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At least 1,117 records · Page 62

Economical Fabrication of Thick-Section Ceramic Matrix Composites

A method was developed for producing thick-section [>2 in. (approx.5 cm)], continuous fiber-reinforced ceramic matrix composites (CMCs). Ultramet-modified fiber interface coating and melt infiltration processing, developed previously for thin-section components, were used for the fabrication of CMCs that were an order of magnitude greater in thickness [up to 2.5 in. (approx.6.4 cm)]. Melt processing first involves infiltration of a fiber preform with the desired interface coating, and then with carbon to partially densify the preform. A molten refractory metal is then infiltrated and reacts with the excess carbon to form the carbide matrix without damaging the fiber reinforcement. Infiltration occurs from the inside out as the molten metal fills virtually all the available void space. Densification to <5 vol% porosity is a one-step process requiring no intermediate machining steps. The melt infiltration method requires no external pressure. This prevents over-infiltration of the outer surface plies, which can lead to excessive residual porosity in the center of the part. However, processing of thick-section components required modification of the conventional process conditions, and the means by which the large amount of molten metal is introduced into the fiber preform. Modification of the low-temperature, ultraviolet-enhanced chemical vapor deposition process used to apply interface coatings to the fiber preform was also required to accommodate the high preform thickness. The thick-section CMC processing developed in this work proved to be invaluable for component development, fabrication, and testing in two complementary efforts. In a project for the Army, involving SiC/SiC blisk development, nominally 0.8 in. thick x 8 in. diameter (approx. 2 cm thick x 20 cm diameter) components were successfully infiltrated. Blisk hubs were machined using diamond-embedded cutting tools and successfully spin-tested. Good ply uniformity and extremely low residual porosity (<2 percent) were achieved, the latter being far lower than that achieved with SiC matrix composites fabricated via CVI or PIP. The pyrolytic carbon/zirconium nitride interface coating optimized in this work for use on carbon fibers was incorporated in the SiC/SiC composites and yielded a >41 ksi (approx. 283 MPa) flexural strength.

Babcock, Jason↗

Developing NDE Techniques for Large Cryogenic Tanks - Year 2 Report

The Shuttle Program requires very large cryogenic ground storage tanks in which to store liquid oxygen and hydrogen. The existing Launch Complex-39 Pad tanks, which will be passed onto future launch programs, are over 40 years old and have received minimal refurbishment and only external inspections over the years. The majority of the structure is inaccessible without a full system drain of cryogenic liquid and insulation in the annular region. It was previously thought that there was a limit to the number of temperature cycles that the tanks could handle due to possible insulation compaction before undergoing a costly and time consuming complete overhaul; therefore the tanks were not drained and performance issues with these tanks, specifically the Pad B LH2 tank, were accepted. There is a need and an opportunity, as the Shuttle program ends and work to upgrade the launch pad progresses, to develop innovative non-destructive evaluation (NDE) techniques to analyze the current tanks. Techniques are desired that can aid in determining the extent of refurbishment required to keep the tanks in service for another 20+ years. A non-destructive technique would also be a significant aid in acceptance testing of new and refurbished tanks, saving significant time and money, if corrective actions can be taken before cryogen is introduced to the systems. Year one of this project concentrated on analysis of the current tanks located at LC-39 while cryogen was present. Year two of this project concentrated on analysis of detectable thermal variations on the outer surface of the tanks as the cryogen was drained and the inner vessel warmed to ambient conditions. Two techniques have been deployed in the field to monitor the tank. The first consisted of a displacement sensor to monitor for any expansions at the base of the tank during warm-up that could indicate a compaction issue with the insulation. The second technique was continued thermal monitoring of the tank through and after warm up. The indications noted in the thermal images were compared to bore-scope images of the annular region taken once the tank was inert and warmed to ambient conditions. Similar thermal imaging was performed on a smaller tank where an insulation void was induced to compare the effectiveness of thermal imagining on a different tank geometry.

