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NASA NTRS2010

Fiber Optic Cables for Transmission of High-Power Laser Pulses in Spaceflight Applications

Lasers with high peak power pulses are commonly used in spaceflight missions for a wide range of applications, from LIDAR systems to optical communications. Due to the high optical power needed, the laser has to be located on the exterior of the satellite or coupled through a series of free space optics. This presents challenges for thermal management, radiation resistance, and mechanical design. Future applications will require multiple lasers located close together, which further complicates the design. Coupling the laser energy into a fiber optic cable allows the laser to be relocated to a more favorable position on the spacecraft. Typical fiber optic termination procedures are not sufficient for injection of these high-power laser pulses without catastrophic damage to the fiber endface. In the current study, we will review the causes of fiber damage during high-power injection and discuss our new manufacturing procedures that overcome these issues to permit fiber use with high reliability in these applications. We will also discuss the proper methods for launching the laser pulses into the fiber to avoid damage and how this is being implemented for current spaceflight missions.

Thomes, W. J., Jr.↗

NASA NTRS2019

Automated Fiber Placement Manufactured Composites for Science Applications

Science instruments with large collecting areas that maintain dimensional stability, such as James Webb Space Telescope and Wide Field Space Telescope, help achieve next generation science advancements. Composite materials often used for science applications include high modulus fibers in cyanate ester matrices to result in dimensionally stable structures with low contamination. Hand lay-up fabrication is the most common approach for science instrument structures. Automated Fiber Placement (AFP) using intermediate modulus fibers is commonplace in aircraft production reducing manufacturing time and increasing quality and consistency. AFP manufacturing for future large science instruments can similarly reduce costs and increase reliability. However, high modulus fibers are more prone to damage than intermediate modulus fibers. This study investigates the manufacturing viability of M55J/RS3C (Tencate) slit tape material using AFP processing. Tencate provides slit tape materials. NASA Langley Research Center (LaRC) manufactured hand layup and AFP lay-up laminates under room temperature for initial trials, Marshall Space Flight Center (MSFC) manufactured AFP laminates under room temperature and elevated temperature conditions to evaluate processing affects. Goddard Space Flight Center (GSFC) tests and evaluates tension and Coefficient of Thermal Expansion (CTE) properties by hand lay-up and AFP slit tape automated manufacturing for large science applications. These results show processing material warm reduces process induced fiber fracture; leading to stiffness and CTE properties consistent with hand lay-up, while observing a slight degradation in tensile strength.

Segal, Kenneth N.↗

NASA NTRS2019

Few-Mode Fiber Coupled Superconducting Nanowire Single-Photon Detectors for Photon Efficient Optical Communications

The NASA Glenn Research Center's development of a high-photon efficiency real-time optical communications ground receiver has added superconducting nanowire single-photon detectors (SNSPDs) coupled with few-mode fibers (FMF). High data rate space-to-ground optical communication links require enhanced ground receiver sensitivity to reduce spacecraft transmitter constraints, and therefore require highly efficient coupling from fiber to detector. In the presence of atmospheric turbulence the received optical wave front can be severely distorted introducing higher-order spatial mode components to the received signal. To reduce mode filtering and mismatch loss and the resulting degradations to detector coupling efficiency, we explore the use of few-mode fiber coupling to commercial single-pixel SNSPDs. Graded index 20-µm few-mode fibers allow the commercial single pixel SNSPD's active area to couple with equal efficiency as single mode fibers. Here we determine detector characteristics such as count rate, detection efficiency, dark counts, and jitter, as well as detection efficiencies for higher-order fiber spatial modes. Additionally, we assess the laboratory performance of the detectors in an optical system which emulates future deep space optical communications links.

