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NASA NTRS2001

An Example of Economic Value in Rapid Prototyping

Today's modern machining projects are composed more and more of complicated and intricate structure due to a variety of reasons including the ability to computer model complex surfaces and forms. The cost of producing these forms can be extremely high not only in dollars but in time to complete. Changes are even more difficult to incorporate. The subject blade shown is an excellent example. Its complex form would have required hundreds of hours in fabrication for just a simple prototype. The procurement would have taken in the neighborhood of six weeks to complete. The actual fabrication would have been an equal amount of time to complete. An alternative to this process would have been a wood model. Although cheaper than a metal fabrication, it would be extremely time intensive and require in the neighborhood of a month to produce in-house.

Hauer, R. L.↗
NASA NTRS2001

X-traktor: A Rookie Robot, Simple, Yet Complex, Impeccably Designed, a Very Innovative Multidisciplinary Engineering Masterpiece

FIRST is the acronym of For Inspiration and Recognition of Science and Technology. FIRST is a 501.C.3 non-profit organization whose mission is to generate an interest in science and engineering among today's young adults and youth. This mission is accomplished through a robot competition held annually in the spring of each year. NASAs Marshall Space Flight Center, Education Programs Department, awarded a grant to Lee High School, the sole engineering magnet school in Huntsville, Alabama. MSFC awarded the grant in hopes of fulfilling its goal of giving back invaluable resources to its community and engineers, as well as educating tomorrow's work force in the high-tech area of science and technology. Marshall engineers, Lee High School students and teachers, and a host of other volunteers and parents officially initiated this robot design process and competitive strategic game plan. The FIRST Robotics Competition is a national engineering contest, which immerses high school students in the exciting world of science and engineering. Teaming with engineers from government agencies, businesses, and universities enables the students to learn about the engineering profession. The students and engineers have six weeks to work together to brainstorm, design, procure, construct, and test their robot. The team then competes in a spirited, 'no-holds barred' tournament, complete with referees, other FIRST-designed robots, cheerleaders, and time clocks. The partnerships developed between schools, government agencies, businesses, and universities provide an exchange of resources and talent that build cooperation and expose students to new and rewarding career options. The result is a fun, exciting, and stimulating environment in which all participants discover the important connections between classroom experiences and real-world applications. This paper will highlight the story, engineering development, and evolutionary design of Xtraktor, the rookie robot, a manufacturing marvel and engineering achievement.

Henderson, A. J., Jr.↗
NASA NTRS2000

Getting Involved with the Discovery Program

NASA's Discovery Program represents the implementation of NASA Administrator Daniel Goldin's vision of 'faster, better, cheaper' planetary missions; encompasses a series of low-cost solar system exploration missions intended to accomplish high quality, focused planetary science investigations using innovative, streamlined, and efficient approaches to assure the highest science value for the cost; and aims to enhance our understanding of the solar system by exploring the planets, their moons and other small bodies, either by traveling to them or remotely from the vicinity of Earth. The objectives of this program include the following: (1) Provide exciting and important scientific data to the global community; (2) Pursue new and innovative ways of doing business; (3) Encourage technological development by designing and testing new technologies and transferring them to the private sector; (4) Increase public awareness of, and appreciation for, solar system exploration through exciting education and public outreach activities; (5) Support national education initiatives through mission-specific programs; and (6) Ensure participation of small disadvantaged businesses, women-owned businesses, HBCUs, and other minority educational institutions in procurements.

Asplund, Shari↗
NASA NTRS2001

Space Transportation Systems Technologies

This document is the final report by the Science Applications International Corporation (SAIC) on contracted support provided to the National Aeronautics and Space Administration (NASA) under Contract NAS8-99060, 'Space Transportation Systems Technologies'. This contract, initiated by NASA's Marshall Space Flight Center (MSFC) on February 8, 1999, was focused on space systems technologies that directly support NASA's space flight goals. It was awarded as a Cost-Plus-Incentive-Fee (CPIF) contract to SAIC, following a competitive procurement via NASA Research Announcement, NRA 8-21. This NRA was specifically focused on tasks related to Reusable Launch Vehicles (RLVs). Through Task Area 3 (TA-3), "Other Related Technology" of this NRA contract, SAIC extensively supported the Space Transportation Directorate of MSFC in effectively directing, integrating, and setting its mission, operations, and safety priorities for future RLV-focused space flight. Following an initially contracted Base Year (February 8, 1999 through September 30, 1999), two option years were added to the contract. These were Option Year 1 (October 1, 1999 through September 30, 2000) and Option Year 2 (October 1, 2000 through September 30, 2001). This report overviews SAIC's accomplishments for the Base Year, Option Year 1, and Option Year 2, and summarizes the support provided by SAIC to the Space Transportation Directorate, NASA/MSFC.