Arens, Ellen↗

Measurement of Insulation Compaction in the Cryogenic Fuel Tanks at Kennedy Space Center by Fast/Thermal Neutron Techniques

The liquid hydrogen and oxygen cryogenic storage tanks at John F. Kennedy Space Center (KSC) use expanded perlite as thermal insulation. Th ere is evidence that some of the perlite has compacted over time, com promising the thermal performance and possibly also structural integr ity of the tanks. Therefore an Non-destructive Testing (NDT) method for measuring the perlite density or void fraction is urgently needed. Methods based on neutrons are good candidates because they can readil y penetrate through the 1.75 cm outer steel shell and through the ent ire 120 cm thickness of the perlite zone. Neutrons interact with the nuclei of materials to produce characteristic gamma rays which are the n detected. The gamma ray signal strength is proportional to the atom ic number density. Consequently, if the perlite is compacted then the count rates in the individual peaks in the gamma ray spectrum will i ncrease. Perlite is a feldspathic volcanic rock made up of the major elements Si, AI, Na, K and 0 along with some water. With commercially available portable neutron generators it is possible to produce simul taneously fluxes of neutrons in two energy ranges: fast (14 MeV) and thermal (25 meV). Fast neutrons produce gamma rays by inelastic scatt ering which is sensitive to Fe and O. Thermal neutrons produce gamma rays by radiative capture in prompt gamma neutron activation (PGNA) and this is sensitive to Si, AI, Na, Kand H. Thus the two energy ranges produce complementary information. The R&D program has three phases: numerical simulations of neutron and gamma ray transport with MCNP s oftware, evaluation of the system in the laboratory on test articles and finally mapping of the perlite density in the cryogenic tanks at KSC. The preliminary MCNP calculations have shown that the fast/therma l neutron NDT method is capable of distinguishing between expanded an d compacted perlite with excellent statistics.

Livingston, R. A.↗

MCNP Simulations of Measurement of Insulation Compaction in the Cryogenic Rocket Fuel Tanks at Kennedy Space Center by Fast/Thermal Neutron Techniques

MCNP simulations have been run to evaluate the feasibility of using a combination of fast and thermal neutrons as a nondestructive method to measure of the compaction of the perlite insulation in the liquid hydrogen and oxygen cryogenic storage tanks at John F. Kennedy Space Center (KSC). Perlite is a feldspathic volcanic rock made up of the major elements Si, AI, Na, K and 0 along with some water. When heated it expands from four to twenty times its original volume which makes it very useful for thermal insulation. The cryogenic tanks at Kennedy Space Center are spherical with outer diameters of 69-70 feet and lined with a layer of expanded perlite with thicknesses on the order of 120 cm. There is evidence that some of the perlite has compacted over time since the tanks were built 1965, affecting the thermal properties and possibly also the structural integrity of the tanks. With commercially available portable neutron generators it is possible to produce simultaneously fluxes of neutrons in two energy ranges: fast (14 Me V) and thermal (25 me V). The two energy ranges produce complementary information. Fast neutrons produce gamma rays by inelastic scattering, which is sensitive to Fe and O. Thermal neutrons produce gamma rays by prompt gamma neutron activation (PGNA) and this is sensitive to Si, Al, Na, K and H. The compaction of the perlite can be measured by the change in gamma ray signal strength which is proportional to the atomic number densities of the constituent elements. The MCNP simulations were made to determine the magnitude of this change. The tank wall was approximated by a I-dimensional slab geometry with an 11/16" outer carbon steel wall, an inner stainless wall and 120 cm thick perlite zone. Runs were made for cases with expanded perlite, compacted perlite or with various void fractions. Runs were also made to simulate the effect of adding a moderator. Tallies were made for decay-time analysis from t=0 to 10 ms; total detected gamma-rays; detected gamma-rays from thermal neutron reactions d. detected gamma-rays from non-thermal neutron reactions and total detected gamma-rays as a function of depth into the annulus volume. These indicated a number of possible independent metrics of perlite compaction. For example the count rate for perlite elements increased from 3600 to 8500 cps for an increase in perlite density from 6 lbs/lcf to 16.5 lbs/cf. Thus the MCNP simulations have confirmed the feasibility of using neutron methods to map the compaction of perlite in the walls of the cryogenic tanks.

