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Modified spot-welding gun includes pivoting twin-collet assembly that holds two spot-welding electrodes. Designed to weld highly conductive (30 percent gold) brazing-alloy foils to thin nickel alloy workpieces; also suitable for other spot-welding applications compatible with two-electrode configuration.
The helicopter industry is vigorously pursuing development of civil tiltrotors. One key to efficient high speed performance of this rotorcraft is prop-rotor performance. Of equal, if not greater, importance is assurance that the flight envelope is free of aeroelastic instabilities well beyond currently envisioned cuise speeds. This later condition requires study at helical tip Match numbers well in excess of 1.0. Two 1940's 'supersonic' propeller experiments conducted by NACA have provided an immensely valuable data bank with which to study prop-rotor behavior at transonic and supersonic helical tip Mach numbers. Very accurate 'blades alone' data were obtained by using nearly an infinite hub. Tabulated data were recreated from the many thrust and power figures and are included in two Appendices to this report. This data set is exceptionally well suited to re-evaluating classical blade element theories as well as evolving computational fluid dynamic (CFD) analyses. A limited comparison of one propeller's experimental results to a modem rotorcraft CFD code is made. This code, referred to as TURNS, gives very encouraging results. Detailed analysis of the performance data from both propellers is provided in Appendix A. This appendix quantifies the minimum power required to produce usable prop-rotor thrust. The dependence of minimum profile power on Reynolds number is quantified. First order compressibility power losses are quantified as well and a first approximation to design air-foil thickness ratio to avoid compressibility losses is provided. Appendix A's results are applied to study high speed civil tiltrotor cruise performance. Predicted tiltrotor performance is compared to two turboprop commercial transports. The comparison shows that there is no fundamental aerodynamic reason why the rotorcraft industry could not develop civil tiltrotor aircraft which have competitive cruise performance with today's regional, turboprop airlines. Recommendations for future study that will insure efficient prop-rotor performance to well beyond 400 knots are given.
This paper describes the development and characterization of two technology demonstrators that were produced under the auspices of an ARPA sponsored smart materials synthesis and processing effort. The ARPA Smart Materials and Synthesis (SMS) Program was a 2 year, $10M partnership led by Martin Marietta Laboratories - Baltimore and included Lockheed Missiles & Space Co., NRL, AVX Corp., Martin Marietta Astronautics Groups, BDM Federal, Inc., Virginia Tech, Clemson, University of Maryland, Denver University, and The Johns Hopkins University. In order to demonstrate the usefulness of magnetron sputtered shape memory foil and the manufacturability of reliable, reproducible electrostrictive actuators, the team designed a broadband active vibration cancellation device for suppressing the vibration load on delicate instruments and precision pointing devices mounted on orbiting satellites and spacecraft. The results of extensive device characterization and bench testing are discussed. Initial simulation results show excellent control authority and amplitude attenuation over the range of anticipated disturbance frequencies. The SMS Team has also developed an active 1-3 composite comprising micro-electrostrictive actuators embedded in a polymeric matrix suitable for underwater applications such as sonar quieting and listening arrays, and for medical imaging. Follow-on programs employing these technologies are also described.
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.
A reusable Thermal Protection System (TPS) that is not only lightweight, but durable, operable and cost effective is one of the technologies required by the Reusable Launch Vehicle (RLV) to achieve the goal of drastically reducing the cost of delivering payload to orbit. Metallic TPS is one of the systems being developed to meet this challenge. Current efforts involve improving the superalloy honeycomb TPS concept, which consists of a foil-gage metallic box encapsulating a low density fibrous insulation, and evaluating it for RLV requirements. The superalloy honeycomb TPS concept is mechanically attached to the vehicle structure. Improvements include more efficient internal insulation, a simpler, lighter weight configuration, and a quick-release fastener system for easier installation and removal. Evaluation includes thermal and structural analysis, fabrication and testing of both coupons and TPS panels under conditions simulating RLV environments. Coupons of metallic honeycomb sandwich, representative of the outer TPS surface, were subjected to low speed impact, hypervelocity impact, and rain erosion testing as well as subsequent arcjet exposure. Arrays of TPS panels have been subjected to radiant heating in a thermal/vacuum facility, aerodynamic heating in an arcjet facility and acoustic loading.
The aeroacoustics of flow-hydrofoil interactions exhibits distinct characteristics depending on the physical length scales involved. In the small-foil (relative to acoustic wavelength) limit characteristic of the noise generated by large-scale vortex shedding at low flow Mach number, the noise calculation is facilitated by the use of the Lighthill analogy in conjunction with a free-space Green's function, in the sense of Curle's formulation. A methodology for computing the vortex-shedding noise using the Curle formulation, including both surface-induced dipole sources and volume quadrupole sources, has been developed.
An experimental and computational investigation of the effect of lift-enhancing tabs on a two-element airfoil has been conducted. The objective of the study was to develop an understanding of the flow physics associated with lift-enhancing tabs on a multi-element airfoil. An NACA 63(2)-215 ModB airfoil with a 30% chord fowler flap was tested in the NASA Ames 7- by 10-Foot Wind Tunnel. Lift-enhancing tabs of various heights were tested on both the main element and the flap for a variety of flap riggings. A combination of tabs located at the main element and flap trailing edges increased the airfoil lift coefficient by 11% relative to the highest lift coefficient achieved by any baseline configuration at an angle of attack of 0 deg, and C(sub 1max) was increased by 3%. Computations of the flow over the two-element airfoil were performed using the two-dimensional incompressible Navier-Stokes code INS2D-UP. The computed results predicted all of the trends observed in the experimental data quite well. In addition, a simple analytic model based on potential flow was developed to provide a more detailed understanding of how lift-enhancing tabs work. The tabs were modeled by a point vortex at the air-foil or flap trailing edge. Sensitivity relationships were derived which provide a mathematical basis for explaining the effects of lift-enhancing tabs on a multi-element airfoil. Results of the modeling effort indicate that the dominant effects of the tabs on the pressure distribution of each element of the airfoil can be captured with a potential flow model for cases with no flow separation.
