Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Disk failure”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

161 records · Page 9

Results of Lunar Impact Observations During Geminid Meteor Shower Events

Meteoroids are natural particles with origins from comets, asteroids, and planets from within the solar system. On average, 33 metric tons (73,000 lb) of meteoroids hit Earth everyday with velocities ranging between 20 and 72 km/s. However, the vast majority of these meteoroids disintegrate in the atmosphere and never make it to the ground. The Moon also encounters the same meteoroid flux, but has no atmosphere to stop them from striking the surface. At such speeds even a small meteoroid has incredible energy. A meteoroid with a mass of only 5 kg can excavate a crater over 9 m across, hurling 75 metric tons (165,000 lb) of lunar soil and rock on ballistic trajectories above the lunar surface. Meteoroids with particle sizes as small as 100 micrometer (1 Microgram) can do considerable damage to spacecraft in Earth's orbit and beyond. Impacts can damage thermal protection systems, radiators, windows, and pressurized containers. Secondary effects might include partial penetration or pitting, local deformation, and surface degradation that can cause a failure upon reentry. The speed, mass, density, and flux of meteoroids are important factors for design considerations and mitigation during operations. Lunar operations (unmanned and manned) are also adversely affected by the meteoroid flux. Ejecta from meteoroid impacts is also part of the lunar environment and must be characterized. Understanding meteoroid fluxes and the associated risk of meteoroids impacting spacecraft traveling in and beyond Earth's orbit is the objective of the Meteoroid Environment Office (MEO) located at Marshall Space Flight Center (MSFC). One of the MEO's programs is meteoroid impact monitoring of the Moon. The large collecting area of the night side of the lunar disk provides statistically significant counts of meteoroids that can provide useful information about the flux of meteoroids in the hundreds of grams to kilograms size range. This information is not only important for characterizing the lunar environment associated with larger lunar impactors, but also provides statistical data for verification and improving meteoroid prediction models. Current meteoroid models indicate that the Moon is struck by a sporadic meteoroid with a mass greater than 1 kg over 260 times per year. This number is very uncertain since observations for objects in this mass range are few. Factors of several times, higher or lower, are easily possible. Meteor showers are also present to varying degrees at certain times of the year. The Earth experiences meteor showers when encountering the debris left behind by comets, which is also the case with 2 the Moon. During such times, the rate of shower meteoroids can greatly exceed that of the sporadic background rate for larger meteoroids. Looking for meteor shower impacts on the Moon at about the same time as they occur on Earth will yield important data that can be fed into meteor shower forecasting models, which can then be used to predict times of greater meteoroid hazard on the Moon. The Geminids are one such meteor shower of interest. The Geminids are a major meteor shower that occur in December with a peak intensity occurring usually during the 13th and 14th of the month and appearing to come from a radiant in the constellation Gemini. The Geminids are interesting in that the parent body of the debris stream is an asteroid, which along with the Quadrantids, are the only major meteor showers not originating from a comet. The Geminids parent body, 3200 Phaethon, is about 5 km in diameter and has an orbit that has a 22deg inclination which intersects the main asteroid belt and has a perihelion less than half of Mercury's perihelion distance. Thus, its orbit crosses those of Mars, Earth, Venus, and Mercury. The Geminid debris stream is by far the most massive as compared to the others. When the Earth passes through the stream in mid-December, a peak intensity of approx. equal 120 meteors per hour can be seen. Because of the Geminids' relatively large intensity and unique origin, it is important to monitor and gain information about the Geminids so as to improve their forecasts and understand their contribution to the meteoroid environment in Earth's orbit and at the Moon. It is the purpose of this Technical Memorandum (TM) to document two lunar observing periods coinciding with the Geminid meteor showers that occurred in 2006 and 2010.

