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High-temperature, flexible, fiber-preform seal includes axial core and helical windings, and abrasion-resistant sheath. Seals tailored to service in variety of environments. Used between movable and stationary panels in advanced aircraft engines or to seal gaps of high-temperature furnaces.
In fabrication of O-ring of new type, tube of 304 stainless steel bent around mandril into circle and welded closed into ring. Ring annealed in furnace to make it soft and highly ductile. In this condition, used as crushable, deformable O-ring seal. O-ring replacements used in variety of atmospheres and temperatures, relatively inexpensive, fabricated with minimum amount of work, amenable to one-of-a-kind production, reusable, and environmentally benign.
New process takes significantly less time than prior heat-treatment processes. Involves placing steel plate directly in furnace and heat-treating. Plate then quenched in slowly moving oil to reduce stresses. Any deflection then pressed out. Possible uses of 4340 steel include new and improved bulletproof vests for military and police personnel and armor for bulletproof automobiles for military, police, diplomatic, and private users. Also used in other military land vehicles as tanks and in both military and civilian aircraft. Lighter armorplate enables land vehicles and aircraft to attain greater speed and maneuverability, consume less fuel, and afford better protection from snipers or terrorists.
Abnormal combustion excites characteristic standing wave. Acoustical leak-detection system gives early warning of failure, enabling operating personnel to stop combustion process and repair spray bar before leak grows large enough to cause damage. Applicable to engines, gas turbines, furnaces, and other machines in which acoustic emissions at known frequencies signify onset of damage. Bearings in rotating machines monitored for emergence of characteristic frequencies shown in previous tests associated with incipient failure. Also possible to monitor for signs of trouble at multiple frequencies by feeding output of transducer simultaneously to multiple band-pass filters and associated circuitry, including separate trigger circuit set to appropriate level for each frequency.
Proposed brush seal helps prevent recirculating flow of hot combustion gases from reaching bellows seal located deep in gap in wall of combustion chamber. More durable, more tolerant of irregularities, and easier to install. Seals also helpful in impeding deleterious flows of hot gases in other combustion chambers such as those of furnaces and turbomachines.
The United States Microgravity Laboratory (USML-1) is one part of a science and technology program that will open NASA's next great era of discovery and establish the United States' leadership in space. A key component in the preparation for this new age of exploration, the USML-1 will fly in orbit for extended periods, providing greater opportunities for research in materials science, fluid dynamics, biotechnology, and combustion science. The major components of the USML-1 are the Crystal Growth Furnace, the Surface Tension Driven Convection Experiment (STDCE) Apparatus, and the Drop Physics Module. Other components of USML-1 include Astroculture, Generic Bioprocessing Apparatus, Extended Duration Orbiter Medical Project, Protein Crystal Growth, Space Acceleration Measurement System, Solid Surface Combustion Experiment, Zeolite Crystal Growth and Spacelab Glovebox provided by the European Space Agency.
The Robotics Branch of the Goddard Space Flight Center has under development a robot that fits inside a Get Away Special can. In the RObotic Materials Processing System (ROMPS) HitchHiker experiment, this robot is used to transport pallets containing wafers of different materials from their storage rack to a halogen lamp furnace for rapid thermal processing in a microgravity environment. It then returns them to their storage rack. A large part of the mechanical design of the robot dealt with the potential misalignment between the various components that are repeatedly mated and demated. A system of tapered guides and compliant springs was designed to work within the robot's force and accuracy capabilities. This paper discusses the above and other robot design issues in detail, and presents examples of ROMPS robot analyses that are applicable to other HitcherHiker materials handling missions.
Monotectic alloy materials are created by rapid melt/rapid solidification processing on the NASA KC-135. Separation of the uniform liquid into two liquids may occur by either of two processes; spinodal decomposition or nucleation followed by growth. In the first case, the liquid is unstable to composition waves, which form and grow, giving liquids of two different compositions. In the latter process discrete particles of the second liquid phase form via thermal fluctuations and then grow by diffusion. The two processes are very different, with the determining process being dictated by temperature, composition, and thermodynamic characteristics of the alloy. The first two quantities are process variables, while the third is determined by electronic interactions between the atoms in the alloy. In either case the initial alloy decomposition is followed by coarsening, resulting in growth of the particle size at nearly constant volume fraction. In particular, reduced gravity experiments on monotectic solutions have shown a number of interesting results in the KC-135. Monotectic solutions exhibit a miscibility gap in the liquid state, and consequently, gravity driven forces can dominate the solidification parameters at 1 g. In reduced gravity however, the distribution of the phases is different, resulting in new and interesting microstructures. The Rapid Melt/Rapid Quench Furnace allows one to melt a sample and resolidify it in one parabola of the KC-135's flight path, thus eliminating any accumulative influence of multiple parabolas to affect the microstructure of the material.
