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NASA NTRS2011

Friction Pull Plug Welding in Aluminum Alloys

NASA fs Marshall Space Flight Center (MSFC) has recently invested much time and effort into the process development of Friction Pull Plug Welding (FPPW). FPPW, is a welding process similar to Friction Push Plug Welding in that, there is a small rotating part (plug) being spun and simultaneously pulled (forged) into a larger part. These two processes differ, in that push plug welding requires an internal reaction support, while pull plug welding reacts to the load externally. FPPW was originally conceived as a post proof repair technique for External Tank. FPPW was easily selected as the primary process used to close out the termination hole on the Constellation Program fs ARES I Upper Stage circumferential Self ] Reacting Friction Stir Welds (SR ]FSW). The versatility of FPPW allows it to also be used as a repair technique for both SR ]FSW and Conventional Friction Stir Welds. To date, all MSFC led development has been concentrated on aluminum alloys (2195, 2219, and 2014). Much work has been done to fully understand and characterize the process fs limitations. A heavy emphasis has been spent on plug design, to match the various weldland thicknesses and alloy combinations. This presentation will summarize these development efforts including weld parameter development, process control, parameter sensitivity studies, plug repair techniques, material properties including tensile, fracture and failure analysis.

Brooke, Shane A.↗
NASA NTRS2011

Assembly of 5.5-Meter Diameter Developmental Barrel Segments for the Ares I Upper Stage

Full scale assembly welding of Ares I Upper Stage 5.5-Meter diameter cryogenic tank barrel segments has been performed at the Marshall Space Flight Center (MSFC). One full-scale developmental article produced under the Ares 1 Upper Stage project is the Manufacturing Demonstration Article (MDA) Barrel. This presentation will focus on the welded assembly of this barrel section, and associated lessons learned. Among the MDA articles planned on the Ares 1 Program, the Barrel was the first to be completed, primarily because the process of manufacture from piece parts (barrel panels) utilized the most mature friction stir process planned for use on the Ares US program: Conventional fixed pin Friction Stir Welding (FSW). This process is in use on other space launch systems, including the Shuttle s External Tank, the Delta IV common booster core, the Delta II, and the Atlas V rockets. The goals for the MDA Barrel development were several fold: 1) to prove out Marshall Space Flight Center s new Vertical Weld Tool for use in manufacture of cylindrical barrel sections, 2) to serve as a first run for weld qualification to a new weld specification, and 3) to provide a full size cylindrical section for downstream use in precision cleaning and Spray-on Foam Insulation development. The progression leading into the welding of the full size barrel included sub scale panel welding, subscale cylinder welding, a full length confidence weld, and finally, the 3 seamed MDA barrel processing. Lessons learned on this MDA program have been carried forward into the production tooling for the Ares 1 US Program, and in the use of the MSFC VWT in processing other large scale hardware, including two 8.4 meter diameter Shuttle External Tank barrel sections that are currently being used in structural analysis to validate shell buckling models.

Carter, Robert W.↗
NASA NTRS2012

Determining Damping Trends from a Range of Cable Harness Assemblies on a Launch Vehicle Panel from Test Measurements

The team of authors at Marshall Space Flight Center (MSFC) has been investigating estimating techniques for the vibration response of launch vehicle panels excited by acoustics and/or aero-fluctuating pressures. Validation of the approaches used to estimate these environments based on ground tests of flight like hardware is of major importance to new vehicle programs. The team at MSFC has recently expanded upon the first series of ground test cases completed in December 2010. The follow on tests recently completed are intended to illustrate differences in damping that might be expected when cable harnesses are added to the configurations under test. This validation study examines the effect on vibroacoustic response resulting from the installation of cable bundles on a curved orthogrid panel. Of interest is the level of damping provided by the installation of the cable bundles and whether this damping could be potentially leveraged in launch vehicle design. The results of this test are compared with baseline acoustic response tests without cables. Damping estimates from the measured response data are made using a new software tool that employs a finite element model (FEM) of the panel in conjunction with advanced optimization techniques. This paper will report on the \damping trend differences. observed from response measurements for several different configurations of cable harnesses. The data should assist vibroacoustics engineers to make more informed damping assumptions when calculating vibration response estimates when using model based analysis approach. Achieving conservative estimates that have more flight like accuracy is desired. The paper may also assist analysts in determining how ground test data may relate to expected flight response levels. Empirical response estimates may also need to be adjusted if the measured response used as an input to the study came from a test article without flight like cable harnesses.