Livingston, R. A.↗

Shape Bonding method

The present invention is directed to a method of bonding at least two surfaces together. The methods step of the present invention include applying a strip of adhesive to a first surface along a predefined outer boundary of a bond area and thereby defining a remaining open area there within. A second surface, or gusset plate, is affixed onto the adhesive before the adhesive cures. The strip of adhesive is allowed to cure and then a second amount of adhesive is applied to cover the remaining open area and substantially fill a void between said first and second surfaces about said bond area. A stencil may be used to precisely apply the strip of adhesive. When the strip cures, it acts as a dam to prevent overflow of the subsequent application of adhesive to undesired areas. The method results in a precise bond area free of undesired shapes and of a preferred profile which eliminate the drawbacks of the prior art bonds.

Pontius, James T.↗

Non-ambipolar radio-frequency plasma electron source and systems and methods for generating electron beams

An electron generating device extracts electrons, through an electron sheath, from plasma produced using RF fields. The electron sheath is located near a grounded ring at one end of a negatively biased conducting surface, which is normally a cylinder. Extracted electrons pass through the grounded ring in the presence of a steady state axial magnetic field. Sufficiently large magnetic fields and/or RF power into the plasma allow for helicon plasma generation. The ion loss area is sufficiently large compared to the electron loss area to allow for total non-ambipolar extraction of all electrons leaving the plasma. Voids in the negatively-biased conducting surface allow the time-varying magnetic fields provided by the antenna to inductively couple to the plasma within the conducting surface. The conducting surface acts as a Faraday shield, which reduces any time-varying electric fields from entering the conductive surface, i.e. blocks capacitive coupling between the antenna and the plasma.

Hershkowitz, Noah↗

Testing and Failure Mechanisms of Ice Phase Change Material Heat Exchangers

Phase change materials (PCM) may be useful for thermal control systems that involve cyclical heat loads or cyclical thermal environments such as specific spacecraft orientations in Low Earth Orbit (LEO) and low beta angle Low Lunar Orbit (LLO). Thermal energy can be stored in the PCM during peak heat loads or in adverse thermal environments. The stored thermal energy can then be released later during minimum heat loads or in more favorable thermal environments. One advantage that PCM s have over evaporators in this scenario is that they do not use a consumable. The use of water as a PCM rather than the more traditional paraffin wax has the potential for significant mass reduction since the latent heat of formation of water is approximately 70% greater than that of wax. One of the potential drawbacks of using ice as a PCM is its potential to rupture its container as water expands upon freezing. In order to develop a space qualified ice PCM heat exchanger, failure mechanisms must first be understood. Therefore, a methodical experimental investigation has been undertaken to demonstrate and document specific failure mechanisms due to ice expansion in the PCM. A number of ice PCM heat exchangers were fabricated and tested. Additionally, methods for controlling void location in order to reduce the risk of damage due to ice expansion were investigated. This paper presents the results of testing that occurred from March through September of 2010 and builds on testing that occurred during the previous year.

Leimkuehler, Thomas O.↗

Demonstrating the Operational Value of Thermodynamic Hyperspectral Profiles in the Pre-Convective Environment

The Short-term Prediction Research and Transition Center (SPoRT) is a collaborative partnership between NASA and operational forecasting partners, including a number of National Weather Service (NWS) Weather Forecasting Offices (WFO). As a part of the transition to operations process, SPoRT attempts to identify possible limitations in satellite observations and provide operational forecasters a product that will result in the most impact on their forecasts. One operational forecast challenge that some NWS offices face, is forecasting convection in data-void regions such as large bodies of water. The Atmospheric Infrared Sounder (AIRS) is a sounding instrument aboard NASA's Aqua satellite that provides temperature and moisture profiles of the atmosphere. This paper will demonstrate an approach to assimilate AIRS profile data into a regional configuration of the WRF model using its three-dimensional variational (3DVAR) assimilation component to be used as a proxy for the individual profiles.

