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At least 973 records · Page 54
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Isolating Added Mass Load Components of CPAS Main Clusters

The current simulation for the Capsule Parachute Assembly System (CPAS) lacks fidelity in representing added mass for the 116 ft Do ringsail Main parachute. The availability of 3-D models of inflating Main canopies allowed for better estimation the enclosed air volume as a function of time. This was combined with trajectory state information to estimate the components making up measured axial loads. A proof-of-concept for an alternate simulation algorithm was developed based on enclosed volume as the primary independent variable rather than drag area growth. Databases of volume growth and parachute drag area vs. volume were developed for several flight tests. Other state information was read directly from test data, rather than numerically propagated. The resulting simulated peak loads were close in timing and magnitude to the measured loads data. However, results are very sensitive to data curve fitting and may not be suitable for Monte Carlo simulations. It was assumed that apparent mass was either negligible or a small fraction of enclosed mass, with little difference in results.

Ray, Eric S.↗
NASA NTRS2019

Channel Wall Nozzle Manufacturing Technology Advancements for Liquid Rocket Engines

A regeneratively-cooled nozzle is a critical component for expansion of the hot gases to enable high temperature and performance liquid rocket engines systems. Channel wall nozzles are a design solution used across the propulsion industry as a simplified method to fabricate the nozzle structure with internal coolant passages. The scale and complexity of the channel wall nozzle (CWN) design is challenging to fabricate leading to extended lead times and higher costs. Some of these challenges include: 1) unique and high temperature materials, 2) Tight tolerances during manufacturing and assembly to contain high pressure propellants, 3) thin-walled features to maintain adequate wall temperatures, and 4) Unique manufacturing process operations and tooling. The United States (U.S.) National Aeronautics and Space Administration (NASA) along with U.S. specialty manufacturing vendors are maturing modern fabrication techniques to reduce complexity and decrease costs associated with channel wall nozzle manufacturing technology. Additive Manufacturing (AM) is one of the key technology advancements being evaluated for channel wall nozzles. Much of additive manufacturing for propulsion components has focused on powder bed fusion, but the scale is not yet feasible for application to large scale nozzles. NASA is evolving directed energy deposition (DED) techniques for nozzles including arc-based deposition, blown powder deposition, and Laser Wire Direct Closeout (LWDC). There are different approaches being considered for fabrication of the nozzle and each of these DED processes offer unique process steps for rapid fabrication. The arc-based and blown powder deposition techniques are being used for the forming of the CWN liner. A variety of materials are being demonstrated including Inconel 625, Haynes 230, JBK-75, and NASA HR-1. The blown powder DED process is also being demonstrated for forming an integral channel nozzle in a single operation in similar materials. The LWDC process is a method for closing out the channels within the liner and forming the structural jacket using a localized laser wire deposition technique. Identical materials mentioned above have been used for this process in addition to bimetallic closeout (C-18150–SS347, and C-18150–Inconel 625). NASA has completed process development, material characterization, and hot-fire testing on a variety of these channel wall nozzle fabrication techniques. This paper will present an overview of the various processes and materials being evaluated and the results from the hot-fire testing. Future development and technology focus areas will also be discussed relative to channel wall nozzle manufacturing.

Gradl, Paul R.↗
NASA NTRS2001

A New Direction for NASA Materials Science Research Using the International Space Station