Smith, Andrew↗
NASA NTRS2012

Marshall Space Flight Center Materials and Processes Laboratory

Marshall?s Materials and Processes Laboratory has been a core capability for NASA for over fifty years. MSFC has a proven heritage and recognized expertise in materials and manufacturing that are essential to enable and sustain space exploration. Marshall provides a "systems-wise" capability for applied research, flight hardware development, and sustaining engineering. Our history of leadership and achievements in materials, manufacturing, and flight experiments includes Apollo, Skylab, Mir, Spacelab, Shuttle (Space Shuttle Main Engine, External Tank, Reusable Solid Rocket Motor, and Solid Rocket Booster), Hubble, Chandra, and the International Space Station. MSFC?s National Center for Advanced Manufacturing, NCAM, facilitates major M&P advanced manufacturing partnership activities with academia, industry and other local, state and federal government agencies. The Materials and Processes Laborato ry has principal competencies in metals, composites, ceramics, additive manufacturing, materials and process modeling and simulation, space environmental effects, non-destructive evaluation, and fracture and failure analysis provide products ranging from materials research in space to fully integrated solutions for large complex systems challenges. Marshall?s materials research, development and manufacturing capabilities assure that NASA and National missions have access to cutting-edge, cost-effective engineering design and production options that are frugal in using design margins and are verified as safe and reliable. These are all critical factors in both future mission success and affordability.

Tramel, Terri L.↗
NASA NTRS2008

Statistical Short-Range Guidance for Peak Wind Speed Forecasts at Edwards Air Force Base, CA

The peak winds near the surface are an important forecast element for Space Shuttle landings. As defined in the Shuttle Flight Rules (FRs), there are peak wind thresholds that cannot be exceeded in order to ensure the safety of the shuttle during landing operations. The National Weather Service Spaceflight Meteorology Group (SMG) is responsible for weather forecasts for all shuttle landings. They indicate peak winds are a challenging parameter to forecast. To alleviate the difficulty in making such wind forecasts, the Applied Meteorology Unit (AMTJ) developed a personal computer based graphical user interface (GUI) for displaying peak wind climatology and probabilities of exceeding peak-wind thresholds for the Shuttle Landing Facility (SLF) at Kennedy Space Center. However, the shuttle must land at Edwards Air Force Base (EAFB) in southern California when weather conditions at Kennedy Space Center in Florida are not acceptable, so SMG forecasters requested that a similar tool be developed for EAFB. Marshall Space Flight Center (MSFC) personnel archived and performed quality control of 2-minute average and 10-minute peak wind speeds at each tower adjacent to the main runway at EAFB from 1997- 2004. They calculated wind climatologies and probabilities of average peak wind occurrence based on the average speed. The climatologies were calculated for each tower and month, and were stratified by hour, direction, and direction/hour. For the probabilities of peak wind occurrence, MSFC calculated empirical and modeled probabilities of meeting or exceeding specific 10-minute peak wind speeds using probability density functions. The AMU obtained and reformatted the data into Microsoft Excel PivotTables, which allows users to display different values with point-click-drag techniques. The GUT was then created from the PivotTables using Visual Basic for Applications code. The GUI is run through a macro within Microsoft Excel and allows forecasters to quickly display and interpret peak wind climatology and likelihoods in a fast-paced operational environment. A summary of how the peak wind climatologies and probabilities were created and an overview of the GUT will be presented.

Dreher, Joseph↗
NASA NTRS2006

Bimetallic Treatment System (BTS) for Removal and Remediation of Polychlorinated Biphenyl from Marshall Space Flight Center's 4696 Fl Stand

This Office of Space Flight (OSF)-funded project sought to demonstrate the application of a Bi-metallic Treatment System (BTS) to remove and degrade PCBs found on NASA facilities. The project initiated with the collection of PCB-containing materials from various MSFC and KSC structures, followed by laboratory evaluation of the BTS' PCB-removal efficiency, and concluded with a field demonstration at MSFC. The project evaluated the optimum formulation required to remove PCBs from aged and weathered paint with the goal of achieving final PCB concentrations less than 50 mg/Kg or 50 percent reduction where PCB starting levels were already below the 50 mg/Kg levels. Using lessons learned from this study, it was anticipated that the research team would be better able to make further recommendation on application strategies for future use of BTS for the treatment of PCB laden coatings on structures.