Kozlowski, Danielle↗

Fracture Mechanics Analyses of Subsurface Defects in Reinforced Carbon-Carbon Joggles Subjected to Thermo-Mechanical Loads

Coating spallation events have been observed along the slip-side joggle region of the Space Shuttle Orbiter wing-leading-edge panels. One potential contributor to the spallation event is a pressure build up within subsurface voids or defects due to volatiles or water vapor entrapped during fabrication, refurbishment, or normal operational use. The influence of entrapped pressure on the thermo-mechanical fracture-mechanics response of reinforced carbon-carbon with subsurface defects is studied. Plane-strain simulations with embedded subsurface defects are performed to characterize the fracture mechanics response for a given defect length when subjected to combined elevated-temperature and subsurface-defect pressure loadings to simulate the unvented defect condition. Various subsurface defect locations of a fixed-length substrate defect are examined for elevated temperature conditions. Fracture mechanics results suggest that entrapped pressure combined with local elevated temperatures have the potential to cause subsurface defect growth and possibly contribute to further material separation or even spallation. For this anomaly to occur, several unusual circumstances would be required making such an outcome unlikely but plausible.

Knight, Norman F., Jr.↗

Joint Test Protocol for Validation of Alternative Low-Emission Surface Preparation/Depainting Technologies for Structural Steel

Headquarters National Aeronautics and Space Administration (NASA) chartered the Acquisition Pollution Prevention (AP2) Office to coordinate agency activities affecting pollution prevention issues identified during system and component acquisition and sustainment processes. The primary objectives of the AP2 Office are to: (1) Reduce or eliminate the use of hazardous materials (HazMats) or hazardous processes at manufacturing, remanufacturing, and sustainment locations. (2) A void duplication of effort in actions required to reduce or eliminate HazMats through joint center cooperation and technology sharing. This project will identify, evaluate and approve alternative surface preparation technologies for use at NASA and Air Force Space Command (AFSPC) installations. Materials and processes will be evaluated with the goal of selecting those processes that will improve corrosion protection at critical systems, facilitate easier maintenance activity, extend maintenance cycles, eliminate flight hardware contamination and reduce the amount of hazardous waste generated. This Joint Test Protocol (JTP) contains the critical requirements and tests necessary to qualify alternative Low-Emission Surface Preparation/Depainting Technologies for Structural Steel Applications. These tests were derived from engineering, performance, and operational impact (supportability) requirements defined by a consensus of NASA and Air Force Space Command (AFSPC) participants. The Field Test Plan (FTP), entitled Joint Test Protocol for Validation of Alternative Low Emission Surface Preparation/Depainting Technologies for Structural Steel, prepared by ITB, defines the field evaluation and testing requirements for validating alternative surface preparation/depainting technologies and supplements the JTP.

Lewis, Pattie↗

Thermodynamics of the Solar Corona and Evolution of the Solar Magnetic Field as Inferred from the Total Solar Eclipse Observations of 11 July 2010

We report on multi-wavelength observations of the corona taken simultaneously in broadband white light, and in seven spectral lines, H-alpha 656.3 nm, Fe IX 435.9 nm, Fe X 637.4 nm, Fe XI 789.2 nm, Fe XIII 1074.7 nm, Fe XIV 530.3 nm and Ni XV 670.2 nm. The observations were made during the total solar eclipse of 11 July 2010 from the atoll of Tatakoto in French Polynesia. Simultaneous imaging with narrow bandpass filters in each of these spectral lines and in their corresponding underlying continua maximized the observing time during less than ideal observing conditions and yielded outstanding quality data. The application of two complementary image processing techniques revealed the finest details of coronal structures at 1" resolution in white light, and 6.5" in each of the spectral lines. This comprehensive wavelength coverage confirmed earlier eclipse findings that the solar corona has a clear two-temperature structure: The open field lines, expanding outwards from the solar surface, are characterized by electron temperatures near 1 X 10(exp 6) K, while the hottest plasma around 2X 10(exp 6) K resides in loop-like structures forming the bulges of streamers. The first images of the corona in the forbidden lines of Fe IX and Ni XV, showed that there was very little coronal plasma at temperatures below 5 X 10(exp 5) K and above 2.5X 10(exp 6) K. The data also enabled temperature differentiations as low as 0:2 X 10(exp 6) K in different density structures. These observations showed how the passage of CMEs through the corona, prior to totality, produced large scale ripples and very sharp streaks, which could be identified with distinct temperatures for the first time. The ripples were most prominent in emission from spectral lines associated with temperatures around 10(exp 6) K. The most prominent streak was associated with a conical-shaped void in the emission from the coolest line of Fe IX and from the hottest line of Ni XV. A prominence, which erupted prior to totality, appeared in the shape of a hook in the cooler lines of Fe X and Fe XI, spanning 0.5 R(solar) in extent starting at a heliocentric distance of 1.3 R(solar), with a complex trail of hot and cool twisted structures connecting it to the solar surface. Simultaneous Fe X 17.4 nm observations from space by Proba2/SWAP provided an ideal opportunity for comparing emission from a coronal forbidden line, namely Fe X 637.4 nm, with a space-based EUV allowed line. Comparison of the Fe X 17.4 nm and 637.4 nm emission provided the first textbook example of the role of radiative excitation in extending the detectability of coronal emission to much larger heliocentric distances than its collisionally excited component. These eclipse observations demonstrate the unique capabilities of coronal forbidden lines for exploring the evolution of the coronal magnetic field in the heliocentric distance range of 1 - 3 R(solar), which is currently inaccessible to any space-borne or ground-based observatory.

