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All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Specification, Design, and Analysis of Advanced HUMS Architectures

During the two-year project period, we have worked on several aspects of domain-specific architectures for HUMS. In particular, we looked at using scenario-based approach for the design and designed a language for describing such architectures. The language is now being used in all aspects of our HUMS design. In particular, we have made contributions in the following areas. 1) We have employed scenarios in the development of HUMS in three main areas. They are: (a) To improve reusability by using scenarios as a library indexing tool and as a domain analysis tool; (b) To improve maintainability by recording design rationales from two perspectives - problem domain and solution domain; (c) To evaluate the software architecture. 2) We have defined a new architectural language called HADL or HUMS Architectural Definition Language. It is a customized version of xArch/xADL. It is based on XML and, hence, is easily portable from domain to domain, application to application, and machine to machine. Specifications written in HADL can be easily read and parsed using the currently available XML parsers. Thus, there is no need to develop a plethora of software to support HADL. 3) We have developed an automated design process that involves two main techniques: (a) Selection of solutions from a large space of designs; (b) Synthesis of designs. However, the automation process is not an absolute Artificial Intelligence (AI) approach though it uses a knowledge-based system that epitomizes a specific HUMS domain. The process uses a database of solutions as an aid to solve the problems rather than creating a new design in the literal sense. Since searching is adopted as the main technique, the challenges involved are: (a) To minimize the effort in searching the database where a very large number of possibilities exist; (b) To develop representations that could conveniently allow us to depict design knowledge evolved over many years; (c) To capture the required information that aid the automation process.

Mukkamala, Ravi↗
NASA NTRS2006

Tool for Two Types of Friction Stir Welding

A tool that would be useable in both conventional and self-reacting friction stir welding (FSW) has been proposed. The tool would embody both a prior tooling concept for self-reacting FSW and an auto-adjustable pin-tool (APT) capability developed previously as an augmentation for conventional FSW. Some definitions of terms are prerequisite to a meaningful description of the proposed tool. In conventional FSW, depicted in Figure 1, one uses a tool that includes (1) a rotating shoulder on top (or front) of the workpiece and (2) a rotating pin that protrudes from the shoulder into the depth of the workpiece. The main axial force exerted by the tool on the workpiece is reacted through a ridged backing anvil under (behind) the workpiece. When conventional FSW is augmented with an APT capability, the depth of penetration of the pin into the workpiece is varied in real time by a position- or force-control system that extends or retracts the pin as needed to obtain the desired effect. In self-reacting (also known as self-reacted) friction stir welding (SR-FSW), there are two rotating shoulders: one on top (or front) and one on the bottom (or back) of the workpiece. In this case, a threaded shaft protrudes from the tip of the pin to beyond the back surface of the workpiece. The back shoulder is held axially in place against tension by a nut on the threaded shaft. The main axial force exerted on the workpiece by the tool and front shoulder is reacted through the back shoulder and the threaded shaft, back into the FSW machine head, so that a backing anvil is no longer needed. A key transmits torque between the bottom shoulder and the threaded shaft, so that the bottom shoulder rotates with the shaft. A tool for SRFSW embodying this concept was reported in "Mechanism for Self-Reacted Friction Stir Welding" (MFS-31914), NASA Tech Briefs, Vol. 28, No. 10 (October 2004), page 53. In its outward appearance, the proposed tool (see Figure 2) would fit the above description of an SR-FSW tool. In this case, the FSW machine would have an APT capability and the pin would be modified to accept a bottom shoulder. The APT capability could be used to vary the distance between the front and back shoulders in real time to accommodate process and workpiece-thickness variations. The tool could readily be converted to a conventional FSW tool, with or without APT capability, by simply replacing the modified pin with a conventional FSW pin.

