extended operation of a small process-development unit routinely produced high quality silane in 97+% yield from dichlorosilane. The production rate was consistent with design loadings for the fractionating column and for the redistribution reactor. A glass fluid-bed reactor was constructed for room temperature operation. The behavior of a bed of silcon particles was observed as a function of various feedstocks, component configurations, and operating conditions. For operating modes other than spouting, the bed behaved in an erratic and unstable manner. A method was developed for casting molten silicon powder into crack-free solid pellets for process evaluation. The silicon powder was melted and cast into thin walled quartz tubes that sacrificially broke on cooling.

Breneman, W. C.↗
NASA NTRS1985

Investigation of test methods, material properties and processes for solar cell encapsulants

The historical development of ethylene vinyl acetate (EVA) is presented, including the functional requirements, polymer selection, curing, stabilization, production and module processing. The construction and use of a new method for the accelerated aging of polymers is detailed. The method more closely resembles the conditions that may be encountered in actual module field exposure and additionally may permit service life to be predicted accurately. The use of hardboard as a low cost candidate substrate material is studied. The performance of surface antisoiling treatments useful for imparting a self cleaning property to modules is updated.

Willis, P. B.↗
NASA NTRS2010

Application of a Modified Universal Design Survey for Evaluation of Ares 1 Ground Crew Worksites

Operability is a driving requirement for NASA's Ares 1 launch vehicle. Launch site ground operations include several operator tasks to prepare the vehicle for launch or to perform maintenance. Ensuring that components requiring operator interaction at the launch site are designed for optimal human use is a high priority for operability. To support design evaluation, the Ares 1 Upper Stage (US) element Human Factors Engineering (HFE) group developed a survey based on the Universal Design approach. Universal Design is a process to create products that can be used effectively by as many people as possible. Universal Design per se is not a priority for Ares 1 because launch vehicle processing is a specialized skill and not akin to a consumer product that should be used by all people of all abilities. However, applying principles of Universal Design will increase the probability of an error free and efficient design which is a priority for Ares 1. The Design Quality Evaluation Survey centers on the following seven principles: (1) Equitable use, (2) Flexibility in use, (3) Simple and intuitive use, (4) Perceptible information, (5) Tolerance for error, (6) Low physical effort, (7) Size and space for approach and use. Each principle is associated with multiple evaluation criteria which were rated with the degree to which the statement is true. All statements are phrased in the utmost positive, or the design goal so that the degree to which judgments tend toward "completely agree" directly reflects the degree to which the design is good. The Design Quality Evaluation Survey was employed for several US analyses. The tool was found to be most useful for comparative judgments as opposed to an assessment of a single design option. It provided a useful piece of additional data when assessing possible operator interfaces or worksites for operability

Blume, Jennifer L.↗
NASA NTRS1983

ECUT: Energy Conversion and Utilization Technologies program biocatalysis research activity. Potential membrane applications to biocatalyzed processes: Assessment of concentration polarization and membrane fouling

Separation and purification of the products of biocatalyzed fermentation processes, such as ethanol or butanol, consumes most of the process energy required. Since membrane systems require substantially less energy for separation than most alternatives (e.g., distillation) they have been suggested for separation or concentration of fermentation products. This report is a review of the effects of concentration polarization and membrane fouling for the principal membrane processes: microfiltration, ultrafiltration, reverse osmosis, and electrodialysis including a discussion of potential problems relevant to separation of fermentation products. It was concluded that advanced membrane systems may result in significantly decreased energy consumption. However, because of the need to separate large amounts of water from much smaller amounts of product that may be more volatile than wate, it is not clear that membrane separations will necessarily be more efficient than alternative processes.

