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NASA NTRS2004

Gear Performance Improved by Coating

Gears, bearings, and other mechanical elements transmit loads through contacting surfaces. Even if properly designed, manufactured, installed, and maintained, gears and bearings will eventually fail because of the fatigue of the working surfaces. Economical means for extending the fatigue lives of gears and bearings are highly desired, and coatings offer the opportunity to engineer surfaces to extend the fatigue lives of mechanical components. A tungsten-containing diamondlike-carbon coating exhibiting high hardness, low friction, and good toughness was evaluated for application to spur gears. Fatigue testing was done at the NASA Glenn Research Center on both uncoated and coated spur gears. The results showed that the coating extended the surface fatigue lives of the gears by a factor of about 5 relative to the uncoated gears. For the experiments, a lot of spur test gears made from AISI 9310 gear steel were case-carburized and ground to aerospace specifications. The geometries of the 28-tooth, 8-pitch gears were verified as meeting American Gear Manufacturing Association (AGMA) quality class 12. One-half of the gears were randomly selected for coating. The method of coating was selected to achieve desired adherence, toughness, hardness, and low-friction characteristics. First the gears to be coated were prepared by blasting (vapor honing) with Al2O3 particles and cleaning. Then, the gears were provided with a thin adhesion layer of elemental chromium followed by magnetron sputtering of the outer coating consisting of carbon (70 at.%), hydrogen (15 at.%), tungsten (12 at.%), and nickel (3 at.%) (atomic percent at the surface). In total, the coating thickness was about 2.5 to 3 microns. As compared with the steel substrate, the coated surface was harder by a factor of about 2 and had a smaller elastic modulus. All gears were tested using a 5-centistoke synthetic oil, a 10,000-rpm rotation speed, and a hertzian contact stress of at least 1.7 GPa (250 ksi). Tests were run until either surface fatigue occurred or 300 million stress cycles were completed. Tests were run using either a pair of uncoated gears or a pair of coated gears (coated gears mated with uncoated gears were not evaluated). The fatigue test results, shown on Weibull coordinates in the graph, demonstrate that the coating provided substantially longer fatigue lives even though some of the coated gears endured larger stresses. The increase in fatigue life was a factor of about 5 and the statistical confidence for the improvement is high (greater than 99 percent). Examination of the tested gears revealed substantial reductions of total wear for coated gears in comparison to uncoated gears. The coated gear surface topography changed with running, with localized areas of the tooth surface becoming smoother with running. Theories explaining how coatings can extend gear fatigue lives are research topics for coating, tribology, and fatigue specialists. This work was done as a partnership between NASA, the U.S. Army Research Laboratory, United Technologies Research Corporation, and Sikorsky Aircraft.

Krantz, Timothy L.↗
NASA NTRS2005

The Supercritical Pile Model for GRBs

We present the spectral and tempora1 radiative signatures expected within the "Supercritical Pile" model of Gamma Ray Bursts (GRB). This model is motivated by the need for a process that provides the dissipation necessary in GRB and presents a well defined theme for converting the energy stored in the relativistic protons of the Relativistic Blast Waves (RBW) associated with GRB into radiation; at the same it leads to spectra which exhibit a peak in the burst vFv, distribution at an energy Ep l. MeV in the observer's frame, in agreement with observation and largely independent of the Lorentz factor P of the associated relativistic outflow. Furthermore, this scheme does not require (but does not preclude) acceleration of particles at the shock other than that provided by the isotropization of the flow kinetic energy on the RBW frame. In the present paper we model in detail the evolution of protons, electrons and photons from a RBW within the framework of this model to produce detailed spectra of the prompt GRB phase as a function of time from across a very broad range spanning roughly 4log10P decades in frequency. The model spectra are in general agreement with observations and provide a means for the delineating of the model parameters through direct comparison with trends observed in GRB properties.