Carter, Robert↗
NASA NTRS2013

High-Powered, Ultrasonically Assisted Thermal Stir Welding

This method is a solid-state weld process capable of joining metallic alloys without melting. The weld workpieces to be joined by thermal stir welding (TSW) are drawn, by heavy forces, between containment plates past the TSW stir tool that then causes joining of the weld workpiece. TSW is similar to friction stir welding (FSW) in that material is heated into a plastic state (not melted) and stirred using a stir rod. The FSW pin tool is an integrated geometrical structure consisting of a large-diameter shoulder, and a smaller-diameter stir pin protruding from the shoulder. When the pin is plunged into a weld workpiece, the shoulder spins on the surface of the weld workpiece, thus inducing frictional heat into the part. The pin stirs the fraying surfaces of the weld joint, thus joining the weld workpiece into one structure. The shoulder and stir pin of the FSW pin tool must rotate together at a desired rotational speed. The induced frictional energy control and stir pin control of the pin tool cannot be de-coupled. The two work as one integrated unit. TSW, on the other hand, de-couples the heating and stirring of FSW, and allows for independent control of each process element. A uniquely designed induction coil heats the weld workpiece to a desired temperature, and once heated, the part moves into a stir rod whose RPM is also independently controlled. As the weld workpiece moves into the stir rod, the piece is positioned, or sandwiched, between upper and lower containment plates. The plate squeezes together, thus compressing the upper and lower surfaces of the weld workpiece. This compressive force, also called consolidation force, consolidates the plastic material within the weld nugget material as it is being stirred by the stir rod. The stir rod is positioned through the center of the top containment plate and protrudes midway through the opposite lower containment plate where it is mechanically captured. The upper and lower containment plates are separated by a distance equal to the thickness of the material being welded. The TSW process can be significantly improved by reducing the draw forces. This can be achieved by reducing the friction forces between the weld workpieces and the containment plates. High-power ultrasonic (HPU) vibrations of the containment plates achieve friction reduction in the TSW process. Furthermore, integration of the HPU energy into the TSW stir rod can increase tool life of the stir rod, and can reduce shear forces to which the stir rod is subjected during the welding process. TSW has been used to successfully join 0.500-in (≈13-mm) thick commercially pure (CP) titanium, titanium 6AL- 4V, and titanium 6AL-4V ELI in weld joint lengths up to 9 ft (≈2.75-m) long. In addition, the TSW process was used to fabricate a sub-scale hexagonally shaped gun turret component for the U.S. Navy. The turret is comprised of six 0.5000-in (≈13-mm) thick angled welds. Each angled weld joint was prepared by machining the mating surfaces to 120deg. The angled weld joint was then fixtured using an upper and lower containment plate of the same geometry of the angled weld joint. The weld joint was then stirred by the stir rod as it and the upper and lower containment plates traverse through the angled joint prep.

Ding, Robert↗
NASA NTRS2015

Performance Improvement of Friction Stir Welds by Better Surface Finish

The as-welded friction stir weld has a cross section that may act as a stress concentrator. The geometry associated with the stress concentration may reduce the weld strength and it makes the weld challenging to inspect with ultrasound. In some cases, the geometry leads to false positive nondestructive evaluation (NDE) indications and, in many cases, it requires manual blending to facilitate the inspection. This study will measure the stress concentration effect and develop an improved phased array ultrasound testing (PAUT) technique for friction stir welding. Post-welding, the friction stir weld (FSW) tool would be fitted with an end mill that would machine the weld smooth, trimmed shaved. This would eliminate the need for manual weld preparation for ultrasonic inspections. Manual surface preparation is a hand operation that varies widely depending on the person preparing the welds. Shaving is a process that can be automated and tightly controlled.

Russell, Sam↗
NASA NTRS2017

Major Pathways to Electron Distribution Function Formation in Regions of Diffuse Aurora

This paper discusses the major pathways of electron distribution function formation in the region of diffuse aurora. The diffuse aurora accounts for about of 75% of the auroral energy precipitating into the upper atmosphere, and its origin has been the subject of much discussion. We show that an earthward stream of precipitating electrons initially injected from the Earth's plasma sheet via wave-particle interactions degrades in the atmosphere toward lower energies and produces secondary electrons via impact ionization of the neutral atmosphere. These electrons of magnetospheric origin are then reflected back into the magnetosphere along closed dipolar magnetic field lines, leading to a series of reflections and consequent magnetospheric interactions that greatly augment the initially precipitating flux at the upper ionospheric boundary (700-800 km). To date this, systematic magnetosphere-ionosphere coupling element has not been included in auroral research models, and, as we demonstrate in this article, has a dramatic effect (200-300%) on the formation of the precipitating fluxes that result in the diffuse aurora. It is shown that wave-particle interaction processes that drive precipitating fluxes in the region of diffuse aurora from the magnetospheric altitudes are only the first step in the formation of electron precipitation at ionospheric altitudes, and they cannot be separated from the atmospheric collisional machine that redistributes and transfers their energy inside the magnetosphere-ionosphere-atmosphere coupling system.