NASA recently created a fifth Strategic Enterprise, the Office of Biological and Physical Research (OBPR), to bring together physics, chemistry, biology, and engineering to foster interdisciplinary research. The Materials Science Program is one of five Microgravity Research disciplines within this new enterprise's Division of Physical Sciences Research. The Materials Science Program will participate within this new enterprise structure in order to facilitate effective use of ISS facilities, target scientific and technology questions and transfer scientific and technology results for Earth benefits. The Materials Science research will use a low gravity environment for flight and ground-based research in crystallization, fundamental processing, properties characterization, and biomaterials in order to obtain fundamental understanding of various phenomena effects and relationships to the structures, processing, and properties of materials. Completion of the International Space Station's (ISS) first major assembly, during the past year, provides new opportunities for on-orbit research and scientific utilization. Accommodations will support a variety of Materials Science payload hardware both in the US and international partner modules with emphasis on early use of Express Rack and Glovebox facilities. This paper addresses the current scope of the flight investigator program. These investigators will use the various capabilities of the ISS to achieve their research objectives. The type of research and classification of materials being studied will be addressed. This includes the recent emphasis being placed on nanomaterials and biomaterials type research. Materials Science Program will pursue a new, interdisciplinary approach, which contributes, to Human Space Flight Exploration research. The Materials Science Research Facility (MSRF) and other related American and International experiment modules will serve as the foundation for this research. Discussion will be included to explain the changing concept for materials science research processing capabilities aboard the ISS along with the various ground facilities necessary to support the program. Finally, the paper will address the initial utilization schedule and strategy for the various materials science payloads including their corresponding hardware.

Schlagheck, Ronald↗
NASA NTRSDate not supplied

Habitable-zone Exoplanet Observatory (HabEx) Baseline 4-m Telescope Design and Predicted Performance

The Habitable Exoplanet Observatory Mission (HabEx) is one of four missions under study for the 2020 Astrophysics Decadal Survey. Its goal is to directly image and spectroscopically characterize planets in the habitable zone around nearby sun-like stars. Additionally, HabEx will perform a broad range of general astrophysics science enabled by 115 to 1700 nm spectral range and 3x3 arc-minute FOV instruments. Critical to achieving its science goals is a large, ultra-stable UV/Optical/Near-IR (UVOIR) telescope. The baseline HabEx telescope is a 4-meter off-axis unobscured three-mirror-anastigmatic, diffraction limited at 400 nm with wavefront stability on the order of a few 10s of picometers. This paper summarizes the opto-mechanical design of the HabEx baseline optical telescope assembly, including a discussion of how science requirements drive the telescope’s specifications, and presents analysis that the baseline telescope structure meets its specified tolerances.

HabEx↗
NASA NTRSDate not supplied

Developing Procedures to Implement Geometric Imperfections Beyond Right Circular Cylindrical Shells in Finite Element Method Models

Analysis of aerospace structures is frequently conducted using nominal dimensions and frequently assumes ideal conditions in loading, contact, constraints, et cetera. Off-nominal dimensions and nonideal conditions, however, are present in all structures. These are the result of widely ranging causes from coefficient of thermal expansion mismatches, manufacturing tooling anomalies, to assembly procedures that inadvertently alter the structure. Specifically, geometric imperfections can have potentially significant influence on the response of a structural test article observed in an experiment versus the response given by a numerical simulation. The Python Tool for Implementing Geometric Imperfections in Reduced Structures (Py_TIGIRS) was previously presented as a set of Python scripts to calculate and implement as-manufactured geometric midsurface and thickness imperfections into finite element method (FEM) shell models of nominally right circular cylinders. By taking advantage of the simple shape of a right circular cylinder, interpolations of the measured data points were able to be performed along directions that aligned to the cylindrical coordinate system axes of the entire structure. By taking advantage of the shell representation of the real structure as opposed to modeling using a continuum representation, the thickness variation was able to be implemented by shell section definitions instead of having to modify the position of multiple nodes in the thickness direction. Py_TIGIRS is a useful tool that established a procedural example on how to implement geometric imperfections in right circular cylindrical shell structures. Three new procedures, each expanded from concepts established in Py_TIGIRS, are proposed for various test-article designs and are intended to broaden the range of structures that can be modeled with measured geometric imperfections in the structural analysis community. Each test-article design introduces new challenges to successfully implement geometric imperfections into a FEM model. The first test-article design consists of a carbon fiber reinforced polymer square plate with a hat-shaped stiffener co-cured on one side. This test-article design was for a novel seven-point bend test that was also previously presented. Manufacturing and cure-cycle imperfections are observed using digital image correlation (DIC) techniques. As thermal expansion coefficient mismatches between the plate and stiffener materials were anticipated, a thermal analysis study with continuum shell and solid elements was conducted to capture the global shape observed prior to testing. The second test-article design is of a similar hat-stiffened plate configuration, but with a side length ratio near 3:1 with elongation in the stiffener direction. The test article was used to characterize the response to uniaxial compressive loading in the direction of the stiffener. Due to differing manufacturing steps, a thermal analysis like the one developed for the seven-point bend configuration was unable to mimic the observed geometric imperfections. Instead, a strategy based on applying deformations directly to the structure during analysis was developed for continuum shell and solid element representation of a stiffened panel.

