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NASA NTRS1999

Friction Stir Welding of SiC/Aluminum Metal Matrix Composites

Friction Stir Welding (FSW) is a new solid state process for joining metals by plasticizing and consolidating materials around the bond line using thermal energy producing from frictional forces. A feasibility study for FSW of Metal Matrix Composites (MMC) was investigated using aluminum 6092 alloy reinforced with 17% SiC particulates. FSW process consists of a special rotating pin tool that is positioned to plunge into the MMC surface at the bond line. As the tool rotates and move forward along the bond line, the material at the bond line is heated up and forced to flow around the rotating tip to consolidate on the tip's backside to form a solid state joint. FSW has the potential for producing sound welds with MMC because the processing temperature occurs well below the melting point of the metal matrix; thereby eliminating the reinforcement-to-matrix solidification defects, reducing the undesirable chemical reactions and porosity problems.

Lee, Jonathan A.↗

NASA NTRS1999

STS-93 Flight Day 5 Highlights and Crew Activities

Columbia's crew began packing up experiments and preparing to return to Earth tomorrow with a touchdown planned for Kennedy Space Center at 10:20 p.m. CDT. Commander Eileen Collins and Pilot Jeff Ashby checked out the cockpit instruments, displays and flight control systems. They also test fired the 38 small steering jets. Everything was in good shape and ready for the trip back to Earth. Also, Collins and Ashby were joined by the rest of the crew for a press conference, fielding questions from reporters in Houston, Florida and Massachusetts.

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NASA NTRS1999

Tetragonal Lysozyme Interactions Studied by Site Directed Mutagenesis

A number of recent experimental and theoretical studies have indicated that tetragonal lysozyme crystal growth proceeds by the addition of aggregates, formed by reversible self association of the solute molecules in the bulk solution. Periodic bond chain and atomic force microscopy studies have indicated that the probable growth unit is at minimum a 43 tetramer, and most likely an octamer composed of two complete turns about the 43 axis. If these results are correct, then there are intermolecular interactions which are only formed in the solution and others only formed at the joining of the growth unit to the crystal surface. We have set out to study these interactions, and the correctness of this hypothesis, using site directed mutagenesis of specific amino acid residues involved in the different bonds. We had initially expressed wild type lysozyme in S. cervasiae with yields of approximately 5 mg/L, which were eventually raised to approximately 40 mg/L. We are now moving the expression to the Pichia system, with anticipated yields of 300 to (3)500 mg/L, comparable to what can be obtained from egg whites. An additional advantage of using recombinant protein is the greater genetic homogeneity of the material obtained and the absence of any other contaminating egg proteins. The first mutation experiments are TYR 23 (Registered) PHE or ALA and ASN 113 (Registered) ALA or ASP. Both TYR 23 and ASN 113 form part of the postulated dimerization intermolecular binding site which lead to the formation of the 43 helix. Tyrosine also participates in an intermolecular hydrogen bond with ARG 114. The results of these and subsequent experiments will be discussed.

