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NASA NTRS1995

Manufacturing methods for machining spring ends parallel at loaded length

A first end surface of a coiled compression spring at its relaxed length is machined to a plane transverse to the spring axis. The spring is then placed in a press structure having first and second opposed planar support surfaces, with the machined spring end surface bearing against the first support surface, the unmachined spring end surface bearing against a planar first surface of a lateral force compensation member, and an opposite, generally spherically curved surface of the compensation member bearing against the second press structure support surface. The spring is then compressed generally to its loaded length, and a circumferentially spaced series of marks, lying in a plane parallel to the second press structure support surface, are formed on the spring coil on which the second spring end surface lies. The spring is then removed from the press structure, and the second spring end surface is machined to the mark plane. When the spring is subsequently compressed to its loaded length the precisely parallel relationship between the machined spring end surfaces substantially eliminates undesirable lateral deflection of the spring.

Hinke, Patrick Thomas↗

NASA NTRS1996

Advanced Manufacturing of Superconducting Magnets

The development of specialized materials, processes, and robotics technology allows for the rapid prototype and manufacture of superconducting and normal magnets which can be used for magnetic suspension applications. Presented are highlights of the Direct Conductor Placement System (DCPS) which enables automatic design and assembly of 3-dimensional coils and conductor patterns using LTS and HTS conductors. The system enables engineers to place conductors in complex patterns with greater efficiency and accuracy, and without the need for hard tooling. It may also allow researchers to create new types of coils and patterns which were never practical before the development of DCPS. The DCPS includes a custom designed eight-axis robot, patented end effector, CoilCAD(trademark) design software, RoboWire(trademark) control software, and automatic inspection.

Senti, Mark W.↗

NASA NTRS1996

Design of a Superconducting Magnetic Suspension System for a Liquid Helium Flow Experiment

We discuss a preliminary design for a superconducting magnetic suspension system for measurement of drag on rotationally symmetric bodies in liquid helium. Superconducting materials are a natural choice for liquid helium studies, since temperatures are well below most critical temperatures, so that the resulting heat load is negligible. Also, due to its diamagnetic properties, a superconducting model (for example made or coated with Nb) is inherently stable against disturbances. Issues which we consider include model placement during initial cool-down, maintaining placement during anticipated drag and lift forces, and force measurement. This later can be achieved by a passive technique, where the body is allowed to deflect under the influence of drag from its neutral position. The resulting shift in flux is detected via a superconducting pickup coil. The pickup coil may be connected either to a SQUID, or a secondary loop wound around a Hall probe. Both options are discussed. The objective of this work is to gain a better understanding of the nature of turbulent fields in normal and superfluid helium for potential application to problems in classical high Reynolds number turbulence.

Smith, Michael R.↗

NASA NTRS1997

A New 1000 F Magnetic Bearing Test Rig

NASA and the Army are currently exploring the possibility of using magnetic bearings in gas turbine engines. The use of magnetic bearings in gas turbine engines could increase the reliability by eliminating the lubrication system. The use of magnetic bearings could also increase the speed and the size of the shafts in the engine, thus reducing vibrations and possibly eliminating third bearings. Magnetic bearings can apply forces to the shafts and move them so that blade tips and seals do not rub. This could be part of an active vibration cancellation system. Also, whirling (displacing the shaft center line) may delay rotating stall and increase the stall margin of the engine. Magnetic bearings coupled with an integral starter generator could result in a more efficient 'more electric' engine. The IHPTET program, a joint DOD-industry program, has identified a need for a high temperature, (as high as 1200 F), magnetic bearing that could be demonstrated in a phase m engine. A magnetic bearing is similar to an electric motor. The magnetic bearing has a laminated rotor and stator made out of cobalt steel. The stator has a series of coils of wire wound around it. These coils f u. a series of electromagnets around the circumference. These magnets exert a force on the rotor to keep the rotor in the center of the cavity. The centering force is commanded by a controller based on shaft position, (measured by displacement probes). The magnetic bearing can only pull and is basically unstable before active control is applied The engine shafts, bearings, and case form a flexible structure which contain a large number of modes. A controller is necessary to stabilize these modes. A power amplifier is also necessary to provide the current prescribed by the controller to the magnetic bearings. In case of very high loads, a conventional back up bearing will engage and stop the rotor and stator from rubbing.