Laue, Jay H.↗
NASA NTRS2000

Lightweight Lidar Telescopes for Space Applications

NASA is intent on exploiting the unique perspective of space-based remote optical instruments to observe and study large-scale environmental processes. Emphasis on smaller and more affordable missions continues to force the remote sensing instruments to find innovative ways to reduce the size, weight, and cost of the sensor package. This is a challenge because many of the proposed instruments incorporate a high quality meter-class telescope that can be a significant driver of total instrument costs. While various methods for telescope weight reduction have been achieved, many of the current approaches rely on exotic materials and specialized manufacturing techniques that limit availability or substantially increase costs. A competitive lightweight telescope technology that is especially well suited to space-based coherent Doppler wind lidar has been developed through a collaborative effort involving NASA Marshall Space Flight Center (MSFC) through the Global Hydrology and Climate Center (GHCC) and the University of Alabama in Huntsville (UAH) at the Center for Applied Optics (CAO). The new lightweight optics using metal alloy shells and surfaces (LOMASS) fabrication approach is suitable for high quality metal mirrors and meter-class telescopes. Compared to alternative materials and fabrication methods the new approach promises to reduce the areal density of a meter-class telescope to less than 15-kg/sq m; deliver a minimum VIO-RMS surface optical quality; while using commercial materials and equipment to lower procurement costs. The final optical figure and finish is put into the mirrors through conventional diamond turning and polishing techniques. This approach is especially advantageous for a coherent lidar instrument because the reduced telescope weight permits the rotation of the telescope to scan the beam without requiring heavy wedges or additional large mirrors. Ongoing investigations and preliminary results show promise for the LOMASS approach to be successful in demonstrating a novel alternative approach to fabricating lightweight mirrors with performance parameters comparable with the Space Readiness Coherent Lidar Experiment (SPARCLE). Development and process characterization is continuing with the design and fabrication of mirrors for a 25-cm telescope suitable for a lidar instrument.

Peters, Bruce R.↗
NASA NTRS2001

Demonstration of Imaging Fourier Transform Spectrometer (FTS) Performance for Planetary and Geostationary Earth Observing

The combination of massively parallel spatial sampling and accurate spectral radiometry offered by imaging FTS makes it extremely attractive for earth and planetary remote sensing. We constructed a breadboard instrument to help assess the potential for planetary applications of small imaging FTS instruments in the 1 - 5 micrometer range. The results also support definition of the NASA Geostationary Imaging FTS (GIFTS) instrument that will make key meteorological and climate observations from geostationary earth orbit. The Planetary Imaging FTS (PIFTS) breadboard is based on a custom miniaturized Bomen interferometer that uses corner cube reflectors, a wishbone pivoting voice-coil delay scan mechanism, and a laser diode metrology system. The interferometer optical output is measured by a commercial infrared camera procured from Santa Barbara Focalplane. It uses an InSb 128x128 detector array that covers the entire FOV of the instrument when coupled with a 25 mm focal length commercial camera lens. With appropriate lenses and cold filters the instrument can be used from the visible to 5 micrometers. The delay scan is continuous, but slow, covering the maximum range of +/- 0.4 cm in 37.56 sec at a rate of 500 image frames per second. Image exposures are timed to be centered around predicted zero crossings. The design allows for prediction algorithms that account for the most recent fringe rate so that timing jitter produced by scan speed variations can be minimized. Response to a fixed source is linear with exposure time nearly to the point of saturation. Linearity with respect to input variations was demonstrated to within 0.16% using a 3-point blackbody calibration. Imaging of external complex scenes was carried out at low and high spectral resolution. These require full complex calibration to remove background contributions that vary dramatically over the instrument FOV. Testing is continuing to demonstrate the precise radiometric accuracy and noise characteristics.