Kazanas, Demos↗
NASA NTRS2006

The Supercritical Pile Model for GRBs

We present the spectral and temporal radiative signatures expected within the Supercritical Pile model of Gamma Ray Bursts (GRB). This model is motivated by the need for a process that provides the dissipation necessary in GRB and presents a well defined scheme for converting the energy stored in the relativistic protons of the Relativistic Blast Waves (RBW) associated with GRB into radiation; at the same time it leads to spectra which exhibit a peak in the burst nuF(sub nu) distribution at an energy E(sub p) approximately equal to 1 MeV in the observer s frame, in agreement with observation and largely independent of the Lorentz factor GAMMA of the associated relativistic outflow. Furthermore, this scheme does not require (but does not preclude) acceleration of particles at the shock other than that provided by the isotropization of the flow bulk kinetic energy on the RBW frame. In the present paper we model in detail the evolution of protons, electrons and photons from a RBW to produce detailed spectra of the prompt GRB phase as a function of time from across a very broad range spanning roughly 4 log10 GAMMA decades in frequency. The model spectra are in general agreement with observations and provide a means for the delineating of the model parameters through direct comparison with trends observed in GRB properties.

Kazanas, Demos↗
NASA NTRS2005

The Supercritical Pile Model for GRBs

We present the spectral and temporal radiative signatures expected within the "Supercritical Pile" model of Gamma Ray Bursts (GRB). This model is motivated by the need for a process that provides the dissipation necessary in GRB and presents a well defined scheme for converting the energy stored in the relativistic protons of the Relativistic Blast Waves (RBW) associated with GRB into radiation; at the same time it leads to spectra which exhibit a peak in the burst nuF(sub nu) distribution at an energy E(sub p) approx. equal to 1 MeV in the observer s frame, in agreement with observation and largely independent of the Lorentz factor r of the associated relativistic outflow. Futhermore, this scheme does not require (but does not preclude) acceleration of particles at the shock other than that provided by the isotropization of the flow bulk kinetic energy on the RBW frame. In the present paper we model in detail the evolution of protons, electrons and photons from a RBW to produce detailed spectra of the prompt GRB phase as a function of time from across a very broad range spanning roughly 4 log10Gamma decades in frequency. The model spectra are in general agreement with observations and provide a means for the delineating of the model parameters through direct comparison with trends observed in GRB properties.

Kazanas, D.↗
NASA NTRS2005

Keeping the Air Clean and Safe: An Anthrax Smoke Detector

Scientists at work in the Planetary Protection division at NASA s Jet Propulsion Laboratory (JPL) sterilize everything before blasting it to the Red Planet. They take great pains to ensure that all spacecraft are void of bacterial life, especially the microscopic bacteria that can live hundreds of years in their spore states. No one is quite sure what Earthly germs would do on Mars, but scientists agree that it is safest to keep the Martian terrain as undisturbed as possible. Errant Earth germs would also render useless the instruments placed on exploration rovers to look for signs of life, as the life that they registered would be life that came with them from Earth. A team at JPL, headed by Dr. Adrian Ponce, developed a bacterial spore-detection system that uses a simple and robust chemical reaction that visually alerts Planetary Protection crews. It is a simple air filter that traps micron-sized bacterial spores and then submits them to the chemical reaction. When the solution is then viewed under an ultraviolet light, the mixture will glow green if it is contaminated by bacteria. Scientists can then return to the scrubbing and cleaning stages of the sterilization process to remove these harmful bacteria. The detection system is the space-bound equivalent of having your hands checked for cleanliness before being allowed to the table; and although intended to keep terrestrial germs from space, this technology has awesome applications here on Mother Earth. The bacterial spore-detection unit can recognize anthrax and other harmful, spore-forming bacteria and alert people of the impending danger. As evidenced in the anthrax mailings of fall 2001 in the United States, the first sign of anthrax exposure was when people experienced flu-like symptoms, which unfortunately, can take as much as a week to develop after contamination. Anthrax cost 5 people their lives and infected 19 others; and the threat of bioterrorism became a routine concern, with new threats popping up nearly everyday. The attacks threatened the safety that so many Americans took for granted, as the very air that people breathed became suspect. Any building with a circulation system, where large groups congregate, was now a potential target.