Thin film thermocouples have been developed for use on metal parts in jet engines to 1000 C. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose of this work is to develop thin film thermocouples for use on ceramic materials. The thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high-heating-rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hours or more up to temperatures of 1500 C depending on the stability of the particular ceramic substrate.
Prototype thin film heat flux sensors have been constructed and tested. The sensors can be applied to propulsion system materials and components. The sensors can provide steady state and fast transient heat flux information. Fabrication of the sensor does not require any matching of the mounting surface. Heat flux is proportional to the temperature difference across the upper and lower surfaces of an insulation material. The sensor consists of an array of thermocouples on the upper and lower surfaces of a thin insulating layer. The thermocouples for the sensor are connected in a thermopile arrangement. A 100 thermocouple pair heat flux sensor has been fabricated on silicon wafers. The sensor produced an output voltage of 200-400 microvolts when exposed to a hot air heat gun. A 20 element thermocouple pair heat flux sensor has been fabricated on aluminum oxide sheet. Thermocouples are Pt-Pt/Rh with silicon dioxide as the insulating material. This sensor produced an output of 28 microvolts when exposed to the radiation of a furnace operating at 1000 C. Work is also underway to put this type of heat flux sensor on metal surfaces.
Topics concerning the Robot-Operated Material Processing in Space (ROMPS) Program are presented in viewgraph form and include the following: a systems overview; servocontrol and servomechanisms; testbed and simulation results; system V controller; robot module; furnace module; SCL experiment supervisor; SCL script sample processing control; SCL experiment supervisor fault handling; block diagrams; hitchhiker interfaces; battery systems; watchdog timers; mechanical/thermal systems; and fault conditions and recovery.
The first set of hydrogen reduction experiments to use actual lunar material was recently completed. The sample, 70035, is a coarse-grained vesicular basalt containing 18.46 wt. percent FeO and 12.97 wt. percent TiO2. The mineralogy includes pyroxene, ilmenite, plagioclase, and minor olivine. The sample was crushed to a grain size of less than 500 microns. The crushed basalt was reduced with hydrogen in seven tests at temperatures of 900-1050 C and pressures of 1-10 atm for 30-60 minutes. A capacitance probe, measuring the dew point of the gas stream, was used to follow reaction progress. Experiments were also conducted using a terrestrial basalt similar to some lunar mare samples. Minnesota Lunar Simulant (MLS-1) contains 13.29 wt. percent FeO, 2.96 wt. percent Fe2O3, and 6.56 wt. percent TiO2. The major minerals include plagioclase, pyroxene, olivine, ilmenite, and magnetite. The rock was ground and seived, and experiments were run on the less than 74- and 500-1168-micron fractions. Experiments were also conducted on less than 74-micron powders of olivine, pyroxene, synthetic ilmenite, and TiO2. The terrestrial rock and mineral samples were reduced with flowing hydrogen at 1100 C in a microbalance furnace, with reaction progress monitored by weight loss. Experiments were run at atmospheric pressure for durations of 3-4 hr. Solid samples from both sets of experiments were analyzed by Mossbauer spectroscopy, petrographic microscopy, scanning electron microscopy, tunneling electron microscopy, and x-ray diffraction. Apollo 17 soil 78221 was examined for evidence of natural reduction in the lunar environment. This sample was chosen based on its high maturity level (I sub s/FeO = 93.0). The FeO content is 11.68 wt. percent and the TiO2 content is 3.84 wt. percent. A polished thin section of the 90-150 micron size fraction was analyzed by petrographic microscopy and scanning electron microscopy.
In line with the specified objectives, a Bridgman-type growth configuration in which unavoidable end effects - conventionally leading to growth interface relocation - are compensated by commensurate input-power changes is developed; the growth rate on a microscale is predictable and unaffected by changes in heat transfer conditions. To permit quantitative characterization of the growth furnace cavity (hot-zone), a 3-D thermal field mapping technique, based on the thermal image, is being tested for temperatures up to 1100 C. Computational NIR absorption analysis was modified to now permit characterization of semi-insulating single crystals. Work on growth and characterization of bismuth-silicate was initiated. Growth of BSO (B12SiO20) for seed material by the Czochralski technique is currently in progress. Undergraduate research currently in progress includes: ground based measurements of the wetting behavior (contact angles) of semiconductor melts on substrates consisting of potential confinement materials for solidification experiments in a reduced gravity environment. Hardware modifications required for execution of the wetting experiments in a KC-135 facility are developed.