Suggs, R. J.↗

Active Blade Vibration Control Being Developed and Tested

Gas turbine engines are currently being designed to have increased performance, lower weight and manufacturing costs, and higher reliability. Consequently, turbomachinery components, such as turbine and compressor blades, have designs that are susceptible to new vibration problems and eventual in-service failure due to high-cycle fatigue. To address this problem, researchers at the NASA Glenn Research Center are developing and testing innovative active blade vibration control concepts. Preliminary results of using an active blade vibration control system, involving a rotor supported by an active magnetic bearing in Glenn's Dynamic Spin Rig, indicate promising results (see the photograph). Active blade vibration control was achieved using feedback of blade strain gauge signals within the magnetic bearing control loop. The vibration amplitude was reduced substantially (see the graphs). Also, vibration amplitude amplification was demonstrated; this could be used to enhance structural mode identification, if desired. These results were for a nonrotating two-bladed disk. Tests for rotating blades are planned. Current and future active blade vibration control research is planned to use a fully magnetically suspended rotor and smart materials. For the fully magnetically suspended rotor work, three magnetic bearings (two radial and one axial) will be used as actuators instead of one magnetic bearing. This will allow additional degrees of freedom to be used for control. For the smart materials work, control effectors located on and off the blade will be considered. Piezoelectric materials will be considered for on-the-blade actuation, and actuator placement on a stator vane, or other nearby structure, will be investigated for off-the-blade actuation. Initial work will focus on determining the feasibility of these methods by performing basic analysis and simple experiments involving feedback control.

Johnson, Dexter↗

Durability Assessment of Gamma Tial

Gamma TiAl was evaluated as a candidate alloy for low-pressure turbine blades in aeroengines. The durability of g-TiAl was studied by examining the effects of impact or fretting on its fatigue strength. Cast-to-size Ti-48Al-2Cr-2Nb was studied in impact testing with different size projectiles at various impact energies as the reference alloy and subsequently fatigue tested. Impacting degraded the residual fatigue life. However, under the ballistic impact conditions studied, it was concluded that the impacts expected in an aeroengine would not result in catastrophic damage, nor would the damage be severe enough to result in a fatigue failure under the anticipated design loads. In addition, other gamma alloys were investigated including another cast-to-size alloy, several cast and machined specimens, and a forged alloy. Within this Ti-48-2-2 family of alloys aluminum content was also varied. The cracking patterns as a result of impacting were documented and correlated with impact variables. The cracking type and severity was reasonably predicted using finite element models. Mean stress affects were also studied on impact-damaged fatigue samples. The fatigue strength was accurately predicted based on the flaw size using a threshold-based, fracture mechanics approach. To study the effects of wear due to potential applications in a blade-disk dovetail arrangement, the machined Ti-47-2-2 alloy was fretted against In-718 using pin-on-disk experiments. Wear mechanisms were documented and compared to those of Ti-6Al-4V. A few fatigue samples were also fretted and subsequently fatigue tested. It was found that under the conditions studied, the fretting was not severe enough to affect the fatigue strength of g-TiAl.

Draper, Susan L.↗

Slow Strain Rate Tensile Testing to Assess the Ability of Superalloys to Resist Environment-Assisted Intergranular Cracking

Intergranular fatigue crack initiation and growth due to environmental degradation, especially at notched features, can often limit the fatigue life of disk superalloys at high temperatures. For clear comparisons, the effects of alloy composition on cracking in air needs to be understood and compared separately from variables associated with notches and cracks such as effective stress concentration, plastic flow, stress relaxation, and stress redistribution. The objective of this study was to attempt using simple tensile tests of specimens with uniform gage sections to compare the effects of varied alloy composition on environment-assisted cracking of several powder metal and cast and wrought superalloys including ME3, LSHR, Udimet 720, ATI 718Plus alloy, Haynes 282, and Inconel 740. Slow and fast strain-rate tensile tests were found to be a useful tool to compare propensities for intergranular surface crack initiation and growth. The effects of composition and heat treatment on tensile fracture strain and associated failure modes were compared. Environment interactions were determined to often limit ductility, by promoting intergranular surface cracking. The response of various superalloys and heat treatments to slow strain rate tensile testing varied substantially, showing that composition and microstructure can significantly influence environmental resistance to cracking.