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NASA NTRS2005

Techniques for Transition and Surface Temperature Measurements on Projectiles at Hypersonic Velocities- A Status Report

A research effort to advance techniques for determining transition location and measuring surface temperatures on graphite-tipped projectiles in hypersonic flight in a ballistic range is described. Projectiles were launched at muzzle velocities of approx. 4.7 km/sec into air at pressures of 190-570 Torr. Most launches had maximum pitch and yaw angles of 2.5-5 degrees at pressures of 380 Torr and above and 3-6 degrees at pressures of 190-380 Torr. Arcjet-ablated and machined, bead-blasted projectiles were launched; special cleaning techniques had to be developed for the latter class of projectiles. Improved methods of using helium to remove the radiating gas cap around the projectiles at the locations where ICCD (intensified charge coupled device) camera images were taken are described. Two ICCD cameras with a wavelength sensitivity range of 480-870 nm have been used in this program for several years to obtain images. In the last year, a third camera, with a wavelength sensitivity range of 1.5-5 microns [in the infrared (IR)], has been added. ICCD and IR camera images of hemisphere nose and 70 degree sphere-cone nose projectiles at velocities of 4.0-4.7 km/sec are presented. The ICCD images clearly show a region of steep temperature rise indicative of transition from laminar to turbulent flow. Preliminary temperature data for the graphite projectile noses are presented.

Wilder, M. C.↗
NASA NTRS2006

Dust-gas Interactions in Dusty X-ray Emitting Plasmas

Dusty shocked plasmas cool primarily by infrared emission from dust that is collisionally heated by the ambient hot gas. The infrared emission provides therefore an excellent diagnostic of the conditions (density and temperature) of the shocked gas. In this review I will discuss the physical processes in these plasmas, with a particular emphasis on recent infrared observations of the interaction between the blast wave of SN1987a and its equatorial ring.

Dwek, Eli↗
NASA NTRS2006

A Chandra ACIS Observation of the X-ray Luminous SN 1988Z

SN 1988Z is the most luminous X-ray-emitting supernova, initially detected in 1995 using the ROSAT HRI with the luminosity of approx. 8x10(exp 40) erg/s . Its high luminosity was ascribed to expansion of the blast wave into an especially dense circumstellar medium. In this paper, we describe a recent observation of SN 1988Z using the ACIS detector on CHANDRA. We readily detect SN 1988Z, obtaining approx. 30 net counts which corresponds to a 0.2-2.0 keV luminosity of approx. 3.2x10(exp 39) erg/s. The calculated quantiles for the extracted counts allow a broad range of temperatures, but require a temperature hotter than 5 keV if there is no intrinsic absorption. The X-ray luminosity indicates that the emitting region has a high density (>10(exp 5)/cu cm)and that the density profile is not consistent with a constant mass loss stellar wind during the approx. 5,000 years before the explosion. If the circumstellar medium is due to progenitor mass loss, then the mass loss rate is extremely high (approx.10(exp -3) Solar Mass/yr(V(sub omega)/10 km/s)). The X-ray results are compared with the predictions of models of SN 1988Z.