Kascak, Albert F.↗

NASA NTRS1998

Non-Contact EDDY Current Hole Eccentricity and Diameter Measurement

Precision holes are among the most critical features of a mechanical component. Deviations from permissible tolerances can impede operation and result in unexpected failure. We have developed an automated non-contact eddy current hole diameter and eccentricity measuring system. The operating principle is based on the eddy current lift-off effect, which is the coil impedance as a function of the distance between the coil and the test object. An absolute eddy current probe rotates in the hole. The impedance of each angular position is acquired and input to the computer for integration and analysis. The eccentricity of the hole is the profile of the impedance as a function of angular position as compared to a straight line, an ideal hole. The diameter of the hole is the sum of the diameter of the probe and twice the distance-calibrated impedance. An eddy current image is generated by integrating angular scans for a plurality of depths between the top and bottom to display the eccentricity profile. This system can also detect and image defects in the hole. The method for non-contact eddy current hole diameter and eccentricity measurement has been granted a patent by the U.S. Patent and Trademark Office.

Chern, E. James↗

NASA NTRS1998

Report 1: Basic Operation of the Switched Reluctance Motor

Typically salient poles have windings forming coils wrapped around the waists (or pole cores) of each pole. This is true for the stator of the SRM but not for the rotor. The rotor has no windings, no coils, no magnets, no commutator, or slip rings it is only comprised of laminated steel sheets stamped in the shape of the pole design and mounted on a shaft. This allows for ease in manufacturing the rotor as well as reducing the rotor's inertia. There is also no electrical loss associated with the rotor since there are no windings, commutator, or slip rings.

Pillay, Pragasen↗

NASA NTRS2000

Animal trials of a Magnetically Levitated Left-Ventricular Assist Device

The University of Pittsburgh/Magnetic Moments mag-lev left-ventricular assist devices (LVADs), the Streamliner HG3b and HG3c, have successfully been implanted in calves. The first was implanted for 4 hours on July 10, 1998 and the second for 34 days on August 24, 1999 respectively. The tests confirmed the feasibility of low power levitation (1.5 watts coil power) and very low blood damage in a mag-lev ventricular assist device. In this paper, we describe the unique geometry of this pump and its design. Key features of this LVAD concept are the passive radial suspension and active voice-coil thrust bearing.

Paden, Brad↗

NASA NTRS2001

Flightweight Electro-Magnet Systems

NASA has a need for lightweight high performance magnets to be used in propulsion systems involving plasmas. We report the design, construction, and testing of a six inch diameter by twelve inch long solenoid using high purity aluminum wire operating at a temperature of 77 Kelvin (K) for the current carrying element. High purity aluminum is the material of choice because of three properties that make it optimal for magnetic construction. At 77 K high purity aluminum has one of the lowest resistivities at 77 K of any metal (p = 0.254 muOMEGA-cm), thus reducing the power requirements for creating magnetic fields. Aluminum is a low-density (2.6989 g/cc) material and the end product magnet will be of low total mass compared to similar designs involving copper or other elements. The magneto-resistance of aluminum saturates at low magnetic fields and does not increase indefinitely as is the case in copper. The magnet consists of four layers of closely wound wire and is approximately 150 mm in diameter by 300 mm long. A cylinder made from G - 10 was machined with a spiral groove to hold the high purity Al wire and the wire wound on it. Following the winding, each layer was potted in STYCAST high thermal conductivity epoxy to provide insulation between the turns of the coil and mechanical strength. The magneto-resistance of the coil has been measured at the National High Magnetic Field Laboratory (NHMFL), Tallahassee, FL in externally applied fields to 10 tesla. Following these tests it was energized to the full 2 tesla field it can produce using the facilities of the NHMFL at the Los Alamos National Laboratory. The results of all of these tests will be presented.