Quinn, Jacqueline↗
NASA NTRS2013

Internal Social Media at Marshall Space Flight Center - An Engineer's Snapshot

In the brief span of about six years (2004-2010), social media radically enhanced people's ways of maintaining recreational friendships. Social media's impact on public affairs (PAO) and community engagement is equally striking: NASA has involved millions of non-NASA viewers in its activities via outward-facing social media, often in a very two-way street fashion. Use of social media as an internal working tool by NASA's tens of thousands of civil servants, onsite contractor employees, and external stakeholders is evolving more slowly. This paper examines, from an engineer's perspective, Marshall Space Flight Center s (MSFC) efforts to bring the power of social media to the daily working environment. Primary emphasis is on an internal Social Networking Service called Explornet that could be scaled Agency-wide. Other topics include MSFC use of other social media day-to-day for non-PAO purposes, some specialized uses of social techniques in space flight control operations, and how to help a community open up so it can discover and adopt what works well.

Scott, David W.↗
NASA NTRS2013

Powerpack Testing of the J2-X Oxidizer Turbopump

The J-2X PPA-2 (Powerpack 2) test series was conducted from February through December 2012 on the A1 test stand at NASA Stennis Space Center in a joint effort between Pratt and Whitney Rocketdyne (PWR) and NASA Marshall Space Flight Center (MSFC). The series consisted of 13 tests for a total hotfire duration close to 6500 seconds. Among the chief test objectives was characterization of the capabilities of the new J-2X turbopumps. This paper concentrates on the test results pertaining specifically to the Oxidizer Turbopump (OTP) operation in liquid oxygen (LOX). The two bladed inducer configuration that was tested had a 0.81% blade height tip clearance and incorporated the B-groove modification to the inducer tunnel outboard of the inducer leading edge. Data was collected on inducer suction performance, pump radial loading, and the pump dynamic environment in LOX. Comparisons were made to prior data collected on two geometrically similar subscale inducers tested in water at NASA MSFC (70% scale) and Concepts NREC (52% scale). In overview, the results of the powerpack testing were consistent with the radial load assessment from the water tests. The inducer performed differently in the other two categories, however. The inducer suction performance capability in LOX was notably improved. This was expected and is probably attributable to thermal suppression head (TSH) effects. While the dynamic environment was similar in most aspects to water test observations, the higher order cavitation (HOC) during the powerpack testing was much more benign.

Jambusaria, Mitul↗
NASA NTRS2013

Testing of an Annular Linear Induction Pump for the Fission Surface Power Technology Demonstration Unit

Results of performance testing of an annular linear induction pump that has been designed for integration into a fission surface power technology demonstration unit are presented. The pump electromagnetically pushes liquid metal (NaK) through a specially-designed apparatus that permits quantification of pump performance over a range of operating conditions. Testing was conducted for frequencies of 40, 55, and 70 Hz, liquid metal temperatures of 125, 325, and 525 C, and input voltages from 30 to 120 V. Pump performance spanned a range of flow rates from roughly 0.3 to 3.1 L/s (4.8 to 49 gpm), and pressure heads of <1 to 104 kPa (<0.15 to 15 psi). The maximum efficiency measured during testing was 5.4%. At the technology demonstration unit operating temperature of 525 C the pump operated over a narrower envelope, with flow rates from 0.3 to 2.75 L/s (4.8 to 43.6 gpm), developed pressure heads from <1 to 55 kPa (<0.15 to 8 psi), and a maximum efficiency of 3.5%. The pump was supplied with three-phase power at 40 and 55 Hz using a variable-frequency motor drive, while power at 55 and 70 Hz was supplied using a variable-frequency power supply. Measured performance of the pump at 55 Hz using either supply exhibited good quantitative agreement. For a given temperature, the peak in efficiency occurred at different flow rates as the frequency was changed, but the maximum value of efficiency was relative insensitive within 0.3% over the frequency range tested, including a scan from 45 to 78 Hz. The objectives of the FSP technology project are as follows:5 • Develop FSP concepts that meet expected surface power requirements at reasonable cost with added benefits over other options. • Establish a nonnuclear hardware-based technical foundation for FSP design concepts to reduce overall development risk. • Reduce the cost uncertainties for FSP and establish greater credibility for flight system cost estimates. • Generate the key nonnuclear products to allow Agency decision makers to consider FSP as a viable option for potential future flight development. The pump must be compatible with the liquid NaK coolant and have adequate performance to enable a viable flight system. Idaho National Laboratory (INL) was tasked with the design and fabrication of an ALIP suitable for the FSP reference mission. Under the program, a quarter-scale FSP technology demonstration is under construction to test the end-to-end conversion of simulated nuclear thermal power to usable electrical power intended to raise the entire FSP system to Technology Readiness Level 6. An ALIP for this TDU was fabricated under the direction of the INL and shipped to NASA Marshall Space Flight Center (MSFC) for testing at representative operating conditions. This pump was designed to meet the requirements of the TDU experiment. The ALIP test circuit (ATC) at MSFC, previously used to conduct performance evaluation on another ALIP6 was used to test the present TDU pump for the FSP Technology Development program.