Geometric imperfections↗
NASA NTRS1990

Multipurpose hardened spacecraft insulation

A Multipurpose Hardened Spacecraft Multilayer Insulation (MLI) system was developed and implemented to meet diverse survivability and performance requirements. Within the definition and confines of a MLI assembly (blanket), the design: (1) provides environmental protection from natural and induced nuclear, thermal, and electromagnetic radiation; (2) provides adequate electrostatic discharge protection for a geosynchronous satellite; (3) provides adequate shielding to meet radiated emission needs; and (4) will survive ascent differential pressure loads between enclosed volume and space. The MLI design is described which meets these requirements and design evolution and verification is discussed. The application is for MLI blankets which closeout the area between the laser crosslink subsystem (LCS) equipment and the DSP spacecraft cabin. Ancillary needs were implemented to ease installation at launch facility and to survive ascent acoustic and vibration loads. Directional venting accommodations were also incorporated to avoid contamination of LCS telescope, spacecraft sensors, and second surface mirrors (SSMs).

Steimer, Carlos H.↗
NASA NTRS2010

Automation Hooks Architecture Trade Study for Flexible Test Orchestration

We describe the conclusions of a technology and communities survey supported by concurrent and follow-on proof-of-concept prototyping to evaluate feasibility of defining a durable, versatile, reliable, visible software interface to support strategic modularization of test software development. The objective is that test sets and support software with diverse origins, ages, and abilities can be reliably integrated into test configurations that assemble and tear down and reassemble with scalable complexity in order to conduct both parametric tests and monitored trial runs. The resulting approach is based on integration of three recognized technologies that are currently gaining acceptance within the test industry and when combined provide a simple, open and scalable test orchestration architecture that addresses the objectives of the Automation Hooks task. The technologies are automated discovery using multicast DNS Zero Configuration Networking (zeroconf), commanding and data retrieval using resource-oriented Restful Web Services, and XML data transfer formats based on Automatic Test Markup Language (ATML). This open-source standards-based approach provides direct integration with existing commercial off-the-shelf (COTS) analysis software tools.

Lansdowne, Chatwin A.↗
NASA NTRS2020

Habitable Exoplanet Observatory (HabEx) Telescope: Systems Engineering and STOP Modeling

The Habitable Exoplanet Observatory Mission (HabEx) is one of four missions studied for the 2020 Astrophysics Decadal Survey. Its goal is to directly image and spectroscopically characterize planetary systems in the habitable zone around nearby sun-like stars. Additionally, HabEx will perform a broad range of general astrophysics science enabled by 115 to 1700 nm spectral range and 3 x 3 arc-minute FOV. Critical to achieving its science goals is a large, ultra-stable UV/Optical/Near-IR (UVOIR) telescope. The baseline HabEx telescope is a 4-meter off-axis unobscured three-mirror-anastigmatic, diffraction limited at 400 nm with wavefront stability on the order of a few 10s of picometers. This paper summarizes the opto-mechanical design of the baseline optical telescope assembly, including a discussion of how we applied science driven systems engineering to derive the telescope’s engineering specifications from the mission’s science requirements, and presents analysis that the baseline telescope structure meets its specified tolerances.