Goodrich, Roy G.↗

NASA NTRS2002

Magnetized Target Fusion

Magnetized target fusion (MTF) is under consideration as a means of building a low mass, high specific impulse, and high thrust propulsion system for interplanetary travel. This unique combination is the result of the generation of a high temperature plasma by the nuclear fusion process. This plasma can then be deflected by magnetic fields to provide thrust. Fusion is initiated by a small traction of the energy generated in the magnetic coils due to the plasma's compression of the magnetic field. The power gain from a fusion reaction is such that inefficiencies due to thermal neutrons and coil losses can be overcome. Since the fusion reaction products are directly used for propulsion and the power to initiate the reaction is directly obtained from the thrust generation, no massive power supply for energy conversion is required. The result should be a low engine mass, high specific impulse and high thrust system. The key is to successfully initiate fusion as a proof-of-principle for this application. Currently MSFC is implementing MTF proof-of-principle experiments. This involves many technical details and ancillary investigations. Of these, selected pertinent issues include the properties, orientation and timing of the plasma guns and the convergence and interface development of the "pusher" plasma. Computer simulations of the target plasma's behavior under compression and the convergence and mixing of the gun plasma are under investigation. This work is to focus on the gun characterization and development as it relates to plasma initiation and repeatability.

Steven T. Griffin↗

NASA NTRS1980

Loudspeaker Performance Aid

Many manufacturers of loudspeakers are now using a magnetic liquid cooling agent known as ferrofluid. Commercialized by Ferrofluids Corporation, ferrofluid is a liquid material in which sub-microscopic particles of iron oxide are permanently suspended. Injected into the voice coil segment of speaker system, magnetic liquid serves as superior heat transfer medium for cooling the voice coil, thus substantially increasing the system's ability to handle higher power levels and decreasing chance of speaker failure. Ferrofluid offers several additional advantages which add up to improved speaker performance, lower manufacturing costs and fewer rejects.

Source record↗

NASA NTRS2004

Magnetic-Nozzle Studies for Fusion Propulsion Applications: Gigawatt Plasma Source Operation and Magnetic Nozzle Analysis

This project has been a multiyear effort to assess the feasibility of a key process inherent to virtually all fusion propulsion concepts: the expansion of a fusion-grade plasma through a diverging magnetic field. Current fusion energy research touches on this process only indirectly through studies of plasma divertors designed to remove the fusion products from a reactor. This project was aimed at directly addressing propulsion system issues, without the expense of constructing a fusion reactor. Instead, the program designed, constructed, and operated a facility suitable for simulating fusion reactor grade edge plasmas, and to examine their expansion in an expanding magnetic nozzle. The approach was to create and accelerate a dense (up to l0(exp 20)/m) plasma, stagnate it in a converging magnetic field to convert kinetic energy to thermal energy, and examine the subsequent expansion of the hot (100's eV) plasma in a subsequent magnetic nozzle. Throughout the project, there has been a parallel effort between theoretical and numerical design and modelling of the experiment and the experiment itself. In particular, the MACH2 code was used to design and predict the performance of the magnetoplasmadynamic (MPD) plasma accelerator, and to design and predict the design and expected behavior for the magnetic field coils that could be added later. Progress to date includes the theoretical accelerator design and construction, development of the power and vacuum systems to accommodate the powers and mass flow rates of interest to out research, operation of the accelerator and comparison to theoretical predictions, and computational analysis of future magnetic field coils and the expected performance of an integrated source-nozzle experiment.