Polzin, K. A.↗
NASA NTRS2013

Development of Stacked Core Technology for the Fabrication of Deep Lightweight UV Quality Space Mirrors

Decadal Survey stated that an advanced large-aperture ultraviolet, optical, near-infrared (UVOIR) telescope is required to enable the next generation of compelling astrophysics and exoplanet science; and, that present technology is not mature enough to affordably build and launch any potential UVOIR mission concept. Under Science and Technology funding, NASA's Marshall Space Flight Center (MSFC) and ITT Exelis have developed a more cost effective process to make up to 4m monolithic spaceflight UV quality, low areal density, thermally and dynamically stable primary mirrors. A proof of concept mirror was completed at ITT Exelis and tested down to 250K at MSFC which would allow imaging out to 2.5 microns. The parameters and test results of this concept mirror will be shown. The scale-up process will be discussed and the technology development path to a 4m mirror system by 2018 will also be outlined.

Matthews, Gary↗
NASA NTRS2013

Development of Mirror Modules for the ART-XC Instrument aboard the Spectrum-Roentgen-Gamma Mission

The Marshall Space Flight Center (MSFC) is developing x-ray mirror modules for the Astronomical Roengen Telescope- X-ray Concentrator (ART-XC) instrument on board the Spectrum-Roentgen-Gamma Mission. ART-XC will consist of seven co-aligned x-ray mirror modules with seven corresponding CdTe focal plane detectors. Each module provides an effective area of 65 sq cm at 8 keV, response out to 30 keV, and an angular resolution of 45 arcsec or better HPD. We will present a status of the ART x-ray module development at MSFC.

Gubarev, Mikhail V.↗
NASA NTRS2013

Pushing the Limits of Cubesat Attitude Control: A Ground Demonstration

A cubesat attitude control system (ACS) was designed at the NASA Marshall Space Flight Center (MSFC) to provide sub-degree pointing capabilities using low cost, COTS attitude sensors, COTS miniature reaction wheels, and a developmental micro-propulsion system. The ACS sensors and actuators were integrated onto a 3D-printed plastic 3U cubesat breadboard (10 cm x 10 cm x 30 cm) with a custom designed instrument board and typical cubesat COTS hardware for the electrical, power, and data handling and processing systems. In addition to the cubesat development, a low-cost air bearing was designed and 3D printed in order to float the cubesat in the test environment. Systems integration and verification were performed at the MSFC Small Projects Rapid Integration & Test Environment laboratory. Using a combination of both the miniature reaction wheels and the micro-propulsion system, the open and closed loop control capabilities of the ACS were tested in the Flight Robotics Laboratory. The testing demonstrated the desired sub-degree pointing capability of the ACS and also revealed the challenges of creating a relevant environment for development testin

Sanders, Devon S.↗
NASA NTRS2013

Development of Stacked Core Technology for the Fabrication of Deep Lightweight UV Quality Space Mirrors

Decadal Survey stated that an advanced large-aperture ultraviolet, optical, near-infrared (UVOIR) telescope is required to enable the next generation of compelling astrophysics and exoplanet science; and, that present technology is not mature enough to affordably build and launch any potential UVOIR mission concept. Under Science and Technology funding, NASA's Marshall Space Flight Center (MSFC) and ITT Exelis have developed a more cost effective process to make up to 4m monolithic spaceflight UV quality, low areal density, thermally and dynamically stable primary mirrors. A proof of concept mirror was completed at ITT Exelis and tested down to 250K at MSFC which would allow imaging out to 2.5 microns. The parameters and test results of this concept mirror will be shown. The scale-up process will be discussed and the technology development path to a 4m mirror system by 2018 will also be outlined.