Stahl, H. Philip↗
NASA NTRSDate not supplied

The Plankton, Aerosol, Cloud, Ocean Ecosystem (Pace) Mission Overview: From Concept to Launch

Abstract for Technical Review: The Plankton, Aerosol, Cloud, ocean Ecosystem (PACE) mission is a strategic climate continuity mission that was defined in the 2010 document Responding to the Challenge of Climate and Environmental Change: NASA’s Plan for Climate-Centric Architecture for Earth Observations and Applications from Space (referred to as the “Climate Initiative”). Launched in February 2024, the PACE mission represents NASA’s next investment in ocean biology, clouds, and aerosol data records. PACE will extend the high quality ocean ecological, ocean biogeochemical, cloud, and aerosol particle data records begun by NASA in the 1990s, building on the exceptional heritages of the Sea-Viewing Wide Field-of-View Sensor (SeaWiFS), the Moderate Resolution Imaging Spectroradiometer (MODIS), the Multi-angle Imaging SpectroRadiometer (MISR), and the Visible Infrared Imaging Radiometer Suite (VIIRS). NASA Headquarters directed the mission development and implementation to the NASA Goddard Space Flight Center (GSFC) with guidance to utilize a Design-to-Cost (DTC) process. Mission studies were conducted to define appropriate approaches within and across elements while maximizing science capabilities at a high cost confidence. Mission baseline requirements development is also embedded within the DTC process, as these requirements were not established at the onset of the mission concept development. The PACE project office at NASA’s GSFC was responsible for the satellite development, launch and commissioning. The NASA Headquarters PACE Program Science office is responsible for supporting the science data processing system and assembling competed community science teams, which includes field-based vicarious calibration and data product validation efforts to support the PACE Project Science team. The PACE observatory is comprised of three instruments, the Ocean Color Instrument (OCI) and two polarimeters, the Hyper-Angular Rainbow Polarimeter 2 (HARP2) and the Spectro-Polarimeter for Exploration (SPEXone) and the PACE spacecraft. The observatory has been commissioned and is performing on-orbit science data collection operations. Summary for Program: The Plankton, Aerosol, Cloud, ocean Ecosystem (PACE) mission is a strategic climate continuity mission that was defined in the 2010 document Responding to the Challenge of Climate and Environmental Change: NASA’s Plan for Climate-Centric Architecture for Earth Observations and Applications from Space (referred to as the “Climate Initiative”). Launched in February 2024 under the leadership of the NASA Goddard Space Flight Center (GSFC), the PACE mission represents NASA’s next investment in ocean biology, clouds, and aerosol data records. PACE will extend the high quality ocean ecological, ocean biogeochemical, cloud, and aerosol particle data records begun by NASA in the 1990s. The PACE observatory is comprised of the Ocean Color Instrument (OCI), the Hyper-Angular Rainbow Polarimeter 2 (HARP2) and the Spectro-Polarimeter for Exploration (SPEXone), along with the PACE spacecraft.

Robert H Estep, Jr↗
NASA NTRSDate not supplied

Mission Overview and Status from Concept to Launch

The Plankton, Aerosol, Cloud, ocean Ecosystem (PACE) mission is a strategic climate continuity mission that was defined in the 2010 document Responding to the Challenge of Climate and Environmental Change: NASA’s Plan for Climate-Centric Architecture for Earth Observations and Applications from Space (referred to as the “Climate Initiative”). Launched in February 2024, the PACE mission represents NASA’s next investment in ocean biology, clouds, and aerosol data records. PACE will extend the high quality ocean ecological, ocean biogeochemical, cloud, and aerosol particle data records begun by NASA in the 1990s, building on the exceptional heritages of the Sea-Viewing Wide Field-of-View Sensor (SeaWiFS), the Moderate Resolution Imaging Spectroradiometer (MODIS), the Multi-angle Imaging SpectroRadiometer (MISR), and the Visible Infrared Imaging Radiometer Suite (VIIRS). NASA Headquarters directed the mission development and implementation to the NASA Goddard Space Flight Center (GSFC) with guidance to utilize a Design-to-Cost (DTC) process. Mission studies were conducted to define appropriate approaches within and across elements while maximizing science capabilities at a high cost confidence. Mission baseline requirements development is also embedded within the DTC process, as these requirements were not established at the onset of the mission concept development. The PACE project office at NASA’s GSFC was responsible for the satellite development, launch and commissioning. The NASA Headquarters PACE Program Science office is responsible for supporting the science data processing system and assembling competed community science teams, which includes field-based vicarious calibration and data product validation efforts to support the PACE Project Science team. The PACE observatory is comprised of three instruments, the Ocean Color Instrument (OCI) and two polarimeters, the Hyper-Angular Rainbow Polarimeter 2 (HARP2) and the Spectro-Polarimeter for Exploration (SPEXone) and the PACE spacecraft. The observatory has been commissioned and is performing on-orbit science data collection operations. Summary for Program: The Plankton, Aerosol, Cloud, ocean Ecosystem (PACE) mission is a strategic climate continuity mission that was defined in the 2010 document Responding to the Challenge of Climate and Environmental Change: NASA’s Plan for Climate-Centric Architecture for Earth Observations and Applications from Space (referred to as the “Climate Initiative”). Launched in February 2024 under the leadership of the NASA Goddard Space Flight Center (GSFC), the PACE mission represents NASA’s next investment in ocean biology, clouds, and aerosol data records. PACE will extend the high quality ocean ecological, ocean biogeochemical, cloud, and aerosol particle data records begun by NASA in the 1990s. The PACE observatory is comprised of the Ocean Color Instrument (OCI), the Hyper-Angular Rainbow Polarimeter 2 (HARP2) and the Spectro-Polarimeter for Exploration (SPEXone), along with the PACE spacecraft.