Heat resistant alloys↗

Ceramic Inclusions In Powder Metallurgy Disk Alloys: Characterization and Modeling

Powder metallurgy alloys are increasingly used in gas turbine engines, especially as the material chosen for turbine disks. Although powder metallurgy materials have many advantages over conventionally cast and wrought alloys (higher strength, higher temperature capability, etc.), they suffer from the rare occurrence of ceramic defects (inclusions) that arise from the powder atomization process. These inclusions can have potentially large detrimental effect on the durability of individual components. An inclusion in a high stress location can act as a site for premature crack initiation and thereby considerably reduce the fatigue life. Because these inclusions are exceedingly rare, they usually don't reveal themselves in the process of characterizing the material for a particular application (the cumulative volume of the test bars in a fatigue life characterization is typically on the order of a single actual component). Ceramic inclusions have, however, been found to be the root cause of a number of catastrophic engine failures. To investigate the effect of these inclusions in detail, we have undertaken a study where a known population of ceramic particles, whose composition and morphology are designed to mimic the 'natural' inclusions, are added to the precursor powder. Surface connected inclusions have been found to have a particularly large detrimental effect on fatigue life, therefore the volume of ceramic 'seeds' added is calculated to ensure that a minimum number will occur on the surface of the fatigue test bars. Because the ceramic inclusions are irregularly shaped and have a tendency to break up in the process of extrusion and forging, a method of calculating the probability of occurrence and expected intercepted surface and embedded cross-sectional areas were needed. We have developed a Monte Carlo simulation to determine the distributions of these parameters and have verified the simulated results with observations of ceramic inclusions found in macro slices from extrusions and forgings. The ultimate goal of this study will be to use probabilistic methods to determine the reliability detriment that can be attributed to these ceramic inclusions.

Bonacuse, Pete↗

An overview of elevated temperature damage mechanisms and fatigue behavior of a unidirectional SCS-6/Ti-15-3 composite

The fatigue behavior of a unidirectionally reinforced titanium matrix composite (TMC), SiC/Ti-15-3, was thoroughly characterized to support life prediction modeling of advanced TMC disks designed for gas turbine engine applications. The results of this coupon-level experimental investigation are reviewed. On a stress basis, the isothermal fatigue behavior of the (0 deg) TMC revealed significant improvements over the unreinforced matrix. In contrast, the (90 deg) TMC exhibited degraded properties and lives for similar comparisons. This was attributed to the weak fiber/matrix interfacial bond. Encasing the (0 deg) TMC with a Ti-15-3 case did not affect isothermal fatigue lives at higher strain levels. However, at lower strain levels, rapid initiation and propagation of large fatigue cracks in the case degraded the fatigue lives. Thermomechanical fatigue (TMF) lives were significantly reduced for the (0 deg) TMC when compared to isothermal lives. At high strains, in-phase TMF produced extremely short lives. This degradation was attributed to fiber overload failures brought about by stress relaxation in the matrix. At low strains, out-of-phase TMF conditions became life limiting. Environment-assisted surface cracking was found to accelerate fatigue failure. This produced extensive matrix damage with minimal fiber damage. For the (90 deg) TMC, TMF conditions did not promote an additional degradation in cyclic life beyond that observed under isothermal conditions.

Castelli, Michael G.↗

Ceramic Inclusions in Powder Metallurgy Disk Alloys: Characterization and Modeling

Powder metallurgy alloys are increasingly used in gas turbine engines, especially in turbine disk applications. Although powder metallurgy materials have many advantages over conventionally cast and wrought alloys (higher strength, higher temperature capability, etc.), they suffer from the rare occurrence of ceramic defects (inclusions) that are inherent to the powder atomization process. These inclusions can have a potentially large detrimental effect on the durability of individual components. An inclusion in a high stress location can act as a site for premature crack initiation and thereby considerably reduce the fatigue life. Because these inclusions are exceedingly rare, they typically do not reveal themselves in the process of characterizing the material for a particular application (the cumulative volume of the test bars in a fatigue life characterization is typically on the order of a single actual component). Ceramic inclusions have, however, been found to be the root cause of a number of catastrophic engine failures. To investigate the effect of these inclusions in detail, we have undertaken a study where known populations of ceramic particles, whose composition and morphology are designed to mimic the "natural" inclusions, are added to the precursor powder. Surface-connected inclusions have been found to have a particularly large detrimental effect on fatigue life; therefore, the quantity of ceramic "seeds" added is calculated to ensure that a minimum number will intersect the surface of the fatigue test bars. Because the ceramic inclusions are irregularly shaped and have a tendency to break up in the process of extrusion and forging, a method of calculating the probability of occurrence and expected intercepted surface area was needed. We have developed a Monte Carlo simulation to determine the distributions of these parameters and have verified the simulated results with observations of ceramic inclusions found in macroscopic slices from extrusions and forgings. Fatigue specimens have been machined from Udimet 720 (a powder metallurgy superalloy) forgings, to determine the effects of the inclusions on fatigue life. The ultimate goal of this study will be to use probabilistic methods to determine the reliability detriment that can be attributed to these ceramic inclusions. This work has been supported by the Ultra Safe and Ultra- Efficient Engine Technologies programs.