Revercomb, Henry E.↗
NASA NTRS2001

An Overview of NASA Efforts on Zero Boiloff Storage of Cryogenic Propellants

Future mission planning within NASA has increasingly motivated consideration of cryogenic propellant storage durations on the order of years as opposed to a few weeks or months. Furthermore, the advancement of cryocooler and passive insulation technologies in recent years has substantially improved the prospects for zero boiloff storage of cryogenics. Accordingly, a cooperative effort by NASA's Ames Research Center (ARC), Glenn Research Center (GRC), and Marshall Space Flight Center (MSFC) has been implemented to develop and demonstrate "zero boiloff" concepts for in-space storage of cryogenic propellants, particularly liquid hydrogen and oxygen. ARC is leading the development of flight-type cryocoolers, GRC the subsystem development and small scale testing, and MSFC the large scale and integrated system level testing. Thermal and fluid modeling involves a combined effort by the three Centers. Recent accomplishments include: 1) development of "zero boiloff" analytical modeling techniques for sizing the storage tankage, passive insulation, cryocooler, power source mass, and radiators; 2) an early subscale demonstration with liquid hydrogen 3) procurement of a flight-type 10 watt, 95 K pulse tube cryocooler for liquid oxygen storage and 4) assembly of a large-scale test article for an early demonstration of the integrated operation of passive insulation, destratification/pressure control, and cryocooler (commercial unit) subsystems to achieve zero boiloff storage of liquid hydrogen. Near term plans include the large-scale integrated system demonstration testing this summer, subsystem testing of the flight-type pulse-tube cryocooler with liquid nitrogen (oxygen simulant), and continued development of a flight-type liquid hydrogen pulse tube cryocooler.

Hastings, Leon J.↗
NASA NTRS1995

Ames Research Center Mars/Pathfinder Heat Shield Design Verification ARC-JET Test

Design verification tests were performed on samples representing the aerobrake of the Mars/Pathfinder vehicle. The test specimens consisted of the SLA-561V ablator bonded to the honeycomb structure. The primary objective was to evaluate the ablation materials performance and to measure temperatures within the ablator, at the structural bondline and at the back sheet of the honeycomb structure. Other objectives were to evaluate the effect of ablative repair plug material treatment and voids in the heat shield. A total of 29 models were provided for testing in the Ames 60MW arc-jet facility. Of these, 23 models were flat-faced and six remaining models were curved edge ones, intended to simulate the conditions on the curved rim of the forebody where the maximum shear occurred. Eight sets of test conditions were used. The stagnation point heating rates varied from 47 to 240 W/cm2 and the stagnation pressures from 0.15 to 0.27 atm. (The maximum flight values are 132 W/cm2 and 0.25 atm) The majority of these runs were made at a nominal stagnation pressure of 0.25 atm. Two higher pressure runs were made to check the current (denser) ablation material for spallation, or other forms of thermal stress failure. Over 60% of the flatfaced models yielded good thermocouple data and all produced useful surface recession information. Of the five curved-edge models that were tested, only one gave good data; the remaining ones experienced model-holder failure. The test results can be summarized by noting that no failure of the ablative material was observed on any model. Also, the bondline temperature design limit of 250 C was never reached within an equivalent flight time despite a stagnation point heat load that exceeded the maximum flight value by up to 130%. At heating rates of over 200W/cm2 and stagnation pressures of 0.25 atm, or greater, the average surface recessions exceeded 0.5 cm on some models. The surface roughness increased dramatically at pressures above 0.25 atm and was four times greater at 0.27 atm than at 0.25 atm. Procured repair plug material performed much better than room-temperature cured plugs, as observed in the previous tests. Voids in the ablator did not increase local temperatures and gaps did not grow during testing.

Tran, Huy K.↗
NASA NTRS1999

Inertial Electrostatic Confinement Fusion: Set-Up and Operation

During the research period focus was placed upon set-up, installment, and operation of the IEC. While procurement of specific components was difficult, the IEC was on several occasions demonstrated to be practical and safe during operation. Over the course of the summer several different grids were tested and various modes were obtained. While hard data was not produced, the IEC did something more important, which was to become established here at Marshall and pave the way for future IEC systems to be built.

Hurst, Chantelle M.↗
NASA NTRS1999

Enabling Exploration of Deep Space: High Density Storage of Antimatter

Portable electromagnetic antiproton traps are now in a state of realization. This allows facilities like NASA Marshall Space Flight Center to conduct antimatter research remote to production sites. MSFC is currently developing a trap to store 10(exp 12) antiprotons for a twenty-day half-life period to be used in future experiments including antimatter plasma guns, antimatter-initiated microfusion, and the synthesis of antihydrogen for space propulsion applications. In 1998, issues including design, safety and transportation were considered for the MSFC High Performance Antimatter Trap (HiPAT). Radial diffusion and annihilation losses of antiprotons prompted the use of a 4 Tesla superconducting magnet and a 20 KV electrostatic potential at 10(exp -12) Torr pressure. Cryogenic fluids used to maintain a trap temperature of 4K were sized accordingly to provide twenty days of stand-alone storage time (half-life). Procurement of the superconducting magnet with associated cryostat has been completed. The inner, ultra-high vacuum system with electrode structures has been fabricated, tested and delivered to MSFC along with the magnet and cryostat. Assembly of these systems is currently in progress. Testing under high vacuum conditions, using electrons and hydrogen ions will follow in the months ahead.