Robby Estep↗
NASA NTRS2001

Performance Testing of a Lightweight, High Efficiency 95 K Cryocooler

Performance data are presented for a flight-like, lightweight, high efficiency pulse tube cryogenic cooler. The cooler has a mass of less than 4.0 kg, and an efficiency of 12 W/W, which is 18% of Carnot at 95 K, nearly double the efficiency of previous cooler designs, The mass of the cooler has been reduced by approximately a factor of three. The design point cooling power is 10 watts at 95 K at a heat rejection temperature of 300 K. The no-load temperature is 45 K. The compressor is built by Hymatic Engineering, UK, and is of a horizontally opposed piston design using flexure bearings. The vertical pulse tube is built by TRW with the heat exchanger or cold block located approximately mid-way along the tube. The final assembly and integration is also performed by TRW. The inertance tube and dead volume are contained within one of the compressor end caps. The cooler was developed by TRW under a joint NASA-DOD program, and has a goal of 10 yr operating lifetime. Potential NASA applications will focus on using coolers of this type in Zero boil off (ZBO) cryogen storage topologies for next generation launch vehicles. Zero boil off systems will feature significant reductions in tank size and Initial Mass to Low Earth Orbit (IMLEO), thereby significantly reducing the cost of access to space, and enabling future missions. The coolers can be used directly in liquid oxygen (LOx) or liquid methane ZBO systems, as shield coolers in liquid hydrogen tanks, or as first stage coolers in two-stage liquid hydrogen (LH2) ZBO cooler systems. Finally, the coolers could find applications in exploration missions where either propellants or breathable oxygen are extracted from the planetary atmosphere using a Sabatier or similar process. The gases could then be liquefied for storage either directly in return vehicle propellant tanks or on the planetary surface. Data presented were taken with the cooler operating in a vacuum of 10 (exp -5) torr, at controlled rejection temperatures from 300 K down to 275 K using a cold water heat exchanger bolted to the cooler. Heat loads were varied between 0.5 W and 15 W by supplying current to a 50 omega resistor mounted on a copper cold plate which was bolted to the cooler cold block. Silicon diodes mounted on both the cold plate and the heat exchanger provided accurate temperature measurement to within plus or minus 0.25 K and plus or minus 0.5 K respectively, up to 100 K with plus or minus 1% accuracy above 100 K. Input power to the compressor was limited to 180 W, corresponding to a maximum stroke of 80%.