Bonacuse, Peter J.↗

Use of Slow Strain Rate Tensile Testing to Assess the Ability of Several Superalloys to Resist Environmentally-Assisted Intergranular Cracking

Intergranular fatigue crack initiation and growth due to environmental degradation, especially at notched features, can often limit the fatigue life of disk superalloys at high temperatures. For clear comparisons, the effects of alloy composition on cracking in air needs to be understood and compared separately from variables associated with notches and cracks such as effective stress concentration, plastic flow, stress relaxation, and stress redistribution. The objective of this study was to attempt using simple tensile tests of specimens with uniform gage sections to compare the effects of varied alloy composition on environment-assisted cracking of several powder metal and cast and wrought superalloys including ME3, LSHR, Udimet 720(TradeMark) ATI 718Plus(Registered TradeMark) alloy, Haynes 282(Trademark), and Inconel 740(TradeMark) Slow and fast strain-rate tensile tests were found to be a useful tool to compare propensities for intergranular surface crack initiation and growth. The effects of composition and heat treatment on tensile fracture strain and associated failure modes were compared. Environment interactions were determined to often limit ductility, by promoting intergranular surface cracking. The response of various superalloys and heat treatments to slow strain rate tensile testing varied substantially, showing that composition and microstructure can significantly influence environmental resistance to cracking.

fatigue(materials)↗

Low strain, long life creep fatigue of AF2-1DA and INCO 718

Two aircraft turbine disk alloys, GATORIZED AF2-DA and INCO 718 were evaluated for their low strain long life creep-fatigue behavior. Static (tensile and creep rupture) and cyclic properties of both alloys were characterized. The cntrolled strain LCF tests were conducted at 760 C (1400 F) and 649 C (1200 F) for AF2-1DA and INCO 718, respectively. Hold times were varied for tensile, compressive and tensile/compressive strain dwell (relaxation) tests. Stress (creep) hold behavior of AF2-1DA was also evaluated. Generally, INCO 718 exhibited more pronounced reduction in cyclic life due to hold than AF2-1DA. The percent reduction in life for both alloys for strain dwell tests was greater at low strain ranges (longer life regime). Changing hold time from 0 to 0.5, 2.0 and 15.0 min. resulted in corresponding reductions in life. The continuous cycle and cyclic/dwell initiation failure mechanism was predominantly transgranular for AF2-1DA and intergranular for INCO 718.

Thakker, A. B.↗

Mechanism of lubrication by tricresylphosphate (TCP)

The coefficient of friction was measured as a function of temperature on a pin-on-disk tribometer. Pins and disks of 440C and 52100 steels were lubricated with tricresylphosphate (TCP), 3.45 percent TCP in squalene, and pure squalene. The M-50 pins and disks were lubricated with 3.45 percent TCP in squalene and pure squalene. Experiments were conducted under limited lubrication conditions in dry ( 100 ppm H2O) air and dry ( pp H2O) nitrogen at 50 rpm (equivalent to a sliding velocity of 13 cm sec) and a constant load of 9.8 N (1 kg). Characteristic temperatures T sub r were identified for TCP on 52100 steel and for squalene on M-50 and 52100 steels, where the friction decreased because of a chemical reaction between the lubricant and the metal surface. The behavior of squalene obscured the influence of 3.45 percent TCP solute on the friction of the system. Wear volume measurements demonstrated that wear was lowest at temperatures just above T sub r. Comparing the behavior of TCP on M-50, 440C, and 52100 steels revealed that the TCP either reacted to give T sub r behavior or produced initial failure in the temperature range 223 + or - 5 C.