Schlegel, Eric M.↗
NASA NTRS2006

The Evolution of Dust in Extreme Astrophysical Environments

The recent discovery of QSOs located at redshift z greater than 6, with high infrared luminosities (typically 1.E13 solar luminosities), challenges our understanding of dust evolution. Indeed, these high infrared luminosities imply more than 1.E8 solar masses of dust and nearly solar gas-to-dust mass ratios. An interesting question is how do we make so much dust within approx. 400 Myr, which is roughly the age of the galaxy assuming it formed at z-10. During this epoch, AGB stars could not have enriched the ISM, so that all the dust must have formed by supernovae (SN). However, SN blast waves also play an important role in destroying the dust in the ISM. Understanding the formation and evolution of the dust in such objects requires therefore the construction of a detailed model for the chemical evolution of the gas and dust phases of the ISM. We focus on the well-studied quasar SDSS J1148+5251, at z=6.42. Using the IR luminosities as tracers of of the star formation rate (SFR) in these objects implies a rates of 3E3 Msun/yr, and SN rates of about 200/yr. However, this quasar contains an embedded AGN, so that the IR luminosity may not be a good tracer of the SFR in this object. Using the estimated mass of gas as a tracer of the SFR we construct a self-consistent model for the evolution of interstellar dust, which also follows the formation and destruction of the dust by SN. Finally, we discuss the contribution of the AGN to the total infrared luminosity, and its implications for the mass of the black hole that is required to power the observed IR emission.

Dwek, Eli↗
NASA NTRS2006

Clean Water for Remote Locations

Marshall Space Flight Center engineers are working on creating the Regenerative Environmental Control and Life Support System, a complex system of devices intended to sustain the astronauts living on the ISS and, in the future, sustain those who are blasting off to the Moon or Mars. The devices make use of the available resources, by turning wastewater from respiration, sweat, and urine into drinkable water. One of the devices that Marshall has been working on is the Water Recovery System (WRS). Marshall has teamed with long-time NASA contractor, Hamilton Sundstrand Space Systems International, Inc., of Windsor Locks, Connecticut. Hamilton Sundstrand, the original designer of the life support devices for the space suits, developed the Water Processor Assembly (WPA). It, along with the Urine Processor Assembly (UPA) developed by Marshall, combines to make up the total system, which is about the size of two refrigerators, and will support up to a six-member crew. The system is currently undergoing final testing and verification. "The Water Processor Assembly can produce up to about 28 gallons of potable recycled water each day," said Bob Bagdigian, Marshall Regenerative Environmental Control and Life Support System project manager. After the new systems are installed, annual delivered water to the ISS should decrease by approximately 15,960 pounds, or about 1,600 gallons.

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NASA NTRS2007

Adhesion of Lunar Dust

This paper reviews the physical characteristics of lunar dust and the effects of various fundamental forces acting on dust particles on surfaces in a lunar environment. There are transport forces and adhesion forces after contact. Mechanical forces (i.e., from rover wheels, astronaut boots and rocket engine blast) and static electric effects (from UV photo-ionization and/or tribo-electric charging) are likely to be the major contributors to the transport of dust particles. If fine regolith particles are deposited on a surface, then surface energy-related (e.g., van der Walls) adhesion forces and static-electric-image forces are likely to be the strongest contributors to adhesion. Some measurement techniques are offered to quantify the strength of adhesion forces. And finally some dust removal techniques are discussed.

Walton, Otis R.↗
NASA NTRS2007

Research Opportunities in Space Propulsion

Rocket propulsion determines the primary characteristics of any space vehicle; how fast and far it can go, its lifetime, and its capabilities. It is the primary factor in safety and reliability and the biggest cost driver. The extremes of heat and pressure produced by propulsion systems push the limits of materials used for manufacturing. Space travel is very unforgiving with little room for errors, and so many things can go wrong with these very complex systems. So we have to plan for failure and that makes it costly. But what is more exciting than the roar of a rocket blasting into space? By its nature the propulsion world is conservative. The stakes are so high at every launch, in terms of payload value or in human life, that to introduce new components to a working, qualified system is extremely difficult and costly. Every launch counts and no risks are tolerated, which leads to the space world's version of Catch-22:"You can't fly till you flown." The last big 'game changer' in propulsion was the use of liquid hydrogen as a fuel. No new breakthrough, low cost access to space system will be developed without new efficient propulsion systems. Because there is no large commercial market driving investment in propulsion, what propulsion research is done is sponsored by government funding agencies. A further difficulty in propulsion technology development is that there are so few new systems flying. There is little opportunity to evolve propulsion technologies and to update existing systems with results coming out of research as there is in, for example, the auto industry. The biggest hurdle to space exploration is getting off the ground. The launch phase will consume most of the energy required for any foreseeable space exploration mission. The fundamental physical energy requirements of escaping earth's gravity make it difficult. It takes 60,000 kJ to put a kilogram into an escape orbit. The vast majority (-97%) of the energy produced by a launch vehicle is used to get propellants off the ground to be burned later. A modem launch vehicle is usually able to put no more than 1.5%-3% of its total liftoff weight into low earth orbit.