magnetospheric↗
NASA NTRS2000

Session on High Speed Civil Transport Design Capability Using MDO and High Performance Computing

Since the inception of CAS in 1992, NASA Langley has been conducting research into applying multidisciplinary optimization (MDO) and high performance computing toward reducing aircraft design cycle time. The focus of this research has been the development of a series of computational frameworks and associated applications that increased in capability, complexity, and performance over time. The culmination of this effort is an automated high-fidelity analysis capability for a high speed civil transport (HSCT) vehicle installed on a network of heterogeneous computers with a computational framework built using Common Object Request Broker Architecture (CORBA) and Java. The main focus of the research in the early years was the development of the Framework for Interdisciplinary Design Optimization (FIDO) and associated HSCT applications. While the FIDO effort was eventually halted, work continued on HSCT applications of ever increasing complexity. The current application, HSCT4.0, employs high fidelity CFD and FEM analysis codes. For each analysis cycle, the vehicle geometry and computational grids are updated using new values for design variables. Processes for aeroelastic trim, loads convergence, displacement transfer, stress and buckling, and performance have been developed. In all, a total of 70 processes are integrated in the analysis framework. Many of the key processes include automatic differentiation capabilities to provide sensitivity information that can be used in optimization. A software engineering process was developed to manage this large project. Defining the interactions among 70 processes turned out to be an enormous, but essential, task. A formal requirements document was prepared that defined data flow among processes and subprocesses. A design document was then developed that translated the requirements into actual software design. A validation program was defined and implemented to ensure that codes integrated into the framework produced the same results as their standalone counterparts. Finally, a Commercial Off the Shelf (COTS) configuration management system was used to organize the software development. A computational environment, CJOPT, based on the Common Object Request Broker Architecture, CORBA, and the Java programming language has been developed as a framework for multidisciplinary analysis and Optimization. The environment exploits the parallelisms inherent in the application and distributes the constituent disciplines on machines best suited to their needs. In CJOpt, a discipline code is "wrapped" as an object. An interface to the object identifies the functionality (services) provided by the discipline, defined in Interface Definition Language (IDL) and implemented using Java. The results of using the HSCT4.0 capability are described. A summary of lessons learned is also presented. The use of some of the processes, codes, and techniques by industry are highlighted. The application of the methodology developed in this research to other aircraft are described. Finally, we show how the experience gained is being applied to entirely new vehicles, such as the Reusable Space Transportation System. Additional information is contained in the original.

Rehder, Joe↗
NASA NTRS2012

Demonstration of Minimally Machined Honeycomb Silicon Carbide Mirrors

Honeycomb silicon carbide composite mirrors are made from a carbon fiber preform that is molded into a honeycomb shape using a rigid mold. The carbon fiber honeycomb is densified by using polymer infiltration pyrolysis, or through a reaction with liquid silicon. A chemical vapor deposit, or chemical vapor composite (CVC), process is used to deposit a polishable silicon or silicon carbide cladding on the honeycomb structure. Alternatively, the cladding may be replaced by a freestanding, replicated CVC SiC facesheet that is bonded to the honeycomb. The resulting carbon fiber-reinforced silicon carbide honeycomb structure is a ceramic matrix composite material with high stiffness and mechanical strength, high thermal conductivity, and low CTE (coefficient of thermal expansion). This innovation enables rapid, inexpensive manufacturing. The web thickness of the new material is less than 1 millimeter, and core geometries tailored. These parameters are based on precursor carbon-carbon honeycomb material made and patented by Ultracor. It is estimated at the time of this reporting that the HoneySiC(Trademark) will have a net production cost on the order of $38,000 per square meter. This includes an Ultracor raw material cost of about $97,000 per square meter, and a Trex silicon carbide deposition cost of $27,000 per square meter. Even at double this price, HoneySiC would beat NASA's goal of $100,000 per square meter. Cost savings are estimated to be 40 to 100 times that of current mirror technologies. The organic, rich prepreg material has a density of 56 kilograms per cubic meter. A charred carbon-carbon panel (volatile organics burnt off) has a density of 270 kilograms per cubic meter. Therefore, it is estimated that a HoneySiC panel would have a density of no more than 900 kilograms per cubic meter, which is about half that of beryllium and about onethird the density of bulk silicon carbide. It is also estimated that larger mirrors could be produced in a matter of weeks. Each cell is completely uniform, maintaining the shape of the inserted mandrel. Furthermore, the layup creates pressure that insures node bond strength. Each node is a composite laminate using only the inherent resin system to form the bond. This contrasts starkly with the other known method of producing composite honeycomb, in which individual corrugations are formed, cured, and then bonded together in a secondary process. By varying the size of the mandrels within the layup, varying degrees of density can be achieved. Typical sizes are 3/8 and 3/16 in. (approximately 10 and 5 millimeters). Cell sizes up to 1 in. (approximately 25 millimeters) have been manufactured. Similarly, the shape of the core can be altered for a flexible honeycomb structure.