Ingham, J. D.↗
NASA NTRS2004

An Integrated Decision-Making Model for Categorizing Weather Products and Decision Aids

The National Airspace System s capacity will experience considerable growth in the next few decades. Weather adversely affects safe air travel. The FAA and NASA are working to develop new technologies that display weather information to support situation awareness and optimize pilot decision-making in avoiding hazardous weather. Understanding situation awareness and naturalistic decision-making is an important step in achieving this goal. Information representation and situation time stress greatly influence attentional resource allocation and working memory capacity, potentially obstructing accurate situation awareness assessments. Three naturalistic decision-making theories were integrated to provide an understanding of the levels of decision making incorporated in three operational situations and two conditions. The task characteristics associated with each phase of flight govern the level of situation awareness attained and the decision making processes utilized. Weather product s attributes and situation task characteristics combine to classify weather products according to the decision-making processes best supported. In addition, a graphical interface is described that affords intuitive selection of the appropriate weather product relative to the pilot s current flight situation.

Elgin, Peter D.↗
NASA NTRS2015

3D Printing Multi-Functionality: Embedded RF Antennas and Components

Significant research and press has recently focused on the fabrication freedom of Additive Manufacturing (AM) to create both conceptual models and final end-use products. This flexibility allows design modifications to be immediately reflected in 3D printed structures, creating new paradigms within the manufacturing process. 3D printed products will inevitably be fabricated locally, with unit-level customization, optimized to unique mission requirements. However, for the technology to be universally adopted, the processes must be enhanced to incorporate additional technologies; such as electronics, actuation, and electromagnetics. Recently, a novel 3D printing platform, Multi3D manufacturing, was funded by the presidential initiative for revitalizing manufacturing in the USA using 3D printing (America Makes - also known as the National Additive Manufacturing Innovation Institute). The Multi3D system specifically targets 3D printed electronics in arbitrary form; and building upon the potential of this system, this paper describes RF antennas and components fabricated through the integration of material extrusion 3D printing with embedded wire, mesh, and RF elements.

antennas↗
NASA NTRS1997

Methyl Chloroform Elimination from the Production of Space Shuttle Sold Rocket Motors

Thiokol Space Operations manufactures the Reusable Solid Rocket Motors used to launch America's fleet of Space Shuttles. In 1989, Thiokol used more than 1.4 Mlb of methyl chloroform to produce rocket motors. The ban placed by the Environmental Protection Agency on the sale of methyl chloroform had a significant effect on future Reusable Solid Rocket Motor production. As a result, changes in the materials and processes became necessary. A multiphased plan was established by Thiokol in partnership with NASA's Marshall Space Flight Center to eliminate the use of methyl chloroform in the Reusable Solid Rocket Motor production process. Because of the extensive scope of this effort, the plan was phased to target the elimination of the majority of methyl chloroform use (90 percent) by January 1, 1996, the 3 Environmental Protection Agency deadline. Referred to as Phase I, this effort includes the elimination of two large vapor degreasers, grease diluent processes, and propellant tooling handcleaning using methyl chloroform. Meanwhile, a request was made for an essential use exemption to allow the continued use of the remaining 10 percent of methyl chloroform after the 1996 deadline, while total elimination was pursued for this final, critical phase (Phase II). This paper provides an update to three previous presentations prepared for the 1993, 1994, and 1995 CFC/Halon Alternative Conferences, and will outline the overall Ozone Depleting Compounds Elimination Program from the initial phases through the final testing and implementation phases, including facility and equipment development. Processes and materials to be discussed include low-pressure aqueous wash systems, high-pressure water blast systems- environmental shipping containers, aqueous and semi-aqueous cleaning solutions, and bond integrity and inspection criteria. Progress toward completion of facility implementation and lessons learned during the scope of the program, as well as the current development efforts and basic requirements of future methyl chloroform handcleaning elimination, will also be outlined.

Golde, Rick P.↗
NASA NTRS1983

ECUT: Energy Conversion and utilization Technologies program biocatalysis research activity. Generation of chemical intermediates by catalytic oxidative decarboxylation of dilute organic acids

A rhodium-based catalyst was prepared and preliminary experiments were completed where the catalyst appeared to decarboxylate dilute acids at concentrations of 1 to 10 vol%. Electron spin resonance spectroscoy was used to characterize the catalyst as a first step leading toward modeling and optimization of rhodium catalysts. Also, a hybrid chemical/biological process for the production of hydrocarbons has been assessed. These types of catalysts could greatly increase energy efficiency of this process.