Rodgers, Stephen L.↗
NASA NTRS2007

Application of Vacuum Swing Adsorption for Carbon Dioxide and Water Vapor Removal from Manned Spacecraft Atmospheres

In NASA's Vision for Space Exploration (Bush, 2004), (Griffin, 2007), humans will once again travel beyond the confines of earth's gravity, this time to remain there for extended periods. These forays will place unprecedented demands on launch systems. They must not only blast out of earth's gravity well as during the Apollo moon missions, but also liftoff the supplies needed to sustain a larger crew over much longer periods. Thus all spacecraft systems, including those for the separation of metabolic carbon dioxide and water from a crewed vehicle, must be minimized with respect to mass, power, and volume. Emphasis is also placed on system robustness both to minimize replacement parts and ensure crew safety when a quick return to earth is not possible. For short-term phases of manned space exploration, such as transit from the earth to the moon, venting of metabolic carbon dioxide and water to space is more efficient than the inclusion of large recycling systems on the spacecraft. The baseline system for the Orion spacecraft is an amine-based vacuum swing system (Smith, Perry et aI., 2006). As part of the development of an alternative approach, a sorbent-based CO2 and H2O removal system (Knox, Adams et aI., 2006), subscale testing was conducted to evaluate potential performance improvements obtainable by recuperating the heat of adsorption to aid in vacuum desorption. This bed design is shown in Figure 1, is depicted here with a lattice structure instead of reticulated foam for heat transfer. The slot widths are approximately 1.2 mm wide and 8.5 mm long. Bed depth is approximately 4.7 mm. Headers (not shown) were produced by the stereo lithography apparatus at MSFC.

Knox, J.↗
NASA NTRS2008

The Manufacturing Process for the NASA Composite Crew Module Demonstration Structure

This paper will describe the approaches and methods selected in fabrication of a carbon composite demonstration structure for the Composite Crew Module (CCM) Program. The program is managed by the NASA Safety and Engineering Center with participants from ten NASA Centers and AFRL. Multiple aerospace contractors are participating in the design development, tooling and fabrication effort as well. The goal of the program is to develop an agency wide design team for composite habitable spacecraft. The specific goals for this development project are: a).To gain hands on experience in design, building and testing a composite crew module. b) To validate key assumptions by resolving composite spacecraft design details through fabrication and testing of hardware. This abstract is based on Preliminary Design data..The final design will continue to evolve through the fall of 2007 with fabrication mostly completed by conference date. From a structures perspective, the.CCM can be viewed as a pressure module with variable pressure time histories and a series of both impact and quasi-static, high intensity point, line, and area distributed loads. The portion of the overall space vehicle being designed and. fabricated by the CCM team is just the pressure module and primary loading points. The heaviest point loads are applied and distributed to the pressure module at.an aluminum Service Module/Alternate Launch Abort System (SM/ALAS) fittings and at Main and Drogue Chute fittings. Significant line loads with metal to metal impact is applied at.the Lids ring. These major external point and line loads as well as pressure impact loads (blast and water landing) are applied to the lobed floor though the reentry shield and crushable materials. The pressure module is divided into upper and lower. shells that mate together with a bonded belly band splice joint to create the completed structural assembly. The benefits of a split CCM far outweigh the risks of a joint. These benefits include lower tooling cost and less manufacturing risk. Assembly of the top and bottom halves of the pressure shell will allow access to the interior of the shell throughout remaining fabrication sequence and can also potentially permit extensive installation of equipment and .crew facilities prior to final assembly of the two shell halves. A Pi pre-form is a woven carbon composite material which is provided in pre-impregnated form and frozen for long term storage. The cross-section shape allows the top of the pi to be bonded to a flat or curved surface with a second flat plate composite section bonded between two upstanding legs of the Pi. One of the regions relying on the merits of the Pi pre-form is the backbone. All connections among plates of the backbone structure, including the upper flanges, and to the lobe base of the pressure shell are currently joined by Pi pre-forms. The intersection of backbone composite plates is formed by application of two Pi pre-forms, top flanges and lobed surfaces are bonded with one Pi pre-form. The process of applying the pre-impregnated pi-preform will be demonstrated to include important steps like surface preparation, forming, application of pressure dams, vacuum bagging for consolidation, and curing techniques. Chopped carbon fiber tooling was selected over other traditional metallic and carbon fiber tooling. The requirement of schedule and cost economy for a moderate reuse cure tool warranted composite tooling options. Composite tooling schedule duration of 18 weeks compared favorably against other metallic tooling including invar tooling. Composite tooling also shows significant cost savings over low CTE metallic options. The composite tooling options were divided into two groups and the final decision was based on the cost, schedule, tolerance, temperature, and reuse requirements.