Habbal, Shadia Rifai↗

Desert Varnish - Preservation of Biofabrics/Implcations for Mars

Desert varnish is the orange to dark brown rind that accumulates on exposed rock surfaces in many arid environments. Samples from the Sonoran Desert of Arizona are composed predominantly of clays (illite, smectite) and Mn- and Fe- oxides (birnessite, hematite). Features that appear to be single organisms are found within the varnish and at the rock-varnish interface. Many of these features are embedded in films that strongly resemble the water-rich extracellular polysaccharides produced by diverse microorganisms. Most common are rod-shaped celllike objects, 0.5-2 microns in the longest dimension, located within the varnish coatings. Some of these objects are shown to contain amines by fluorescence microscopy. The rod-shaped objects are observed in various states of degradation, as indicated by C and S abundances. Rods with higher C and S abundances appear less degraded than those with lower concentrations of these two elements. Regions rich in apparent microbes are present, while other regions display Mn- and Fe-rich mineral fabrics with microbe-sized voids and no obvious cells. These textures are interpreted as biofabrics, preserved by the precipitation of Mn and Fe minerals. We are researching the preservation of biofabrics by desert varnish in Earth's geological record. Rock coatings may similarly preserve evidence of microbial life on the hyper-arid surface of Mars.

Probst, Luke W.↗

Global Cooperation in the Science of Space Weather

The international space science community had recognized the importance of space weather more than a decade ago, which resulted in a number of international collaborative activities such as the Climate and Weather of the Sun Earth System (CAWSES) by SCOSTEP and the International Space Weather Initiative (ISWI). The ISWI program is a continuation of the successful International Heliophysical Year (IHY) program. These programs have brought scientists together to tackle the scientific issues behind space weather. In addition to the vast array of space instruments, ground based instruments have been deployed, which not only filled voids in data coverage, but also inducted young scientists from developing countries into the scientific community. This paper presents a summary of CAWSES and ISWI activities that promote space weather science via complementary approaches in international scientific collaborations. capacity building. and public outreach.

Gopalswamy, Nat↗

Thermal Control Method for High-Current Wire Bundles by Injecting a Thermally Conductive Filler

A procedure was developed to inject thermal filler material (a paste-like substance) inside the power wire bundle coming from solar arrays. This substance fills in voids between wires, which enhances the heat path and reduces wire temperature. This leads to a reduced amount of heat generated. This technique is especially helpful for current and future generation high-power spacecraft (1 kW or more), because the heat generated by the power wires is significant enough to cause unacceptable overheating to critical components that are in close contact with the bundle.

Rodriguez-Ruiz, Juan↗

Processing and Characterization of PETI Composites Fabricated by High Temperature VARTM

The use of composites as primary structures on aerospace vehicles has increased dramatically over the past decade. As these advanced structures increase in size and complexity, their production costs have grown significantly. A major contributor to these manufacturing costs is the requirement of elevated processing pressures, during the thermal cure, to create fully consolidated composites. For certain composite parts, high temperature vacuum assisted resin transfer molding (HT-VARTM) can offer reduced fabrication costs compared to conventional autoclave techniques. The process has been successfully used with phenylethynyl terminated imide (PETI) resins developed by NASA LaRC. In the current study, two PETI resins, LARC(TradeMark) PETI-330 and LARC(TradeMark) PETI-8 have been used to make test specimens using HT-VARTM. Based on previous work at NASA LaRC, larger panels with a quasi-isotropic lay-up were fabricated. The resultant composite specimens exhibited void contents <3% by volume depending on the type of carbon fabric preform used. Mechanical properties of the panels were determined at both room and elevated temperatures. These included open-hole compressive (OHC) and short beam shear (SBS) properties. Limited process modeling efforts were carried out including infusion times, composite panel size limitations and fabric permeability characterization. Work has also been carried out to develop new PETI based resins specifically geared towards HT-VARTM. The results of this work are presented herein.