The design elements of the Robot-Operated Material Processing in Space (ROMPS) system are described in outline and graphical form. The following subsystems/topics are addressed: servo system, testbed and simulation results, System V Controller, robot module, furnace module, SCL experiment supervisor and script sample processing control, battery system, watchdog timers, mechanical/thermal considerations, and fault conditions and recovery.
Under the terms of the NASA/CSA Memorandum of Understanding, Canada will contribute the Mobile Servicing System and be entitled to use 3 percent of all Space Station utilization resources and user accommodations over the 30 year life of the Station. Equally importantly Canada, like NASA, can begin to exploit these benefits as soon as the Man-Tended Capability (MTC) phase begins, in early 1997. Canada has been preparing its scientific community to fully utilize the Space Station for the past five years; most specifically by encouraging, and providing funding, in the area of Materials Science and Applications, and in the area of Space Life Sciences. The goal has been to develop potential applications and an experienced and proficient Canadian community able to effectively utilize microgravity environment facilities such as Space Station Freedom. In addition, CSA is currently supporting four facilities; a Laser Test System, a Large Motion Isolation Mount, a Canadian Float Zone Furnace, and a Canadian Protein Crystallization Apparatus. In late April of this year CSA sent out a Solicitation of Interest (SOI) to potential Canadian user from universities, industry, and government. The intent of the SOI was to determine who was interested, and the type of payloads which the community at large intended to propose. The SOI will be followed by the release of an Announcement of Opportunity (AO) following governmental approval of the Long Term Space plan later this year, or early next year. Responses to the AO will be evaluated and prioritized in a fair and impartial payload selection process, within the guidelines set by our international partners and the Canadian Government. Payload selection is relatively simple compared to the development and qualification process. An end-to-end user support program is therefore also being defined. Much of this support will be provided at the new headquarters currently being built in St. Hubert, Quebec. It is recognized that utilizing the Space Station could be expensive for users; costing in many cases millions of dollars to get a payload from conception to retrieval. It is also recognized that some of the potential users cannot or will not invest a lot of money or effort into Space Station utilization, unless there is a perceived significant commercial potential. How best to fund Space Station payloads is under study. Space Station Freedom will provide the first opportunity for Canada to conduct experiments in a long-duration microgravity environment. CSA have been developing and funding potential users for some time, and considerable interest has been shown by the response to our SOI earlier this year. Canada can be one of the two earliest users for the Space Station, along with NASA. We hope to take full advantage of this opportunity.
Thin film thermocouples were developed for use on metal parts in jet engines to 1000 C. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose is to develop thin film thermocouples for use on ceramic materials. The new thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials tested are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high heating rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hr or more up to temperatures of 1500 C depending on the stability of the particular ceramic substrate.
During the past year significant progress included: a major breakthrough in oxygen production through discs (instead of tubes) that resulted in two orders-of-magnitude increase in the yield rates, proving that oxygen production from any iron-bearing silicate (avoiding costly beneficiation) in lunar in-situ resource utilization (ISRU); construction of a half-scale robotic soil processor; production of melt-spun fibers in a solar furnace; and the culmination of first-stage research in the construction (and delivery to NASA LaRC) of a self-contained portable oxygen plant that incorporates the first generation ISRU technologies developed at UA SERC. In addition, further reductions in mass and power needs were achieved in two smaller oxygen plants, which, however, have far greater production rates. SERC continued to attract bright students both at the undergraduate and graduate levels, and several area high school students through the Professional Internship Program (PIP) administered by the local school district. Invited lectures at elementary schools continue to draw enthusiastic response. Another important first was the creation of the Freshman Colloquium, 'Space in Our Future, and Our Future in Space,' geared toward women and minority students. This course proved to be a success, with more than one-half of the enrollment composed of women. In recognition of these important contributions, the author was appointed to the NRC Committee on Space Science Technologies.
Experiments during the first year of the project were directed towards generating elemental fluorine via the electrolysis of anhydrous molten fluorides. Na2SiF6 was dissolved in either molten NaBF4 or a eutectic (minimum-melting) mixture of KF-LiF-NaF and electrolyzed between 450 and 600 C to Si metal at the cathode and F2 gas at the anode. Ar gas was continuously passed through the system and F2 was trapped in a KBr furnace. Various anode and cathode materials were investigated. Despite many experimental difficulties, the capability of the process to produce elemental fluorine was demonstrated.