Pelham, Larry↗
NASA NTRS2008

High-Resolution N-Band Observations of the Nova Rs Ophiuchi: First Science with the Keck Interferometer Nuller

We report new observations of the nova RS Ophiuchi using the Keck Interferometer Nulling Instrument (KIN), approximately 3.8 days following the most recent outburst that occurred on 2006 February 12. These observations represent the first scientific results from the KIN, which operates in N-band from 8 to 12.5 microns. The nulling technique is the sparse aperture equivalent of the conventional coronagraphic technique used in filled aperture telescopes. By fitting the unique KIN inner and outer spatial regime data, we have obtained an angular size of the mid-infrared continuum of 6.2,4.0, or 5.4 mas for a disk profile, Gaussian profile, and shell profile respectively. The data show evidence of enhanced neutral atomic hydrogen emission and atomic metals including silicon located in the inner spatial regime near the white dwarf relative to the outer regime. There are also nebular emission lines and evidence of hot silicate dust in the outer spatial region, centered at approximately 2.5E14 cm from the WD, that are not found in the inner regime. The nova flash in the outer spatial regime evidently excited these features before the blast wave reached these regions. These identifications support the following interpretation. The dust appears to be present between outbursts and was not created during the outburst event. We further discuss the present results in terms of a unifying model of the system that includes an increase in density in the plane of the orbit of the two stars created by a spiral shock wave caused by the motion of the stars through the cool wind of the red giant star. These data show the power and potential of the nulling technique which has been developed for the detection of Earthlike planets around nearby stars for the Terrestrial Planet Finder Mission and Darwin missions.

Danchi, William↗
NASA NTRS2008

Measured Rattle Threshold of Residential House Windows

Window rattle is a common indoor noise effect in houses exposed to low frequency noise from such sources as railroads, blast noise and sonic boom. Human perception of rattle can be negative that is a motivating factor of the current research effort to study sonic boom induced window rattle. A rattle study has been conducted on residential houses containing windows of different construction at a variety of geographic locations within the United States. Windows in these houses were excited by a portable, high-powered loudspeaker and enclosure specifically designed to be mounted on the house exterior to cover an entire window. Window vibration was measured with accelerometers placed on different window components. Reference microphones were also placed inside the house and inside of the loudspeaker box. Swept sine excitation was used to identify the vibration threshold at which the response of the structure becomes non-linear and begins to rattle. Initial results from this study are presented and discussed. Future efforts will continue to explore the rattle occurrence in windows of residential houses exposed to sonic booms.

Sizov, Natalia↗