Faut, O. D.↗

High discharge rate characteristics of nickel-cadmium batteries for pulse load filtering

Several tests of specially fabricated nickel-cadmium batteries having circular disk type electrodes were considered. These batteries were evaluated as filter elements between a constant current power supply and a five hertz pulsed load demanding approximately twice the power supply current during the load on portion of the cycle. Short tests lasting 10,000 cycles were conducted at up to a 21 C rate and an equivalent energy density of over 40 Joules per pound. In addition, two batteries were subjected to 10 to the 7 charge/discharge cycles, one at a 6.5 C rate and the other at a 13 C rate. Assuming an electrode to battery weight ratio of 0.5, these tests represent an energy density of about 7 and 14 Joules per pound respectively. Energy density, efficiency, capacitance, average voltage, and available capacity were tracked during these tests. After 10 to the 7 cycles, capacity degradation was negligible for one battery and about 20% for the other. Cadmium electrode failure may be the factor limiting lifetime at extremely low depth of discharge cycling. The output was examined and a simple equivalent circuit was proposed.

Gearing, G. M.↗

RAINBOWS and CERAMBOWS: The Technologies of Pre-Stressed Piezo Actuators

Amplified mechanical displacement effects, similar to those observed in the recently reported Rainbow actuators, have also been found to exist in prestressed ceramic/metal composite structures coined as CERAMBOW's - an acronym for CERamic And Metal Biased Oxide Wafer. Mimicking the Rainbows in many ways, the intentionally created internal compressive and tensile stresses within the Cerambows are used to amplify their displacement properties via the combined effects of piezoelectric d31 strain and domain reorientation. They are fabricated from ferroelectric, piezoelectric or electrostrictive materials and metal substrates of significantly different thermal expansions which are largely responsible for the creation of the stress. Typical ceramics used in Cerambows are PZT, PLZT, PBZT, PSZT and PMN and some typical metal substrates are Al, Ag, Ni, brass, steel and Be/Cu foil. Shapes can vary from round disks to square plates and rectangular bars. Formed at an elevated temperature of approximately 250 C, the stresses on cooling to room temperature are generally sufficient to produce displacements as large as 0.125mm (5 mils) when activated unipolar and 0.25mm (10 mils) when operated bipolar at 450 volts in a dome mode. Comparing equal structures of a Cerambow with a Rainbow, the Cerambow was found to achieve approximately 70% of the displacement that would normally be obtained with a Rainbow. Although this difference in displacement is sufficient to prefer a Rainbow for many applications, there are some advantages for the Cerambow. Among these are (1) the processing temperatures are lower, (2) high lead-containing ceramics are not required and (3) in some instances the metal substrate is more convenient to interface with other elements of a device. However, the disadvantages include (1) lower displacement in the dome mode of operation, (2) the higher displacement saddle mode has not yet been demonstrated with a Cerambow and (3) the ceramic/metal bond interface is a possible failure area when operated for extended periods of time. The applications for Cerambows are considered to be similar to Rainbows, i.e., actuators, pumps, deflectors, vibrators, speakers, hydrophones, hydroprojectors, switches, etc.

Haertling, Gene H.↗

The nuclear regions of NGC 3311 and NGC 7768 imaged with the Hubble Space Telescope Planetary Camera

We present high-resolution, V band images of the central regions of the brightest cluster ellipticals NGC 3311 and NGC 7768 taken with the Planetary Camera of the Hubble Space Telescope. The nuclei of both galaxies are found to be obscured by dust, though the morphology of the dust is quite different in the two cases. The dust cloud which obscures the central 3 arcsec of NGC 3311 is complex and irregular, while the central region of NGC 7768 contains a disk of material similar in appearance and scale to that recently observed in HST images of NGC 4261. The bright, relatively blue source detected in ground-based studies of NGC 3311 is marginally resolved and is likely to be a site of ongoing star formation. We examine the distribution of globular clusters in the central regions of NGC 3311. The gradient in the surface density profile of the cluster system is significantly shallower than that found by previous investigators at larger radii. We find a core radius for the cluster distribution of 12 plus or minus 3 kpc, which is even larger than the core radius of the globular cluster system surrounding M87. It is also an order of magnitude larger than the upper limit on the core radius of NGC 3311's stellar light and suggests that the central field-star population and the globular cluster system are dynamically distinct. We briefly discuss possible sources for the cold/warm interstellar material in early-type galaxies. While the issue has not been resolved, models which involve galactic wind failure appear to be mo st naturally consistent with the observations.