Crawford, Lisa↗

NASA NTRS1999

NASA Aeronautics Multidisciplinary Analysis and Design Fellowship Program

This program began as a grant from NASA Headquarters, NGT-10025, which was in effect from 10/l/93 until 10/31/96. The remaining funding for this effort was transferred from NASA Headquarters to NASA Langley and a new grant NGT-1-52155 was issued covering the period II/l/96 to 5/15/99. This report serves as the final report of NGT-1-52155. For a number of years, Virginia Tech had been on the forefront of research in the area of multidisciplinary analysis and design. In June of 1994, faculty members from aerospace and ocean engineering, engineering science and mechanics, mechanical engineering, industrial engineering, mathematics and computer sciences, at Virginia Tech joined together to form the Multidisciplinary Analysis and Design (MAD) Center for Advanced Vehicles. The center was established with the single goal: to perform research that is relevant to the needs of the US industry and to foster collaboration between the university, government and industry. In October of 1994, the center was chosen by NASA headquarters as one of the five university centers to establish a fellowship program to develop a graduate program in multidisciplinary analysis and design. The fellowship program provides full stipend and tuition support for seven U. S. students per year during their graduate studies. The grant is currently being administered by the NMO Branch of NASA Langley. To advise us regarding the problems faced by the industry, an industrial advisory board has been formed consisting of representatives from industry as well as government laboratories. The present membership includes major aerospace companies: Aurora Flight Sciences, Boeing: Philadelphia, Boeing: Long Beach, Boeing: Seattle, Boeing: St. Louis, Cessna, Ford, General Electric, Hughes, Lockheed-Martin: Palo Alto, Northrop-Grumman, Sikorsky, smaller, aerospace software companies: Aerosoft, Phoenix Integration and Proteus Engineering, along with representatives from government agencies, including: NASA Ames, Langley and Lewis. The function of the advisory board is to channel information from its member companies to faculty members concerning problems that need research attention in the general area of multidisciplinary design optimization (MDO). The faculty and their graduate students make presentations to the board on their research. The board makes recommendations on the research and suggests new areas and problems which need attention. Many students participating in the program spend 3-6 months in industry working on their research projects. We are completing the fifth year of the fellowship program and have had four advisory board meetings in Blacksburg. Ten students have spent the three month periods in industry. In addition to the research element of the MAD Center efforts we also have an academic component. We have developed a menu of design-related graduate courses and two new courses: one in Aerospace Manufacturing and another in MDO. Some of the MAD Center activities are described on the world-wide web at http://www.aoe.vt.edu/mads.html The MAD Center represents an innovative approach for joint Industry-Government-University cooperation in the development of a comprehensive program in engineering education which addresses the design needs of industry. The following charts list detail of the grant: mission of the MAD center, faculty members, purpose of the advisory board, board members, summary of the graduate and undergraduate program, history of the fellowship program, mission of the fellowship program, requirements of MAD fellows, course requirements, students supported, advisory board participants, and MAD center research papers

Grossman, B.↗

NASA NTRS1997

Microstructure Characterization and Stress Corrosion Evaluation of Autogenous and Hybrid Friction Stir Welded Al-Cu-Li 2195 Alloy

Friction stir welding process is being evaluated for application on the Al-Cu-Li 2195 Super-Light Weight External Tank of the Space Transportation System. In the present investigation Al-Cu-Li 2195 plates were joined by autogenous friction stir welding (FSW) and hybrid FSW (friction stir welding over existing variable polarity plasma arc weld). Optical microscopy and transmission electron microscopy (TEM) were utilized to characterize microstructures of the weldments processed by both welding methods. TEM observations of autogenous FSW coupons in the center section of the dynamically-recrystallized zone showed an equiaxed recrystallized microstructure with an average grain size of approx. 3.8 microns. No T(sub 1), precipitates were present in the above-mentioned zone. Instead, T(sub B) and alpha precipitates were found in this zone with a lower population. Alternate immersion, anodic polarization, constant load, and slow strain tests were carried out to evaluate the general corrosion and stress-corrosion properties of autogenous and hybrid FSW prepared coupons. The experimental results will be discussed.

Li, Zhixian↗

NASA NTRS1999

Prediction and Measurement of X-Ray Spectral and Intensity Distributions from Low Energy Electron Impact Sources

In-vacuum electron beam welding is a technology that NASA considered as a joining technique for manufacture of space structures. The interaction of energetic electrons with metal produces x-rays. The radiation exposure to astronauts performing the in-vacuum electron beam welding must be characterized and minimized to insure safe operating conditions. This investigation characterized the x-ray environment due to operation of an in-vacuum electron beam welding tool. NASA, in a joint venture with the Russian Space Agency, was scheduled to perform a series of welding in space experiments on board the United States Space Shuttle. This series of experiments was named the International Space Welding Experiment (ISWE). The hardware associated with the ISWE was leased to NASA, by the Paton Welding Institute (PWI) in Ukraine, for ground based welding experiments in preparation for flight. Two tests were scheduled, using the ISWE electron beam welding tool, to characterize the radiation exposure to an astronaut during the operation of the ISWE. These radiation exposure tests consisted of Thermoluminescence Dosimeters (TLD's) shielded with material currently used by astronauts during Extra Vehicular Activities (EVA) and exposed to x-ray radiation generated by operation of an in-vacuum electron beam welding tool. This investigation was the first known application of TLD's to measure absorbed dose from x-rays of energy less than 10 KeV. The ISWE hardware was returned to Ukraine before the issue of adequate shielding for the astronauts was verified. Therefore, alternate experimental and analytical methods were developed to measure and predict the x-ray spectral and intensity distribution generated by electron impact with metal. These x-ray spectra were used to calculate the absorbed radiation dose to astronauts. These absorbed dose values were compared to TLD measurements obtained during actual operation of the in-vacuum electron beam welding tool. The calculated absorbed dose values were found to be in good agreement with the TLD values.