Goodman, William↗
NASA NTRS2015

Toolsets for Airborne Data (TAD): Improving Machine Readability for ICARTT Data Files

The Atmospheric Science Data Center (ASDC) at NASA Langley Research Center is responsible for the ingest, archive, and distribution of NASA Earth Science data in the areas of radiation budget, clouds, aerosols, and tropospheric chemistry. The ASDC specializes in atmospheric data that is important to understanding the causes and processes of global climate change and the consequences of human activities on the climate. The ASDC currently supports more than 44 projects and has over 1,700 archived data sets, which increase daily. ASDC customers include scientists, researchers, federal, state, and local governments, academia, industry, and application users, the remote sensing community, and the general public.

Early, Amanda Benson↗
NASA NTRS2018

Enriching the Twitter Stream Increasing Data Mining Yield and Quality Using Machine Learning

Social media data streams are important sources of real-time and historical global information for science applications. At the NASA Goddard Earth Sciences Data and Information Services Center (GES DISC), we are exploring the Twitter data stream for its potential in augmenting the validation program of NASA Earth science missions, specifically the Global Precipitation Measurement (GPM) mission. We have implemented a tweet processing infrastructure that outputs classified precipitation tweets. Inputs are "passive" tweets, along with a smaller number of tweets from "active" participants, i.e., those knowingly contributing to our effort. The "active" tweets, presumably of higher quality, enrich the Twitter stream. "Active" sources include data scraped from other social media (e.g., public Facebook posts) and data from existing crowdsourcing programs (e.g., mPING reports). In addition, there is likely relevant precipitation information in images and documents that are the end points of links often included in tweets. Information derived from these "active" sources could then be tweeted into the Twitter stream, thus enriching its quality. The objective of our current work is to mine these tweet­ linked images and documents, using neural networks, to increase the information content and quality related to precipitation. For images, we classified them as either precipitation-related or not. For training and validation, we used images obtained via the Google custom search API. We created two models: (1) by training a simple Convolutional Neural Network and (2) by using transfer learning principles to adapt a pre-trained object recognition model. For documents, both those linked to tweets and the tweet contents, we trained Hierarchical Attention Networks to determine precipitation occurrence, type, and intensity. For training and validation, we used a keyword-filtered tweet data set labelled with ground truth data from Dark Sky (an API to retrieve weather-related labels) and the National Severe Storms Laboratory's Multi­ Radar/Multi-Sensor (MRMS) system. Our results demonstrated the efficacy of our machine learning approaches for enriching the Twitter stream, to derive information potentially useful for validation of earth science satellite data.

Albayrak, Arif↗
NASA NTRS1977

Prosthetic EMG control enhancement through the application of man-machine principles

An area in medicine that appears suitable to man-machine principles is rehabilitation research, particularly when the motor aspects of the body are involved. If one considers the limb, whether functional or not, as the machine, the brain as the controller and the neuromuscular system as the man-machine interface, the human body is reduced to a man-machine system that can benefit from the principles behind such systems. The area of rehabilitation that this paper deals with is that of an arm amputee and his prosthetic device. Reducing this area to its man-machine basics, the problem becomes one of attaining natural multiaxis prosthetic control using Electromyographic activity (EMG) as the means of communication between man and prothesis. In order to use EMG as the communication channel it must be amplified and processed to yield a high information signal suitable for control. The most common processing scheme employed is termed Mean Value Processing. This technique for extracting the useful EMG signal consists of a differential to single ended conversion to the surface activity followed by a rectification and smoothing.