Salerno, Lou↗
NASA NTRS2017

Habitable Exoplanet Imager Optical Telescope Concept Design

The Habitable Exoplanet Imaging Mission (HabEx) is one of four missions under study for the 2020 Astrophysics Decadal Survey. Its goal is to directly image and spectroscopically characterize planetary systems in the habitable zone of Sun-like stars. Additionally, HabEx will perform a broad range of general astrophysics science enabled by 100 to 2500 nm spectral range and 3 x 3 arc-minute FOV. Critical to achieving the HabEx science goals is a large, ultra-stable UV/Optical/Near-IR (UVOIR) telescope. The baseline HabEx telescope is a 4-meter off-axis unobscured three-mirror-anastigmatic, diffraction limited at 400 nm with wavefront stability on the order of a few 10s of picometers. This paper summarizes the opto-mechanical design of the HabEx baseline optical telescope assembly, including a discussion of how science requirements drive the telescope's specifications, and presents analysis that the baseline telescope structure meets its specified tolerances.

mirror↗
NASA NTRS1981

Development of a solar receiver for an organic Rankine cycle engine

A prototype power conversion assembly (PCA) developed by an American aerospace company is considered. The PCA will be mounted at the focal point of a 12 meter parabolic dish and will produce approximately 20 kW of 3 kHz ac power to a ground-mounted rectifier. The PCA includes a cavity receiver coupled to an organic Rankine cycle engine. The engine working fluid is toluene. The performance goals of the receiver design are to maximize both the thermal efficiency and the heat capacity of the core. The latter goal is desired for stabilizing the PCA operation during intermittent cloud cover. The receiver design is based upon the utilization of a direct-heated copper shell. It was necessary to develop a feasible manufacturing process for assuring a good braze joint between the stainless steel, containing the toluene, and the copper shell.

Haskins, H. J.↗
NASA NTRS2008

[The Extrasolar Planetary Imaging Coronagraph]

The Extrasolar Planetary Imaging Coronagraph (EPIC) is a proposed NASA Exoplanet Probe mission to image and characterize extr asolar giant planets in orbits with semi-major axes between 2 and 10 AU. EPIC will provide insights into the physical nature of a variety of planets in other solar systems complimenting radial velocity (RV) and astrometric planet searches. It will detect and characterize the atmospheres of planets identified by radial velocity surveys, deter mine orbital inclinations and masses, characterize the atmospheres around A and F type stars which cannot be found with RV techniques, and observe the inner spatial structure and colors of debris disks. EPIC has a heliocentric Earth trailing drift-away orbit, with a 5 year mission lifetime (5 year goal). The robust mission design is simple and flexible ensuring mission success while minimizing cost and risk. The science payload consists of a heritage optical telescope assembly (OTA), and visible nulling coronagraph (VNC) instrument. The instrument achieves a contrast ratio of 10(exp 9) over a 4.84 arcsecond field-of-view with an unprecedented inner working angle of 0.14 arcseconds over the spectral range of 440-880 nm. The telescope is a 1.65 meter off-axis Cassegrain with an OTA wavefront error of /9, which when coupled to the VNC greatly reduces the requirements on the large scale optics, compressing them to stability requirements within the relatively compact VNC optical chain. The VNC features two integrated modular nullers, a spatial filter array (SFA) and an E2V-L3 photon counting CCD. Direct null control is accomplished from the science focal plane mitigating against complex wavefront and amplitude sensing and control strategies.

Clampin, Mark↗
NASA NTRS2018

Overview and Performance Prediction of the Baseline 4-Meter Telescope Concept Design for the Habitable-Zone Exoplanet Observatory

The Habitable Exoplanet Observatory Mission (HabEx) is one of four missions under study for the 2020 Astrophysics Decadal Survey. Its goal is to directly image and spectroscopically characterize planetary systems in the habitable zone around nearby sun-like stars. Additionally, HabEx will perform a broad range of general astrophysics science enabled by 100 to 2500 nm spectral range and 3 x 3 arc-minute FOV. Critical to achieving the HabEx science goals is a large, ultra-stable UV/Optical/Near-IR (UVOIR) telescope. The baseline HabEx telescope is a 4-meter off-axis unobscured three-mirror-anastigmatic, diffraction limited at 400 nm with wavefront stability on the order of a few 10s of picometers. This paper summarizes the opto-mechanical design of the HabEx baseline optical telescope assembly, including a discussion of how science requirements drive the telescope's specifications, and presents analysis that the baseline telescope structure meets its specified tolerances.