Edwards, David L.↗

NASA NTRS1998

Friction-Stir Welding of Large Scale Cryogenic Fuel Tanks for Aerospace Applications

The Marshall Space Flight Center has established a facility for the joining of large-scale aluminum-lithium alloy 2195 cryogenic fuel tanks using the friction-stir welding process. Longitudinal welds, approximately five meters in length, were made possible by retrofitting an existing vertical fusion weld system, designed to fabricate tank barrel sections ranging from two to ten meters in diameter. The structural design requirements of the tooling, clamping and the spindle travel system will be described in this paper. Process controls and real-time data acquisition will also be described, and were critical elements contributing to successful weld operation.

Jones, Clyde S., III↗

NASA NTRS1999

Critical Needs for Robust and Reliable Database for Design and Manufacturing of Ceramic Matrix Composites

Ceramic matrix composite (CMC) components are being designed, fabricated, and tested for a number of high temperature, high performance applications in aerospace and ground based systems. The critical need for and the role of reliable and robust databases for the design and manufacturing of ceramic matrix composites are presented. A number of issues related to engineering design, manufacturing technologies, joining, and attachment technologies, are also discussed. Examples of various ongoing activities in the area of composite databases. designing to codes and standards, and design for manufacturing are given.

Singh, M.↗

NASA NTRS1999

Design Optimization and Analysis of a Composite Honeycomb Intertank

Intertanks, the structure between tanks of launch vehicles, are prime candidates for weight reduction of rockets. This paper discusses the optimization and detailed follow up analysis and testing of a 96 in. diameter, 77 in. tall intertank. The structure has composite face sheets with an aluminum honeycomb core. The ends taper to a thick built up laminate for a double lap bolted splice joint interface. It is made in 8 full length panels joined with bonded double lap joints. The nominal load is 4000 lb/in. Optimization is by Genetic Algorithm and minimizes weight by varying core thickness, number and orientation of acreage and buildup plies, and the size, number and spacing of bolts. A variety of design cases were run with populations up to 2000 and chromosomes as long as 150 bits. Constraints were buckling; face stresses (normal, shear, wrinkling and dimpling); bolt stress; and bolt hole stresses (bearing, net tension, wedge splitting, shear out and tension/shear out). Analysis is by a combination of elasticity solutions and empirical data. After optimization, a series of coupon tests were performed in conjunction with a rigorous analysis involving a variety of finite element models. This analysis and testing resulted in several small changes to the optimized design. The equation used for hole bearing strength was found to be inadequate, resulting in thicker ends. The core thickness increased 0.05", and potting compound was added in the taper to strengthen the facesheet bond. The intertank has undergone a 250,000 lb limit load test and been mated with a composite liquid hydrogen tank. The tank/intertank unit is being installed in a test stand where it will see 200 thermal/load cycles. Afterwards the intertank will be demated and loaded in compression to failure.

Finckenor, Jeff↗

NASA NTRS1998

Friction Stir Welding of Large Scale Cryogenic Tanks for Aerospace Applications

The Marshall Space Flight Center (MSFC) has established a facility for the joining of large-scale aluminum cryogenic propellant tanks using the friction stir welding process. Longitudinal welds, approximately five meters in length, have been made by retrofitting an existing vertical fusion weld system, designed to fabricate tank barrel sections ranging from two to ten meters in diameter. The structural design requirements of the tooling, clamping and travel system will be described in this presentation along with process controls and real-time data acquisition developed for this application. The approach to retrofitting other large welding tools at MSFC with the friction stir welding process will also be discussed.

Russell, Carolyn↗

NASA NTRS1999

Education and Public Outreach for MSFC's Ground-Based Observations in Support of the HESSI Mission

A primary focus of NASA is the advancement of science and the communication of these advances to a number of audiences, both within the science research community and outside it. The upcoming High Energy Solar Spectroscopic Imager (HESSI) mission and the MSFC ground-based observing program, provide an excellent opportunity to communicate our knowledge of the Sun, its cycle of activity, the role of magnetic fields in that activity, and its effect on our planet. In addition to ground-based support of the HESSI mission, MSFC's Solar Observatory, located in North Alabama, will involve students and the local education community in its day-to-day operations, an experience which is more immediate, personal, and challenging than their everyday educational experience. Further, by taking advantage of the Internet, our program can reach beyond the immediate community. By joining with Fernbank Science Center in Atlanta, Georgia, we will leverage their almost 30 years'experience in science program delivery in diverse situations to a distance learning opportunity which can encompass the entire Southeast and beyond. This poster will outline our education and public outreach plans in support of the HESSI mission in which we will target middle and high school students and their teachers.