Smith, Gerald A.↗
NASA NTRS1997

Don't Look Now - Tiltrotors Are Coming!

This paper traces the history of tiltrotors, beginning with the XV-3 and XV-15, to the Marine's V-22 Osprey. The design of the first civil tiltrotor, the Bell-Boeing 609, is now complete and the revolutionary aircraft will debut in 2001 after completion of a rigorous test program. The XV-3 proved the safety and ease of transition from the helicopter mode to the airplane mode; however, it had aeroelastic stability and performance problems. The XV-15 was the tiltrotor of the late 70s and the 80s. In 1981, it was demonstrated to the international aviation community at the Paris Air Show. Its success led to the development of the V-22 Osprey and it returned to Paris in 1995 in the livery of a civil tiltrotor. There, it flew joint demonstrations with the Osprey. One is still flying today as a Civil Tiltrotor (CTR) demonstrator. The V-22 first flew in Mar 1989. After a stormy procurement cycle, the Full Scale Development (FSD) aircraft were superseded by the improved Engineering and Manufacturing Development (EMD) aircraft. The #7 Osprey made its first flight eight years later. Many highlights of the FSD and EMD flight test programs will be covered and illustrated with video clips. The Bell-Boeing 609 design was unveiled at the Smithsonian in November, 1996 and the first orders have been taken for this 250 knot, corporate size tiltrotor. Flight testing of this innovative aircraft will commence in 1999.

Dugan, Daniel C.↗
NASA NTRS1998

Computerized Engineering

In 1966, MacNeal-Schwendler Corporation (MSC) was awarded a contract by NASA to develop a general purpose structural analysis program dubbed NASTRAN (NASA structural analysis). The first operational version was delivered in 1969. In 1982, MSC procured the rights to market their subsequent version of NASTRAN to industry as a problem solver for applications ranging from acoustics to heat transfer. Known today as MSC/NASTRAN, the program has thousands of users worldwide. NASTRAN is also distributed through COSMIC.

Source record↗
NASA NTRS2002

Structural Fluctuations and Thermophysical Properties of Molten II-VI Compounds

The objectives of the project are to conduct ground-based experimental and theoretical research on the structural fluctuations and thermophysical properties of molten II-VI compounds to enhance the basic understanding of the existing flight experiments in microgravity materials science programs as well as to study the fundamental heterophase fluctuation phenomena in these melts by: 1) conducting neutron scattering analysis and measuring quantitatively the relevant thermophysical properties of the II-VI melts (such as viscosity, electrical conductivity, thermal diffusivity and density) as well as the relaxation characteristics of these properties to advance the understanding of the structural properties and the relaxation phenomena in these melts and 2) performing theoretical analyses on the melt systems to interpret the experimental results. All the facilities required for the experimental measurements have been procured, installed and tested. Thermal diffusivity of molten tellurium has been measured by a laser flash method in the temperature range of 500 C to 900 C. The measured diffusivity as a function of temperature agrees fairly well with published data. However, a relaxation phenomenon, which shows a slow drift of the measured thermal conductivity toward the equilibrium value after cooling of the melt, was observed for the first time. An apparatus based on the transient torque induced by a rotating magnetic field has been developed to determine the viscosity and electrical conductivity of semiconducting liquids. Viscosity measurements on molten tellurium showed a similar relaxation behavior to the measured diffusivity. The density and volume expansion coefficients for pure Te and HgTe melts were measured as a function of temperature using a pycnometric method. A density maximum was found for both melts but no relaxation behavior was observed. Neutron scattering experiments were performed on the HgTe and HgZnTe melts and the results on pair distribution showed better resolution than previously reported. A simple kinetic theory, which contains the formation reactions of Te polymerization that increases the molecular weight, was proposed to interpret the relaxation behavior of HgZnTe viscosity data.

Su, Ching-Hua↗
NASA NTRS2002

Development of a Generic Creep-Fatigue Life Prediction Model

The objective of this research proposal is to further compile creep-fatigue data of steel alloys and superalloys used in military aircraft engines and/or rocket engines and to develop a statistical multivariate equation. The newly derived model will be a probabilistic fit to all the data compiled from various sources. Attempts will be made to procure the creep-fatigue data from NASA Glenn Research Center and other sources to further develop life prediction models for specific alloy groups. In a previous effort [1-3], a bank of creep-fatigue data has been compiled and tabulated under a range of known test parameters. These test parameters are called independent variables, namely; total strain range, strain rate, hold time, and temperature. The present research attempts to use these variables to develop a multivariate equation, which will be a probabilistic equation fitting a large database. The data predicted by the new model will be analyzed using the normal distribution fits, the closer the predicted lives are with the experimental lives (normal line 1 to 1 fit) the better the prediction. This will be evaluated in terms of a coefficient of correlation, R 2 as well. A multivariate equation developed earlier [3] has the following form, where S, R, T, and H have specific meaning discussed later.