Grillmair, Carl J.↗

U. radio emission from quiescent filaments

Full-disk Very Large Array (VLA) synthesis maps of the quiet Sun indicate that filaments can be seen in emission at 91.6 cm wavelength; they are detected in absorption at shorter microwave wavelengths. The 91.6 cm emission has a brightness temperature of T sub B = 3 x 10(exp 5) K. It is hotter, wider and longer than the underlying filament detected at H alpha wavelengths, but the similarity between the shape, position, elongation and orientation of the radio and optical features suggests their close association. The 91.6 cm emission is attributed to the thermal-bremsstrahlung of a hot transition sheath that envelopes the H alpha filament and acts as an interface between the cool, dense H alpha filament and the hotter, rarefied corona. The transition sheath is seen in emission because of the lower optical depth of the corona at 90 cm wavelength, and the width of this sheet is 10(exp 9) cm. A power law gradient in pressure provides a better match to the observations than a constant pressure model; definitive tests of theoretical models await simultaneous multi-wavelength studies of filaments at different observing angles. When the thermal bremsstrahlung is optically thin, the magnetic field strength in the transition sheath can be inferred from the observed circular polarization. Variable physical parameters of the sheath, such as width, electron density, and electron temperature, can explain controversial reports of the detection of, or the failure to detect, the meter-wavelength counterpart of H alpha filaments.

Lang, Kenneth R.↗

An Apparatus for Monitoring the Health of Electrical Cables

As with most elements of infrastructure, electrical wiring is innocuous; usually hidden away and unnoticed until it fails. Failure of infrastructure, however, sometimes leads to serious health and safety hazards. Electrical wiring fails when the polymeric (usually rubber) insulation material that sheathes the conductor gets embrittled with age from exposure to pressure, temperature or radiation cycling or when the insulation gets removed by the chafing of wires against each other. Miles of such wiring can be found in typical aircraft, with significant lengths of the wiring immersed in aviation fuel - a recipe for an explosion if a spark were to occur. Diagnosing the health of wiring is thus an important aspect of monitoring the health of aging aircraft. Stress wave propagation through wiring affords a quick and non-invasive method for health monitoring. The extent to which a stress wave propagating through the cable core gets attenuated depends on the condition of the surrounding insulation. When the insulation is in good condition - supple and pliable, there is more damping or attenuation of the waveform. As the insulation gets embrittled and cracked, the attenuation is likely to reduce and the waveform of the propagating stress wave is likely to change. The monitoring of these changes provides a potential tool to evaluate wiring or cabling in service that is not accessible for visual inspection. This experiment has been designed for use in an introductory mechanical or materials engineering instrumentation lab. Initial setup (after procuring all the materials) should take the lab instructor about 4 hours. A single measurement can be initiated and saved to disk in less than 3 minutes, allowing for all the students in a typical lab section to take their own data rather than share a single set of data for the entire class.

Pai, Devdas M.↗

Metallic Environmentally Resistant Coating Rapid Innovation Initiative

Lightweight alloys such as aluminum (Al) and titanium (Ti) are often specified for space systems to minimize mass while maintaining structural integrity [1,2]. Such alloys however, have poor tribological response (high friction and wear), especially in extreme space environments, which becomes worse with the additional presence of lunar regolith. This leads to short lifetimes and premature failures that will ultimately limit long term operations on the lunar surface [2]. This project is addressing this technology gap by developing advanced wear- and radiation-resistant coatings for lightweight parts to extend the life-time and sustainability of both lunar and Martian assets. Ceramics were considered for their high wear resistance, but were rejected because of their low fracture toughness, which would be especially problematic for structural components. The novel and existing coating technologies and deposition methods are being tested in this project. The coating materials are Boron Nitride-Aluminum (BN-Al), Nickle Titanium (NiTi), Aluminum Oxide (AlO3), Ti64 with hBN at 2 and 10 vol percent (Ti-2vol%hBN and Ti-10vol%hBN), and the deposition techniques are high pressure cold-spray (CS) and ambient and vacuum plasma-spray (APS and VPS) [3,4,5]. BN-Al, NiTi, Ti-2vol%hBN, and Ti-10vol%hBN were applied with all three deposition techniques, and AlO3 was applied only using the APS deposition technique. A tungstenite (WS2) film was applied to the NiTi VPS coating. The coating and deposition technique configurations are being tested against several key end-use performance parameters. The parameters include the capabilities of the coatings under wear environments such as regolith simulant, thermal cycling from high (120°C) to cryogenic (-173°C), high vacuum (~10-7 torr), and pre- and post-exposure to ionizing particle radiation. Wear tests include pin on disk, three-body abrasion, and surface erosion by high velocity regolith impacts. The initial down selection is being performed using on virgin and environmental exposure samples using pin on disk and three body abrasion wear tests. From preliminary assessment of this testing, a few configurations were eliminated. Ti-10vol%hBN could not be applied using CS application and NiTi could not be applied using APS or CS application so these configurations did not get tested. Early pin on disk wear tests showed poor wear performance of BN-Al so this coating was eliminated early in the testing process. AlO3 on Al substrate did not survive thermal cycling, but wear testing is continuing for AlO3 on Ti substrate. A more detailed analysis is being con-ducted to further reduce the number of configuration for phase II and III. Phase II testing will include conventionally and additively manufactured substrates with surface erosion testing. In phase III, the coatings will be applied to three mechanism types: channel and slot, ball and socket, and a hinge joint. Each will demonstrate a different type of wear incidence. The mechanisms and their base materials are of direct interest to the end users and infusion points: the Human Landing System (HLS) and the Lunar Surface Innovation Initiative (sustained lunar surface operations). The technology development project is based out of Marshall Space Flight Center, has partnered with Florida International University (Miami, FL) and Plasma Processes (Huntsville, Al), and is supported by a group of NASA mentors from different centers.