Simcox, W. A.↗
NASA NTRS1982

On relationship between microfissuring and microstructure in the HAZ of Inconel 718

Inconel 718, as well as many other metals, is susceptible to intergranular hot cracking in the weld heat-affected-zone (HAZ). These cracks form near the solidus temperature of the metal during the welding process. This problem is of particular concern to NASA/MSFC because the SSME is primarily constructed of welded Inconel 718. The present program studied microfissuring in the weld HAZ of Inconel 718 by simulating HAZ thermal cycles with the Gleeble machine. Previous researchers have studied the instantaneous mechanical properties of the HAZ using the Gleeble. The present study examines the instantaneous microstructure of the HAZ. This approach showed that second phase structures, high in niobium, melt and wet the grain boundaries in the HAZ during welding. It is postulated that the resultant HAZ grain boundaries, enriched in niobium, act as preferred sites for microfissure nucleation as the weld zone cools.

Thompson, R. G.↗
NASA NTRS1983

Method and technique for installing light-weight, fragile, high-temperature fiber insulation

A method of installing fragile, light weight, high temperature fiber insulation, particularly where the insulation is to be used as a seal strip providing a high order of thermal barrier insulation is discussed. The process is based on provision of a strip of the mineral batting cut oversize by a predetermined amount, saturated in a fugitive polymer solution, compressed in a mold, dried and cured to form a rigidized batting material which is machined to required shape. The machine dimensions would normally be at least nominally less than the dimensions of the cavity to be sealed. After insertion in the cavity, which may be a wire-mesh seal enclosure, the apparatus is subjected to baking at a temperature sufficiently high to cause the resin to burn off cleanly, leaving the batting substantially in its original condition and expanded into the cavity or seal enclosure.

Patel, B. C.↗
NASA NTRS1985

User data management

The primary objective is to identify, develop, and demonstrate key data management technologies to support user access to Space Station data. To accomplish this objective, there are several technical challenges which must be addressed. The first is how to provide routine customer access to high volume, dynamic and distributed data bases. This access will encompass the functions of mission and payload planning and operations, data processing and analysis, and data archive and distribution. Secondly, there must be some analysis of architectures for handling high volume data streams like those expected from the Space Station. This analysis will examine the use of packetized versus non-packetized data formats, modular expansion capabilities, real-time versus non-real-time data processing, and the interfaces and architecture required to support telescience operations. The task will also determine benchmarks of performance capabilities for technology operations, such as varied data base structures, data access procedures, distributed data base design, and data base machines. Information is provided here in outline form.

Source record↗
NASA NTRS1992

Constraint monitoring in TOSCA

The Job-Shop Scheduling Problem (JSSP) deals with the allocation of resources over time to factory operations. Allocations are subject to various constraints (e.g., production precedence relationships, factory capacity constraints, and limits on the allowable number of machine setups) which must be satisfied for a schedule to be valid. The identification of constraint violations and the monitoring of constraint threats plays a vital role in schedule generation in terms of the following: (1) directing the scheduling process; and (2) informing scheduling decisions. This paper describes a general mechanism for identifying constraint violations and monitoring threats to the satisfaction of constraints throughout schedule generation.

Beck, Howard↗
NASA NTRS1990

A bit serial sequential circuit

Normally a sequential circuit with n state variables consists of n unique hardware realizations, one for each state variable. All variables are processed in parallel. This paper introduces a new sequential circuit architecture that allows the state variables to be realized in a serial manner using only one next state logic circuit. The action of processing the state variables in a serial manner has never been addressed before. This paper presents a general design procedure for circuit construction and initialization. Utilizing pass transistors to form the combinational next state forming logic in synchronous sequential machines, a bit serial state machine can be realized with a single NMOS pass transistor network connected to shift registers. The bit serial state machine occupies less area than other realizations which perform parallel operations. Moreover, the logical circuit of the bit serial state machine can be modified by simply changing the circuit input matrix to develop an adaptive state machine.