Distefano, S.↗
NASA NTRS1997

Formation of Carbon Nanotube Based Gears: Quantum Chemistry and Molecular Mechanics Study of the Electrophilic Addition of o-Benzyne to Fullerenes, Graphene, and Nanotubes

Considerable progress has been made in recent years in chemical functionalization of fullerene molecules. In some cases, the predominant reaction products are different from those obtained (using the same reactants) from polycyclic aromatic hydrocarbons (PAHs). One such example is the cycloaddition of o-benzyne to C60. It is well established that benzyne adds across one of the rings in naphthalene, anthracene and other PAHs forming the [2+4] cycloaddition product (benzobicyclo[2.2.2.]-octatriene with naphthalene and triptycene with anthracene). However, Hoke et al demonstrated that the only reaction path for o-benzyne with C60 leads to the [2+2] cycloaddition product in which benzyne adds across one of the interpentagonal bonds (forming a cyclobutene ring in the process). Either reaction product results in a loss of aromaticity and distortion of the PAH or fullerene substrate, and in a loss of strain in the benzyne. It is not clear, however, why different products are preferred in these cases. In the current paper, we consider the stability of benzyne-nanotube adducts and the ability of Brenner's potential energy model to describe the structure and stability of these adducts. The Brenner potential has been widely used for describing diamondoid and graphitic carbon. Recently it has also been used for molecular mechanics and molecular dynamics simulations of fullerenes and nanotubes. However, it has not been tested for the case of functionalized fullerenes (especially with highly strained geometries). We use the Brenner potential for our companion nanogear simulations and believe that it should be calibrated to insure that those simulations are physically reasonable. In the present work, Density Functional theory (DFT) calculations are used to determine the preferred geometric structures and energetics for this calibration. The DFT method is a kind of ab initio quantum chemistry method for determining the electronic structure of molecules. For a given basis set expansion, it is comparable in accuracy to the MP2 method (better than Hartree Fock, but less accurate than more extensive electron correlation methods such as MP4 or CCSD). However, for systems with large numbers of basis functions it more efficient than any other methods that include electron correlation effects. In this presentation we show the results of DFT calculations for the reaction of benzyne with naphthalene, C60, and nanotube models. We compare energies for [2+2] and [2+4] cycloaddition products. The preferred products for the naphthalene and C60 reactions have been determined by experiment and, thus, these cases serve as a validation of our quantum chemical approach. We also compare the DFT and Brenner potential results. Finally we can predict the likelihood of reaction between benzyne and nanotubes.

Jaffe, Richard↗
NASA NTRS2009

Onboard Classification of Hyperspectral Data on the Earth Observing One Mission

Remote-sensed hyperspectral data represents significant challenges in downlink due to its large data volumes. This paper describes a research program designed to process hyperspectral data products onboard spacecraft to (a) reduce data downlink volumes and (b) decrease latency to provide key data products (often by enabling use of lower data rate communications systems). We describe efforts to develop onboard processing to study volcanoes, floods, and cryosphere, using the Hyperion hyperspectral imager and onboard processing for the Earth Observing One (EO-1) mission as well as preliminary work targeting the Hyperspectral Infrared Imager (HyspIRI) mission.

cryosphere↗
NASA NTRS1999

Trade Study of Five In-Situ Propellant Production Systems for a Mars Sample Return Mission

One of the goals of NASA's HEDS enterprise is to establish a long-term human presence on Mars at a fraction of the cost of employing today's technology. The most direct method of reducing mission cost is to reduce the launch mass of the spacecraft. If the propellants for the return phase of the mission are produced on Mars, the total spacecraft mass could be reduced significantly. An interim goal is a Mars Sample Return (MSR) mission, which is proposed to demonstrate the feasibility of in-situ propellant production (ISPP). Five candidate ISPP systems for producing two fuels and oxygen from the Martian atmosphere are considered in this design trade-off study: 1) Zirconia cell with methanol synthesis, 2) Reverse water gas shift with water electrolysis and methanol synthesis, 3) Sabatier process for methane product ion with water electrolysis, 4) Sabatier process with water electrolysis and partial methane pyrolysis, and 5) Sabatier/RWGS combination with water electrolysis.

Green, S. T.↗