dust mitigation↗

Ares I-X Ground Diagnostic Prototype

Automating prelaunch diagnostics for launch vehicles offers three potential benefits. First, it potentially improves safety by detecting faults that might otherwise have been missed so that they can be corrected before launch. Second, it potentially reduces launch delays by more quickly diagnosing the cause of anomalies that occur during prelaunch processing. Reducing launch delays will be critical to the success of NASA's planned future missions that require in-orbit rendezvous. Third, it potentially reduces costs by reducing both launch delays and the number of people needed to monitor the prelaunch process. NASA is currently developing the Ares I launch vehicle to bring the Orion capsule and its crew of four astronauts to low-earth orbit on their way to the moon. Ares I-X will be the first unmanned test flight of Ares I. It is scheduled to launch on October 27, 2009. The Ares I-X Ground Diagnostic Prototype is a prototype ground diagnostic system that will provide anomaly detection, fault detection, fault isolation, and diagnostics for the Ares I-X first-stage thrust vector control (TVC) and for the associated ground hydraulics while it is in the Vehicle Assembly Building (VAB) at John F. Kennedy Space Center (KSC) and on the launch pad. It will serve as a prototype for a future operational ground diagnostic system for Ares I. The prototype combines three existing diagnostic tools. The first tool, TEAMS (Testability Engineering and Maintenance System), is a model-based tool that is commercially produced by Qualtech Systems, Inc. It uses a qualitative model of failure propagation to perform fault isolation and diagnostics. We adapted an existing TEAMS model of the TVC to use for diagnostics and developed a TEAMS model of the ground hydraulics. The second tool, Spacecraft Health Inference Engine (SHINE), is a rule-based expert system developed at the NASA Jet Propulsion Laboratory. We developed SHINE rules for fault detection and mode identification. The prototype uses the outputs of SHINE as inputs to TEAMS. The third tool, the Inductive Monitoring System (IMS), is an anomaly detection tool developed at NASA Ames Research Center and is currently used to monitor the International Space Station Control Moment Gyroscopes. IMS automatically "learns" a model of historical nominal data in the form of a set of clusters and signals an alarm when new data fails to match this model. IMS offers the potential to detect faults that have not been modeled. The three tools have been integrated and deployed to Hangar AE at KSC where they interface with live data from the Ares I-X vehicle and from the ground hydraulics. The outputs of the tools are displayed on a console in Hangar AE, one of the locations from which the Ares I-X launch will be monitored. The full paper will describe how the prototype performed before the launch. It will include an analysis of the prototype's accuracy, including false-positive rates, false-negative rates, and receiver operating characteristics (ROC) curves. It will also include a description of the prototype's computational requirements, including CPU usage, main memory usage, and disk usage. If the prototype detects any faults during the prelaunch period then the paper will include a description of those faults. Similarly, if the prototype has any false alarms then the paper will describe them and will attempt to explain their causes.

Schwabacher, Mark↗