Hu, S.↗
NASA NTRS1995

TBC experience in land based gas turbines

Prior and on-going machine evaluations of TBC coatings for power generation applications are summarized. Rainbow testing of various TBC's on turbine nozzles, shrouds and buckets are described along with one test on combustor liners. GEPG has conducted over 15 machine tests with TBC coated turbine nozzles of various coatings. Rainbow test times generally range between 10,000 to 24,000 hours. TBC performance has been quite good and additional testing, including TBC's on shrouds and buckets is continuing. The results show that TBC's have the capability of surviving in power generation machines for the times required. The earlier rainbow tests which evaluated various top coat compositions resulted in confirmation of the superiority of YSZ and especially the 6-8 YSZ composition. On-going tests are more focused on TBC process and property variations. The prevalent failure modes seen thus far in the various rainbow tests are erosion, foreign object damage and buildup of deposits. Additional post test analysis is required to investigate bond coat oxidation and other time/temperature dependent changes to the system.

Nelson, W. A.↗
NASA NTRS1995

Solutions of the benchmark problems by the dispersion-relation-preserving scheme

The 7-point stencil Dispersion-Relation-Preserving scheme of Tam and Webb is used to solve all the six categories of the CAA benchmark problems. The purpose is to show that the scheme is capable of solving linear, as well as nonlinear aeroacoustics problems accurately. Nonlinearities, inevitably, lead to the generation of spurious short wave length numerical waves. Often, these spurious waves would overwhelm the entire numerical solution. In this work, the spurious waves are removed by the addition of artificial selective damping terms to the discretized equations. Category 3 problems are for testing radiation and outflow boundary conditions. In solving these problems, the radiation and outflow boundary conditions of Tam and Webb are used. These conditions are derived from the asymptotic solutions of the linearized Euler equations. Category 4 problems involved solid walls. Here, the wall boundary conditions for high-order schemes of Tam and Dong are employed. These conditions require the use of one ghost value per boundary point per physical boundary condition. In the second problem of this category, the governing equations, when written in cylindrical coordinates, are singular along the axis of the radial coordinate. The proper boundary conditions at the axis are derived by applying the limiting process of r approaches 0 to the governing equations. The Category 5 problem deals with the numerical noise issue. In the present approach, the time-independent mean flow solution is computed first. Once the residual drops to the machine noise level, the incident sound wave is turned on gradually. The solution is marched in time until a time-periodic state is reached. No exact solution is known for the Category 6 problem. Because of this, the problem is formulated in two totally different ways, first as a scattering problem then as a direct simulation problem. There is good agreement between the two numerical solutions. This offers confidence in the computed results. Both formulations are solved as initial value problems. As such, no Kutta condition is required at the trailing edge of the airfoil.

Tam, Christopher K. W.↗
NASA NTRS1997

Low Cost Manufacturing Approach of High Temperature PMC Components

The overall objective is to develop a satisfactory sheet molding compound (SMC) of a high temperature polyimide, such as PMR-11-50, VCAP-75, or NB2-76, and to develop compression molding processing parameters for a random, chopped fiber, high temperature, sheet molding compound that will be more affordable than the traditional hand lay-up fabrication methods. Compression molding will reduce manufacturing costs of composites by: (1) minimizing the conventional machining required after fabrication due to the use of full 360 deg matched tooling, (2) reducing fabrication time by minimizing the intensive hand lay-up operations associated with individual ply fabrication techniques, such as ply orientation and ply count and (3) possibly reducing component mold time by advanced B-staging prior to molding. This program is an integral part of Allison's T406/AE engine family's growth plan, which will utilize technologies developed under NASA's Sub-sonic Transport (AST) programs, UHPTET initiatives, and internally through Allison's IR&D projects. Allison is aggressively pursuing this next generation of engines, with both commercial and military applications, by reducing the overall weight of the engine through the incorporation of advanced, lightweight, high temperature materials, such as polymer matrix composites. This infusion of new materials into the engine is also a major factor in reducing engine cost because it permits the use of physically smaller structural components to achieve the same thrust levels as the generation that it replaced. A lighter, more efficient propulsion system translates to a substantial cost and weight savings to an airframe's structure.

Kannmacher, Kevin↗