Vyhnalek, Brian E.↗

NASA NTRS2019

The Effect of Hole Quality on the Bearing Strength of Carbon Fiber Laminates

On programs involving flight hardware for launch vehicles that the author has been involved in over the years, the question always arises as to how to best machine and inspect holes drilled for fasteners. While common sense dictates that ‘well-drilled’ holes are desired over ‘poorly drilled’ holes for bolt bearing applications, the effect of hole quality on the bearing strength of carbon fiber laminates has not been extensively studied in the open literature. If this effect is not quantitatively known, the question of what hole quality needs to be required for the flight hardware cannot be answered. In addition, the function of the part with respect to the holes needs to be taken into account. There is no such thing as a defect-free hole since some chip-out of fibers within the hole will occur regardless of drill bit and backing plate pressure. For most holes machined in a carbon fiber laminate, some extent of delamination and fiber breakout on the entrance and exit of the hole is going to occur. Much time and money can be spent on trying to perfect the drilling technique and subsequent inspection of holes in carbon fiber laminates, including adding extra plies of cloth to the surfaces to help prevent fiber breakout; but is this effort really justified if little-to-no increase in bearing strength is realized by good-quality holes over those of lesser quality?

Nettles, A. T.↗

NASA NTRS2020

Measurements of few-mode fiber photonic lanterns in emulated atmospheric conditions for a low earth orbit space to ground optical communication receiver application

Photonic lanterns are being evaluated as a component of a scalable photon counting real-time optical ground receiver for space-to-ground photon-starved communication applications. The function of the lantern as a component of a receiver is to efficiently couple and deliver light from the atmospherically distorted focal spot formed behind a telescope to multiple small-core fiber-coupled single-element super-conducting nanowire detectors. This architecture solution is being compared to a multimode fiber coupled to a multi-element detector array. This paper presents a set of measurements that begins this comparison. This first set of measurements are a comparison of the throughput coupling loss at emulated atmospheric conditions for the case of a 60 cm diameter telescope receiving light from a low earth orbit satellite. The atmospheric conditions are numerically simulated at a range of turbulence levels using a beam propagation method and are physically emulated with a spatial light modulator. The results show that for the same number of output legs as the single-mode fiber lantern, the few-mode fiber lantern increases the power throughput up to 3.92 dB at the worst emulated atmospheric conditions tested of D/r(sub 0)=8.6. Furthermore, the coupling loss of the few-mode fiber lantern approaches the capability of a 30 micron graded index multimode fiber chosen for coupling to a 16 element detector array.

Tedder, Sarah A.↗

NASA NTRS2020

Measurements of Few-Mode Fiber Photonic Lanterns in Emulated Atmospheric Conditions for a Low Earth Orbit Space to Ground Optical Communication Receiver Application

Photonic lanterns are being evaluated as a component of a scalable photon counting real-time optical ground receiver for space-to-ground photon-starved communication applications. The function of the lantern as a component of a receiver is to efficiently couple and deliver light from the atmospherically distorted focal spot formed behind a telescope to multiple small-core fiber-coupled single-element super-conducting nanowire detectors. This architecture solution is being compared to a multimode fiber coupled to a multi-element detector array. This paper presents a set of measurements that begins this comparison. This first set of measurements are a comparison of the throughput coupling loss at emulated atmospheric conditions for the case of a 60 cm diameter telescope receiving light from a low earth orbit satellite. The atmospheric conditions are numerically simulated at a range of turbulence levels using a beam propagation method and are physically emulated with a spatial light modulator. The results show that for the same number of output legs as the single-mode fiber lantern, the few mode fiber lantern increases the power throughput up to 3.92 dB at the worst emulated atmospheric conditions tested of D/r0=8.6. Furthermore, the coupling loss of the few mode fiber lantern approaches the capability of a 30 micron graded index multimode fiber chosen for coupling to a 16 element detector array.