Matthews, Gary W.↗
NASA NTRS2013

The Development of Stacked Core Technology for the Fabrication of Deep Lightweight UV-quality Space Mirrors

The Decadal Survey stated that an advanced large-aperture ultraviolet, optical, near-infrared (UVOIR) telescope is required to enable the next generation of compelling astrophysics and exoplanet science; and, that present technology is not mature enough to affordably build and launch any potential UVOIR mission concept. Under Science and Technology funding, NASA's Marshall Space Flight Center (MSFC) and Exelis have developed a more cost effective process to make up to 4m monolithic spaceflight UV quality, low areal density, thermally and dynamically stable primary mirrors. A proof of concept mirror was completed at Exelis and tested down to 250K at MSFC which would allow imaging out to 2.5 microns. The parameters and test results of this concept mirror will be shown. The scale-up process will be discussed and the technology development path to a 4m mirror system by 2018 will also be outlined.

Matthews, Gary W.↗
NASA NTRS2013

Sources and Transportation of Bulk, Low-Cost Lunar Simulant Materials

Marshall Space Flight Center (MSFC) has built the Lunar Surface Testbed using 200 tons of volcanic cinder and ash from the same source used for the simulant series JSC-1. This Technical Memorandum examines the alternatives examined for transportation and source. The cost of low-cost lunar simulant is driven by the cost of transportation, which is controlled by distance and, to a lesser extent, quantity. Metabasalts in the eastern United States were evaluated due to their proximity to MSFC. Volcanic cinder deposits in New Mexico, Colorado, and Arizona were recognized as preferred sources. In addition to having fewer green, secondary minerals, they contain vesicular glass, both of which are desirable. Transportation costs were more than 90% of the total procurement costs for the simulant material.

Rickman, D. L.↗
NASA NTRS2013

Development of Mirror Modules for the ART-XC Instrument aboard the Spectrum-Roentgen-Gamma Mission

The Marshall Space Flight Center (MSFC) is developing x-ray mirror modules for the ART-XC instrument on board the Spectrum-Roentgen Gamma Mission. Four of those modules are being fabricated under a Reimbursable Agreement between NASA and the Russian Space Research Institute (IKI.) An additional three flight modules and one spare for the ART-XC Instrument are produced under a Cooperative Agreement between NASA and IKI. The instrument will consist of seven co-aligned x-ray mirror modules with seven corresponding CdTe focal plane detectors. Each module consists of 28 nested thin Ni/Co shells giving an effective area of 65 cm2 at 8 keV, response out to 30 keV, and an angular resolution of 45 arcsec or better HPD. Delivery of the first four modules is scheduled for November 2013, while the remaining three modules will be delivered to IKI in January 2014. We present a status of the ART x-ray module development at MSFC.

Gubarev, M↗
NASA NTRS2013

Common Web Mapping and Mobile Device Framework for Display of NASA Real-time Data

Scientists have strategic goals to deliver their unique datasets and research to both collaborative partners and more broadly to the public. These datasets can have a significant impact locally and globally as has been shown by the success of the NASA Short‐term Prediction Research and Transition (SPoRT) Center and SERVIR programs at Marshall Space Flight Center. Each of these respective organizations provides near real‐time data at the best resolution possible to address concerns of the operational weather forecasting community (SPoRT) and to support environmental monitoring and disaster assessment (SERVIR). However, one of the biggest struggles to delivering the data to these and other Earth science community partners is formatting the product to fit into an end user's Decision Support System (DSS). The problem of delivering the data to the end‐user's DSS can be a significant impediment to transitioning research to operational environments especially for disaster response where the deliver time is critical. The decision makers, in addition to the DSS, need seamless access to these same datasets from a web browser or a mobile phone for support when they are away from their DSS or for personnel out in the field. A framework has been developed for MSFC Earth Science program that can be used to easily enable seamless delivery of scientific data to end users in multiple formats. The first format is an open geospatial format, Web Mapping Service (WMS), which is easily integrated into most DSSs. The second format is a web browser display, which can be embedded within any MSFC Science web page with just a few lines of web page coding. The third format is accessible in the form of iOS and Android native mobile applications that could be downloaded from an "app store". The framework developed has reduced the level of effort needed to bring new and existing NASA datasets to each of these end user platforms and help extend the reach of science data.

Burks, Jason E.↗