Adams, Mitzi L.↗

NASA NTRS1995

The Future of Geomagnetic Storm Predictions: Implications from Recent Solar and Interplanetary Observations

Within the last 7-8 years, there has been a substantial growth in out knowledge of the solar and interplanetary causes of geomagnetic storms at Earth. This review article will not attempt to cover all of the work done during this period. This can be found elsewhere. Our emphasis here will be on recent efforts that expose important, presently unanswered questions that must be addressed and solved before true predictability of storms can be possible. Hopefully, this article will encourage some readers to join this effort and perhaps make major contributions to the field.

Tsurutani, B. T.↗

NASA NTRS1999

The Ceres S'Cool Project: Operational but not Routine

The first Clouds and the Earth's Radiant Energy System (CERES) instrument has been returning useful data on Earth's radiation budget from the Tropical Rainfall Measuring Mission (TRMM) spacecraft since late 1997. Validation of the initial data is now intensively underway. As one component of this validation, the CERES Students' Cloud Observations On-Line (S'COOL) project has been operational since April 1998 - the 2nd CERES validation month. S'COOL involves school children in over 140 schools in 15 countries on 5 continents in making and reporting observations and measurements which they and CERES scientists can then compare to the satellite retrievals. The project is planned to continue through the life of the CERES Project (nominally 15 years), and new participants are invited to join on a continuous basis. This paper will report on the first year of the operational phase of the project, during which a number of exciting events occurred (a demonstration of the project to First Lady Hillary Rodham Clinton, and visits by CERES personnel to participating schools, among others). It will further report on some of the noteworthy observations and comparisons which have been made possible by this project. We have found that schools are often located in interesting places, in terms of the clouds found there and the satellite's ability to observe these clouds. The paper will also report on the learning opportunities delivered by this project, and on new questions about the planet and its climate which arise in the students' minds as a result of their active participation.

Chambers, Lin H.↗

NASA NTRS1999

Development of Lightweight Mirror Technology for the NGST Program

Recognizing the need to launch larger aperture telescopes to orbit with current launch capability, the NGST program began in 1997, an aggressive technology development effort in lightweight optics. This effort has developed technologies in silicon Carbide, Beryllium, silicon, glass and hybrid mirrors to name a few. The advancement of mirror technology to below the 15 kg/ni2 areal density is challenging enough without the added requirements for NGST that the mirror operate at approximately 35 Kelvin. This paper will discuss the various NGST technology developments including applications relative to bonding or joining mirror materials, subscale developments, the mirror system demonstrator program, the advance mirror demonstrator program and development of the mirror test program. Specific attention will be given to technical issues related to lightweight mirror development and processing. Other issues to be addressed are the development of the roadmap to the NGST flight mirror development and to assess the technology readiness for NGST.

Jacobson, David N.↗

NASA NTRS1997

Recruitment and Retention of Indians in Science and Engineering (RISE)

Fifteen students from Turtle Mountain Community College were selected to participate in activities of the RISE project last summer. Eight students successfully completed project activities and received stipends for their participation. These eight students are (1) Jamie Gable, (2) John Morin, (3) Patrick Belgarde, (4) Jason Laducer, (5) Alex Johnson, (6) Eric Houle, (7) Gary Renault, and (8) Kenny DeCoteau. In the fall of 1998, Jamie Gable and Gary Renault went to North Dakota State University to pursue their undergraduate degrees in mechanical engineering, and John Morin and Alex Johnson joined the University of North Dakota's electrical engineering and industrial technology programs, respectively. Remaining four students will continue to participate in the RISE activities this year and transfer to the universities next year. Seven students who failed to complete the RISE project activities during the current award period are encouraged to participate again this fall. The RISE students were enrolled in a special course called "Introduction to Engineering Materials." The project director, Dr. Kamawat, taught the course on Saturdays and Sundays. Theoretical and mathematical background on engineering materials and careers in various engineering professions were discussed in this course. The students attended guest lectures given by engineers and professors and visited local industries. In addition, the students went to North Dakota State University (NDSU) at Fargo, ND, and the University of Minnesota (UMN) at Minneapolis, MN, to tour their engineering departments. At NDSU, they conducted laboratory tests on various engineering materials, such as concrete, steel, wood, plastics, and carbon composites. The students investigated the mechanical behavior of these materials under various loading conditions, collected data, interpreted data, identified possible errors, determined the mechanical properties, and wrote reports on their findings. The students created posters describing their results on the behavior of engineering material. The posters were displayed in the TMCC's student lounge.