Gilland, James H.↗

NASA NTRS2003

Continuous Cooling from 10 K to 4 K Using a Toroidal ADR

Future large infrared space telescopes will require cooling to 4K to achieve background limited performance for submillimeter wavelengths. These observatories will require lifetimes of many years and will have relatively large cooling requirements making stored helium dewars impractical. We have designed and are building an adiabatic demagnetization refrigerator (ADR) for use in cooling relatively large loads (10- 100 mW) at 4K and rejecting that heat to a cryocooler operating at 1 OK. Cryocoolers below 1 OK have poor thermodynamic efficiency and ADRs can operate in this temperature range with an efficiency of 75% of Carnot or better. Overall, this can save as much as 2/3 of the input power required to operate a 4K cryocooler. The ADR magnet consists of 8 short coils wired in series and arranged in a toroid to provide self shielding of its magnetic field. This will save mass (about 30% of the mass or about 1.5 kg in our small version, higher percentages in higher cooling power, larger versions) that would have been used for passive or active shields in an ordinary solenoid. The toroid has a 100 mm outer diameter and will produce an approximately 3T average field. In the initial demonstration model the toroid coils will be wound with ordinary NbTi wire and operated at 4K. A second version will then use Nb3Sn wire to provide complete 10K operation. As a refrigerant for this temperature range we will use either GdLiF4 or GdF3 crystals, pending tests of these crystals' cooling capacity per field and thermal conductance. Preliminary indications are that these materials are superior to GGG. We will use gas gap heat switches to alternately connect the toroid to the cold load and the warm heat sink. A small continuous stage will maintain the cold end at 4K while the main toroid is recycled.

DiPirro, Michael J.↗

NASA NTRS2003

The Influence of Current Density and Magnetic Field Topography in Optimizing the Performance, Divergence, and Plasma Oscillations of High Specific Impulse Hall Thrusters

Recent studies of xenon Hall thrusters have shown peak efficiencies at specific impulses of less than 3000 s. This was a consequence of modern Hall thruster magnetic field topographies, which have been optimized for 300 V discharges. On-going research at the NASA Glenn Research Center is investigating this behavior and methods to enhance thruster performance. To conduct these studies, a laboratory model Hall thruster that uses a pair of trim coils to tailor the magnetic field topography for high specific impulse operation has been developed. The thruster-the NASA-173Mv2 was tested to determine how current density and magnetic field topography affect performance, divergence, and plasma oscillations at voltages up to 1000 V. Test results showed there was a minimum current density and optimum magnetic field topography at which efficiency monotonically increased with voltage. At 1000 V, 10 milligrams per second the total specific impulse was 3390 s and the total efficiency was 60.8%. Plume divergence decreased at 400-1000 V, but increased at 300-400 V as the result of plasma oscillations. The dominant oscillation frequency steadily increased with voltage, from 14.5 kHz at 300 V, to 22 kHz at 1000 V. An additional oscillatory mode in the 80-90 kHz frequency range began to appear above 500 V. The use of trim coils to modify the magnetic field improved performance while decreasing plume divergence and the frequency and magnitude of plasma oscillations.

Hofer, Richard R.↗

NASA NTRS2004

High Temperature Propulsion System Structural Seals for Future Space Launch Vehicles

Durable, flexible sliding seals are required in advanced hypersonic engines to seal the perimeters of movable engine ramps for efficient, safe operation in high heat flux environments at temperatures of 2000 to 2500 F. Current seal designs do not meet the demanding requirements for future engines, so NASA s Glenn Research Center is developing advanced seals and preloading devices to overcome these shortfalls. An advanced ceramic wafer seal design and two types of seal preloading devices were evaluated in a series of compression, scrub, and flow tests. Silicon nitride wafer seals survived 2000 in. 1000 cycles) of scrubbing at 1600 F against an Inconel 625 rub surface with no chips or signs of damage. Flow rates measured for the wafers before and after scrubbing were almost identical and were up to 32 times lower than those recorded for the best braided rope seal flow blockers. Canted coil springs and silicon nitride compression springs showed promise conceptually as potential seal preloading devices to help maintain seal resiliency. A finite element model of the canted coil spring revealed that it should be possible to produce a spring out of high temperature materials for applications at 2000+ F.

Dunlap, Patrick H., Jr.↗

NASA NTRS2003

High Temperature Propulsion System Structural Seals for Future Space Launch Vehicles

Durable, flexible sliding seals are required in advanced hypersonic engines to seal the perimeters of movable engine ramps for efficient, safe operation in high heat flux environments at temperatures of 2000 to 2500 F. Current seal designs do not meet the demanding requirements for future engines, so NASA's Glenn Research Center is developing advanced seals and preloading devices to overcome these shortfalls. An advanced ceramic wafer seal design and two types of seal preloading devices were evaluated in a series of compression, scrub, and flow tests. Silicon nitride wafer seals survived 2000 in. (1000 cycles) of scrubbing at room temperature against an Inconel 625 rub surface with no chips or signs of damage. Flow rates measured for the wafers before and after scrubbing were almost identical and were much lower than those recorded for the best braided rope seal flow blockers. Canted coil springs and silicon nitride compression springs showed promise conceptually as potential seal preloading devices to help maintain seal resiliency. A finite element model of the canted coil spring revealed that it should be possible to produce a spring out of high temperature materials for applications at 2000+ F.