Tedder, Sarah A.↗

NASA NTRS2021

Novel Fiber Optic Sensing Arrays with Enhanced Sensitivity in Cryogenic Temperatures

State-of-the-art instrumentation techniques have provided an opportunity to obtain greater insight into the characteristics of cryogenic liquid storage. Optical fiber sensors that utilize fiber Bragg gratings are a viable option for temperature sensing in volatile liquid such as liquid oxygen because there is no risk of electrical sparking and no electromagnetic interference. The National Aeronautics and Space Administration (NASA) Armstrong Flight Research Center (Edwards, California) has developed a novel, simple-to-fabricate fiber array sensor that has been tested and found to be three times more sensitive than typical fiber sensors under cryogenic condition (traditional fiber sensors can suffer from reduced sensitivity below 100 K). Cryogenic temperature monitoring using the NASA fiber optic sensing system is demonstrated in a simulated cryostatic condition, as well as in an elevated pressure environment under liquid nitrogen. Measurement accuracy is compared with traditional silicon diodes. Instrument installation, sensor characteristics, and experimental results are discussed in detail.

Hon Man Chan↗

NASA NTRS2003

Design and fabrication of a coherent array of single-mode optical fibers for the nulling coronagraph

We present the development of a single-mode spatial filter array for the nulling coronagraph application. The development consists of two generations of fiber array designs and a Zygo-interferometer based lens array to fiber array alignment methodology. We discuss the use of large mode field diameter (MFD) fibers to relax fiber placement tolerance of the fiber array. The pros and cons of using the Photonic Crystal Fiber (PCF) for building the array are discussed. The future plan for implementing a 1000-channel class, single-mode spatial filter array is described.

Shao, Mike↗

NASA NTRSDate not supplied

Design, Fabrication, Testing and Validation of a Ruggedized Fiber Optic Sensing System (FOSS) for Launch Application

Fiber-optic sensors based on fiber Bragg grating (FBG) is desirable for structural health monitoring and is used for various aerospace applications such as measuring strain and temperature, where a single optical fiber can multiplex hundreds of FBG sensors. The National Aeronautics and Space Administration (NASA) Armstrong Flight Research Center (AFRC) (Edwards, California) has been developing an optical fiber-based sensing suite called Fiber Optics Sensing System (FOSS) over the past two decades. Successful strain monitoring flight demonstrations such as the NASA Ikhana (General Atomics, San Diego, California) remotely piloted aircraft and the X-56A Multi-Utility Technology Testbed (Lockheed Martin Corporation, Bethesda, Maryland) remotely piloted subscale aircraft have been performed. Interest in adapting fiber-optic sensors for aerospace applications has led to commissioning the development of a ruggedized FOSS system for spaceflight through the NASA Launch Services Program (LSP) at the NASA Kennedy Space Center (KSC) (Merritt Island, Florida). In this paper, a ruggedized FOSS suitable for a launch environment is discussed in detail. Thermal analysis and enclosure design will be discussed as well as environmental testing such as shock, random vibration, thermal vacuum, and electromagnetic interference/electromagnetic compatibility (EMI/EMC). With all relevant environmental testing completed, a ruggedized FOSS unit has successfully passed all testing and is now deemed space-launch ready.

Allen R. Parker, Jr↗

NASA NTRSDate not supplied

Finite Element Based Model of Fiber-optic Strain Sensor Mounted on a Semi-monocoque Structure

Fiber-optic strain sensing (FOSS) provides an opportunity for additional awareness and can enable other mitigations such as flutter suppression or gust load alleviation but requires an accurate computational model as part of a design process that integrates structures and controls. A modeling approach for fiber-optic strain sensors has been developed using a shell element formulation in a detailed finite element model. The new FOSS modeling approach is designed to better scale to more complex realistic structures and fiber layouts than previous approaches. The modeling method was applied to the X-56A vehicle and results were compared to experimental static ground-test data. Additionally, the experimental sensor noise of these fiber optic sensors was assessed for the correlations in time and correlations along the fiber. The noise does show significant correlations both in time and along the fibers. These correlations of the noise should also be considered in modeling and assessing algorithms that will use FOSS.