Space Mirror Technology↗
NASA NTRS1985

Quasi non-intrusive sampling and analysis of gases associated with the boundary layer on the tethered satellite and similar supersonic and hypersonic research vehicles

The effect that one candidate inlet, an assembly of capillary openings in a thin glass plate (a multichannel plate), might have on the overall sampling process is considered. The flow characteristics of the plate, under a variety of conditions of external pressure and mass flow, is evaluated. A review of capillary flow theory is presented with some development of the pertinent equations. The predicted mass flow will be compared to that determined perimentally to assess the effect that mass flow through one capillary might have upon a neighboring capillary. Mass spectrometric measurements of mixtures flowing through the multichannel plate (MCP) is also considered. In the first part of the experiments, the flow was in a direction normal to the surface of the plate. The experimental gases were Argon and mixtures of carbon dioxide in air. Ongoing experiments are discussed which are conducted with the flow parallel to the surface of the plate, a simulation of the kind of flow that a flight vehicle would experience.

Fishel, C.↗
NASA NTRS1986

Advanced life support control/monitor instrumentation concepts for flight application

Development of regenerative Environmental Control/Life Support Systems requires instrumentation characteristics which evolve with successive development phases. As the development phase moves toward flight hardware, the system availability becomes an important design aspect which requires high reliability and maintainability. This program was directed toward instrumentation designs which incorporate features compatible with anticipated flight requirements. The first task consisted of the design, fabrication and test of a Performance Diagnostic Unit. In interfacing with a subsystem's instrumentation, the Performance Diagnostic Unit is capable of determining faulty operation and components within a subsystem, perform on-line diagnostics of what maintenance is needed and accept historical status on subsystem performance as such information is retained in the memory of a subsystem's computerized controller. The second focus was development and demonstration of analog signal conditioning concepts which reduce the weight, power, volume, cost and maintenance and improve the reliability of this key assembly of advanced life support instrumentation. The approach was to develop a generic set of signal conditioning elements or cards which can be configured to fit various subsystems. Four generic sensor signal conditioning cards were identified as being required to handle more than 90 percent of the sensors encountered in life support systems. Under company funding, these were detail designed, built and successfully tested.

Heppner, D. B.↗
NASA NTRS2003

Superalloy Lattice Block Developed for Use in Lightweight, High-Temperature Structures

Successful development of advanced gas turbine engines for aircraft will require lightweight, high-temperature components. Currently titanium-aluminum- (TiAl) based alloys are envisioned for such applications because of their lower density (~4 g/cm3) in comparison to superalloys (~8.5 g/cm3), which have been utilized for hot turbine engine parts for over 50 years. However, a recently developed concept (lattice block) by JAMCORP, Inc., of Willmington, Massachusetts, would allow lightweight, high-temperature structures to be directly fabricated from superalloys and, thus, take advantage of their well-known, characterized properties. In its simplest state, lattice block is composed of thin ligaments arranged in a three dimensional triangulated trusslike configuration that forms a structurally rigid panel. Because lattice block can be fabricated by casting, correctly sized hardware is produced with little or no machining; thus very low cost manufacturing is possible. Together, the NASA Glenn Research Center and JAMCORP have extended their lattice block methodology for lower melting materials, such as Al alloys, to demonstrate that investment casting of superalloy lattice block is possible. This effort required advances in lattice block pattern design and assembly, higher temperature mold materials and mold fabrication technology, and foundry practice suitable for superalloys (ref. 1). Lattice block panels have been cast from two different Ni-base superalloys: IN 718, which is the most commonly utilized superalloy and retains its strength up to 650 C; and MAR M247, which possesses excellent mechanical properties to at least 1100 C. In addition to the open-cell lattice block geometry, same-sized lattice block panels containing a thin (~1-mm-thick) solid face on one side have also been cast from both superalloys. The elevated-temperature mechanical properties of the open cell and face-sheeted superalloy lattice block panels are currently being examined, and the microstructure is being characterized in terms of casting defects. In addition, a small study (ref. 3) is being undertaken with GE Aircraft Engines to determine the suitability of superalloy lattice block for engine components.

Hebsur, Mohan G.↗