Dunlap, Patrick H., Jr.↗

NASA NTRS2004

Magnetic and Langmuir Probe Measurements on the Plasmoid Thruster Experiment (PTX)

The Plasmoid Thruster Experiment (PTX) operates by inductively producing plasmoids in a conical theta-pinch coil and subsequently ejecting them at high velocity. An overview of PTX is described in a companion paper. The shape and magnetic field structure of the translating plasmoids will be measured with of an array of inductive magnetic field probes. Six sets of two B-dot probes (for a total of twelve probes) have been constructed for measuring B(sub z) and B(sub theta), the axial and azimuthal components of the magnetic field. The probes were calibrated with a Helmholtz coil, driven alternately by a high-voltage pulser or a signal generator. The probes are wound on a G-10 form, and have an average (calibrated) NA of 9.37 x 10(exp -5) square meters, where N is the number of turns and A is cross-sectional area. The frequency response of the probes was measured over the range from 1 kHz to 10 MHZ. The electron number density n(sub e), electron temperature T(sub e) and velocity v will be determined from measurements taken with a quadruple Langmuir probe, situated in the exhaust chamber. Three of the four probes on the quadruple probe sample the current-voltage characteristic, and from this yield measurements of T(sub e) and n(sub e). The fourth probe provides a measurement of plasma flow velocity. A 6-inch long alumina rod, hollowed with four holes to house the probe wires, is being used to construct the quadruple probe. A variety of propellants will be used, including hydrogen, nitrogen and argon. From the measurements of the plasmoid mass, density, temperature, and velocity, the basic propulsion characteristics of PTX will be evaluated.

Koelfgen, Syri J.↗

NASA NTRS2004

Deep Flaw Detection with Giant Magnetoresistive (GMR) Based Self-Nulling Probe

In this paper a design modification to the Very-Low Frequency GMR Based Self-Nulling Probe has been presented to enable improved signal to noise ratio for deeply buried flaws. The design change consists of incorporating a feedback coil in the center of the flux focusing lens. The use of the feedback coil enables cancellation of the leakage fields in the center of the probe and biasing of the GMR sensor to a location of high magnetic field sensitivity. The effect of the feedback on the probe output was examined, and experimental results for deep flaw detection were presented. The experimental results show that the modified probe is capable of clearly identifying flaws up to 1 cm deep in aluminum alloy structures.

Wincheski, Buzz↗

NASA NTRS2004

Magnetic and Langmuir Probe Measurements on the Plasmoid Thruster Experiment (PTX)

The Plasmoid Thruster Experiment (PTX) operates by inductively producing plasmoids in a conical theta-pinch coil and ejecting them at high velocity. A plasmoid is a plasma with an imbedded closed magnetic field structure. The shape and magnetic field structure of the translating plasmoids have been measured with of an array of magnetic field probes. Six sets of two B-dot probes were constructed for measuring B(sub z) and B(sub theta), the axial and azimuthal components of the magnetic field. The probes are wound on a square G10 form, and have an average (calibrated) NA of 9.37 x l0(exp -5) square meters, where N is the number of turns and A is the cross-sectional area. The probes were calibrated with a Helmholtz coil, driven by a high-voltage pulser to measure NA, and by a signal generator to determine the probe's frequency response. The plasmoid electron number density n(sub e) electron temperature T(sub e), and velocity ratio v/c(sub m), (where v is the bulk plasma flow velocity and c(sub m), is the ion thermal speed) have also been measured with a quadruple Langmuir probe. The Langmuir probe tips are 10 mm long, 20-mil diameter stainless steel wire, housed in a 6-inch long 4-bore aluminum rod. Measurements on PTX with argon and hydrogen from the magnetic field probes and quadruple Langmuir probe will be presented in this paper.

Koelfgen, Syri J.↗