Jeffrey Ouellette↗

NASA NTRSDate not supplied

Finite Element Based Model of Fiber-optic Strain Sensor Mounted on a Semi-monocoque Structure

Jeffrey Ouellette↗

DOE OSTI2013

Activated carbon fibers and engineered forms from renewable resources

A method of producing activated carbon fibers (ACFs) includes the steps of providing a natural carbonaceous precursor fiber material, blending the carbonaceous precursor material with a chemical activation agent to form chemical agent-impregnated precursor fibers, spinning the chemical agent-impregnated precursor material into fibers, and thermally treating the chemical agent-impregnated precursor fibers. The carbonaceous precursor material is both carbonized and activated to form ACFs in a single step. The method produces ACFs exclusive of a step to isolate an intermediate carbon fiber.

36 MATERIALS SCIENCE↗

DOE OSTI2014

System to continuously produce carbon fiber via microwave assisted plasma processing

A method for continuously processing carbon fiber including establishing a microwave plasma in a selected atmosphere contained in an elongated chamber having a microwave power gradient along its length defined by a lower microwave power at one end and a higher microwave power at the opposite end of the elongated chamber. The elongated chamber having an opening in each of the ends of the chamber that are adapted to allow the passage of the fiber tow while limiting incidental gas flow into or out of said chamber. A continuous fiber tow is introduced into the end of the chamber having the lower microwave power. The fiber tow is withdrawn from the opposite end of the chamber having the higher microwave power. The fiber to is subjected to progressively higher microwave energy as the fiber is being traversed through the elongated chamber.

42 ENGINEERING↗

DOE OSTI2014

Carbon nanotube fiber spun from wetted ribbon

A fiber of carbon nanotubes was prepared by a wet-spinning method involving drawing carbon nanotubes away from a substantially aligned, supported array of carbon nanotubes to form a ribbon, wetting the ribbon with a liquid, and spinning a fiber from the wetted ribbon. The liquid can be a polymer solution and after forming the fiber, the polymer can be cured. The resulting fiber has a higher tensile strength and higher conductivity compared to dry-spun fibers and to wet-spun fibers prepared by other methods.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2015

Methods for producing and using densified biomass products containing pretreated biomass fibers

A process is provided comprising subjecting a quantity of plant biomass fibers to a pretreatment to cause at least a portion of lignin contained within each fiber to move to an outer surface of said fiber, wherein a quantity of pretreated tacky plant biomass fibers is produced; and densifying the quantity of pretreated tacky plant biomass fibers to produce one or more densified biomass particulates, wherein said biomass fibers are densified without using added binder.

09 BIOMASS FUELS↗

DOE OSTI2016

System to continuously produce carbon fiber via microwave assisted plasma processing

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2018

Fiber tow treatment apparatus and system

In one embodiment, a fiber treatment system includes a rotatable nubbed roller including an axis of rotation, a surface, and a number of spaced apart nubs projecting away from the surface, the number of spaced apart nubs imparting a number of spaced apart openings in a fiber tow. In another embodiment, the fiber treatment system further includes an optionally rotatable spreader roller for flattening the fiber tow. In yet another embodiment, the loosened, but still continuous fiber tow is chopped by a downstream chopper to form short fibers with reduced tow sizes.

42 ENGINEERING↗

DOE OSTI2018

Sensor system that uses embedded optical fibers

Sensor systems including an interferometer system are disclosed herein. In a general embodiment, the sensor system includes an optical fiber that is embedded into a sample, where the optical fiber has a reflective tip. The optical fiber is optically coupled to a sensor and a detector of the laser interferometer system. The sensor system further includes a computing device or circuit that is configured to receive electrical signals generated by the detector. The laser source is configured to emit light, which is coupled into the optical fiber. The light travels through the optical fiber until the light reaches the reflective tip, where it is reflected back through the optical fiber. The detector is impacted by the reflected light, and generates an electrical signal based upon the reflected light. The computing device generates a value that is indicative of a behavior of the sample based upon the electrical signal.

Chavez, Marcus Alexander↗