Goswami, Tarun↗
NASA NTRS2002

Space Transportation and the Computer Industry: Learning from the Past

Since the space shuttle began flying in 1981, NASA has made a number of attempts to advance the state of the art in space transportation. In spite of billions of dollars invested, and several concerted attempts, no replacement for the shuttle is expected before 2010. Furthermore, the cost of access to space has dropped very slowly over the last two decades. On the other hand, the same two decades have seen dramatic progress in the computer industry. Computational speeds have increased by about a factor of 1000 and available memory, disk space, and network bandwidth has seen similar increases. At the same time, the cost of computing has dropped by about a factor of 10000. Is the space transportation problem simply harder? Or is there something to be learned from the computer industry? In looking for the answers, this paper reviews the early history of NASA's experience with supercomputers and NASA's visionary course change in supercomputer procurement strategy.

Merriam, M. L.↗
NASA NTRS2002

The Goddard Earth Sciences and Technology Center (GEST Center)

The following is a technical report of the progress made under Cooperative Agreement NCC5494, the Goddard Earth Sciences and Technology Center (GEST). The period covered by this report is October 1, 2001 through December 31, 2001. GEST is a consortium of scientists and engineers, led by the University of Maryland, Baltimore County (UMBC), to conduct scientific research in Earth and information sciences and related technologies in collaboration with the NASA Goddard Space Flight Center (GSFC). GEST was established through a cooperative agreement signed May 11, 2000, following a competitive procurement process initiated by GSFC.

Source record↗
NASA NTRS2002

ASK Talks With Judy Stokley

In the summer of 1997, Judy Stokley took over as Program Director of the Air-to-Air Joint System Project Office (JSPO) at Eglin Air Force Base in Florida. As the JSPO Program Director, she directed much of her attention to reforming the Advanced Medium Range Air to Air Missile (AMRAAM) program, which had been operational since 1991 and was presently being produced for the Air Force, Navy, Marine Corps, and many international customers. Upon careful analysis of the program, she found it rife with problems. Two of the most pressing included a bloated Average Unit Procurement Cost and an Air Force mandated draw down plan that had not been met. In this interview, following her presentation at the Fourth NASA Masters Forum of Program and Project Managers in Dallas last February, Stokley discusses some of the difficulties she experienced in carrying out the AMRAAM reforms. Stokley is presently Air Force Program Executive Officer for Weapons in Washington, D.C. She is responsible for the cost, schedule, and technical performance of a portfolio of air-to-air and air-to-ground weapons programs. These programs represent the leading edge of weapons technology, including developing the next generation of precision-guided munitions -- 'smart' bombs -- and air superiority missiles.

Stokley, Judy↗
NASA NTRS2002

Launch Vehicle Sizing Benefits Utilizing Main Propulsion System Crossfeed and Project Status

To meet the goals for a next generation Reusable Launch Vehicle (RLV), a unique propulsion feed system concept was identified using crossfeed between the booster and orbiter stages that could reduce the Two-Stage-to-Orbit (TSTO) vehicle weight and Design, Development, Test and Evaluation (DDT&E) costs by approximately 25%, while increasing safety and reliability. The Main Propulsion System (MPS) crossfeed water demonstration test program addresses all activities required to reduce the risks for the MPS crossfeed system from a Technology Readiness Level (TRL) of 2 to 4 by the completion of testing and analysis by June 2003. During the initial period, that ended in March 2002, a subscale water flow test article was defined. Procurement of a subscale crossfeed check valve was initiated and the specifications for the various components were developed. The fluid transient and pressurization analytical models were developed separately and successfully integrated. The test matrix for the water flow test was developed to correlate the integrated model. A computational fluid dynamics (CFD) model of the crossfeed check valve was developed to assess flow disturbances and internal flow dynamics. Based on the results, the passive crossfeed system concept was very feasible and offered a safe system to be used in an RLV architecture. A water flow test article was designed to accommodate a wide range of flows simulating a number of different types of propellant systems. During the follow-on period, the crossfeed system model will be further refined, the test article will be completed, the water flow test will be performed, and finally the crossfeed system model will be correlated with the test data. This validated computer model will be used to predict the full-scale vehicle crossfeed system performance.

Chandler, Frank↗