Ghose, Sayata↗

Quantitative Examination of a Large Sample of Supra-Arcade Downflows in Eruptive Solar Flares

Sunward-flowing voids above post-coronal mass ejection flare arcades were first discovered using the soft X-ray telescope aboard Yohkoh and have since been observed with TRACE (extreme ultraviolet (EUV)), SOHO/LASCO (white light), SOHO/SUMER (EUV spectra), and Hinode/XRT (soft X-rays). Supra-arcade downflow (SAD) observations suggest that they are the cross-sections of thin flux tubes retracting from a reconnection site high in the corona. Supra-arcade downflowing loops (SADLs) have also been observed under similar circumstances and are theorized to be SADs viewed from a perpendicular angle. Although previous studies have focused on dark flows because they are easier to detect and complementary spectral data analysis reveals their magnetic nature, the signal intensity of the flows actually ranges from dark to bright. This implies that newly reconnected coronal loops can contain a range of hot plasma density. Previous studies have presented detailed SAD observations for a small number of flares. In this paper, we present a substantial SADs and SADLs flare catalog. We have applied semiautomatic detection software to several of these events to detect and track individual downflows thereby providing statistically significant samples of parameters such as velocity, acceleration, area, magnetic flux, shrinkage energy, and reconnection rate. We discuss these measurements (particularly the unexpected result of the speeds being an order of magnitude slower than the assumed Alfven speed), how they were obtained, and potential impact on reconnection models.

Savage, Sabrina L.↗

Effect of Environmental Exposures on Fatigue Life of P/M Disk Superalloys

As the temperature capability of Ni-base superalloy powder metallurgy disks is steadily increased, environmental resistance and protection of advanced nickel-based turbine disk components are becoming increasingly important. Localized surface hot corrosion attack and damage from oxidation have been shown to impair disk fatigue life and may eventually limit disk operating temperatures. NASA Research Announcement (NRA) contracts have been awarded to GE Aviation and Honeywell Aerospace to separately develop fatigue resistant metallic and ceramic coatings for corrosion resistance and the corrosion/fatigue results of selected coatings will be presented. The microstructural response of a bare ME3 disk superalloy has been evaluated for moderate (704 C) and aggressive (760-816 C) oxidizing exposures up to 2,020 hours. Cross section analysis reveals sub-surface damage (significant for aggressive exposures) that consists of Al2O3 "fingers", interfacial voids, a recrystallized precipitate-free layer and GB carbide dissolution. The effects of a Nichrome corrosion coating on this microstructural response will also be presented.

Draper, Susan↗

Gas Phase Pressure Effects on the Apparent Thermal Conductivity of JSC-1A Lunar Regolith Simulant

Gas phase pressure effects on the apparent thermal conductivity of a JSC-1A/air mixture have been experimentally investigated under steady state thermal conditions from 10 kPa to 100 kPa. The result showed that apparent thermal conductivity of the JSC-1A/air mixture decreased when pressure was lowered to 80 kPa. At 10 kPa, the conductivity decreased to 0.145 W/m/degree C, which is significantly lower than 0.196 W/m/degree C at 100 kPa. This finding is consistent with the results of previous researchers. The reduction of the apparent thermal conductivity at low pressures is ascribed to the Knudsen effect. Since the characteristic length of the void space in bulk JSC-1A varies over a wide range, both the Knudsen regime and continuum regime can coexist in the pore space. The volume ratio of the two regimes varies with pressure. Thus, as gas pressure decreases, the gas volume controlled by Knudsen regime increases. Under Knudsen regime the resistance to the heat flow is higher than that in the continuum regime, resulting in the observed pressure dependency of the apparent thermal conductivity.

Yuan, Zeng-Guang↗