Karnawat, Sunil↗

NASA NTRS1999

STS-103 Crew Training

The Hubble Space Telescope (HST) team is preparing for NASA's third scheduled service call to Hubble. This mission, STS-103, will launch from Kennedy Space Center aboard the Space Shuttle Discovery. The seven flight crew members are Commander Curtis L. Brown, Pilot Scott J. Kelly, European Space Agency (ESA) astronaut Jean-Francois Clervoy who will join space walkers Steven L. Smith, C. Michael Foale, John M. Grunsfeld, and ESA astronaut Claude Nicollier. The objectives of the HST Third Servicing Mission (SM3A) are to replace the telescope's six gyroscopes, a Fine-Guidance Sensor, an S-Band Single Access Transmitter, a spare solid-state recorder and a high-voltage/temperature kit for protecting the batteries from overheating. In addition, the crew plans to install an advanced computer that is 20 times faster and has six times the memory of the current Hubble Space Telescope computer. To prepare for these extravehicular activities (EVAs), the SM3A astronauts participated in Crew Familiarization sessions with the actual SM3A flight hardware. During these sessions the crew spent long hours rehearsing their space walks in the Guidance Navigation Simulator and NBL (Neutral Buoyancy Laboratory). Using space gloves, flight Space Support Equipment (SSE), and Crew Aids and Tools (CATs), the astronauts trained with and verified flight orbital replacement unit (ORU) hardware. The crew worked with a number of trainers and simulators, such as the High Fidelity Mechanical Simulator, Guidance Navigation Simulator, System Engineering Simulator, the Aft Shroud Door Trainer, the Forward Shell/Light Shield Simulator, and the Support Systems Module Bay Doors Simulator. They also trained and verified the flight Orbital Replacement Unit Carrier (ORUC) and its ancillary hardware. Discovery's planned 10-day flight is scheduled to end with a night landing at Kennedy.

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NASA NTRS1999

Single Step to Orbit; a First Step in a Cooperative Space Exploration Initiative

At the end of the Cold War, disarmament planners included a recommendation to ease reduction of the U.S. and Russian aerospace industries by creating cooperative scientific pursuits. The idea was not new, having earlier been suggested by Eisenhower and Khrushchev to reduce the pressure of the "Military Industrial Complex" by undertaking joint space exploration. The Space Exploration Initiative (SEI) proposed at the end of the Cold War by President Bush and Premier Gorbachev was another attempt to ease the disarmament process by giving the bloated war industries something better to do. The engineering talent and the space rockets could be used for peaceful pursuits, notably for going back to the Moon and then on to Mars with human exploration and settlement. At the beginning of this process in 1992 staff of the Stanford Center for International Cooperation in Space attended the International Space University in Canada, met with Russian participants and invited a Russian team to work with us on a joint Stanford-Russian Mars Exploration Study. A CIA student and Airforce and Navy students just happened to join the Stanford course the next year and all students were aware that the leader of the four Russian engineers was well versed in Russian security. But, as long as they did their homework, they were welcome to participate with other students in defining the Mars mission and the three engineers they sent were excellent. At the end of this study we were invited to give a briefing to Dr. Edward Teller at Stanford's Hoover Institution of War and Peace. We were also encouraged to hold a press conference on Capitol Hill to introduce the study to the world. At a pre-conference briefing at the Space Council, we were asked to please remind the press that President Bush had asked for a cooperative exploration proposal not a U.S. alone initiative. The Stanford-Russian study used Russia's Energia launchers, priced at $300 Million each. The mission totaled out to $71.5 Billion, to send a six-person crew to establish a Mars base and return. It was an on going international venture with plans for new crews, base expansion, and extended exploration at every two year opportunity. The $71.5 Billion international approach contrasted with NASA's own 90-day U.S. - alone study that proposed a package topping $500 Billion by some admissions. NASA's approach was also challenged by an internal D.O.E. proposal at much lower cost, described to the Mars Society last year by Lowell Wood and, of course, by Bob Zubrin's "Mars Direct" proposal.

Lusignan, Bruce↗

NASA NTRS1999

STS-103 Crew at Breakfast, Suiting, Departing O&C

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