The Analytical Electron Microscope (AEM) equipped with a wavelength-dispersive spectrometer (WDS) should have the ability to resolve peaks which normally overlap in the spectra from an energy-dispersive spectrometer (EDS). With a WDS it should also be possible to measure lower concentrations of elements in thin foils due to the increased peak-to-background ratio compared with EDS. The WDS will measure X-ray from the light elements (4 less than Z less than 1O) more effectively. This paper addresses the possibility of interfacing a compact WDS with a focussing circle of approximately 4 cm to a modem AEM with a high-brightness (field emission) source of electrons.
The AXAF program has undergone major changes since the Announcement of Opportunity was extended by NASA Headquarters in 1983. The Science Instruments (SI's) for AXAF have also experienced several design changes since they were competitively selected in 1985. Moreover, two separate complementary missions are now being baselined for AXAF; one is designated AXAF-I for imaging and will include the high precision Wolter type I optics, and the other is called AXAF-S for spectroscopy. The resulting less-costly AXAF will still be superior to any previous x-ray observatories. Both missions continue to be managed. AXAF-I contains two focal plane SI's, the High Resolution Camera (HRC), and the AXAF Charge-Coupled Device (CCD) imaging spectrometer (ACIS), as well as the High-Energy Transmission Grating Spectrometer (HETGS) and the Low-Energy Transmission Grating Spectrometer (LETGS). Optics/Cryogenics Division (BECD). AXAF-S features only one focal plane SI, the X-Ray Spectrometer (XRS). The grazing incidence mirrors for this mission are mainly to provide a large collecting area and to concentrate these x-ray photons onto the XRS detector. Precise focusing, although preferred, is of secondary importance. Nested conical foil mirrors are currently baselined; however, replicated imaging optics are being evaluated for collecting efficiency and cost. AXAF-S is scheduled to be launched in late 1999. It has been designated as an MSFC in-house project. In addition to overall management, MSFC is fully responsible for the design, development, integration, and test of the complete AXAF-S observatory, including the XRS which will be furnished by the Goddard Space Flight Center (GSFC). Together, AXAF-I and AXAF-S constitute the third of NASA's series of Great Observatories, joining the Hubble space telescope (HST) and the Gamma-Ray Observatory (GRO) which are already operational. The develop- ment, launch, and operation of the Space InfraRed Telescope Facility (SIRTF) will follow later to complete the Great Observatory series. This paper summarizes the impact these changes have had on the SI's.
This report documents the progress achieved over the past 6 to 12 months on four graduate student projects conducted within the NASA-UVA Light Aerospace Alloy and Structures Technology Program. These studies were aimed specifically at light metallic alloy issues relevant to the High Speed Civil Transport. Research on Hydrogen-Enhanced Fracture of High-Strength Titanium Alloy Sheet refined successfully the high resolution R-curve method necessary to characterize initiation and growth fracture toughnesses. For solution treated and aged Low Cost Beta without hydrogen precharging, fracture is by ductile transgranular processes at 25 C, but standardized initiation toughnesses are somewhat low and crack extension is resolved at still lower K-levels. This fracture resistance is degraded substantially, by between 700 and 1000 wppm of dissolved hydrogen, and a fracture mode change is affected. The surface oxide on P-titanium alloys hinders hydrogen uptake and complicates the electrochemical introduction of low hydrogen concentrations that are critical to applications of these alloys. Ti-15-3 sheet was obtained for study during the next reporting period. Research on Mechanisms of deformation and Fracture in High-Strength Titanium Alloys is examining the microstructure and fatigue resistance of very thin sheet. Aging experiments on 0. 14 mm thick (0.0055 inch) foil show microstructural agility that may be used to enhance fatigue performance. Fatigue testing of Ti-15-3 sheet has begun. The effects of various thermo-mechanical processing regimens on mechanical properties will be examined and deformation modes identified. Research on the Effect of Texture and Precipitates on Mechanical Property Anisotropy of Al-Cu-Mg-X and Al-Cu alloys demonstrated that models predict a minor influence of stress-induced alignment of Phi, caused by the application of a tensile stress during aging, on the yield stress anisotropy of both modified AA2519 and a model Al-Cu binary alloy. This project is no longer included in the NASA-UVA LAST program. Research on the Creep Behavior and Microstructural stability of Al-Cu-Mg-Ag and Al-Cu-Li-Mg-Ag showed that the creep resistance of three candidate aluminum alloys (C415, C416 and ML377) was much superior compared to that of the current Concorde alloy, AA2618. Creep induced change in precipitates at grain boundaries was observed in the alloy which exhibits the highest creep strain of the three examined. The other two alloys developed no detectable microstructural changes at grain boundaries under the creep conditions tested.
As part of the International Space Station (ISS) Phase 1 program, NASA Lewis Research Center (LERC) and the Russian Space Agency (RSA) teamed together to design, build and flight test the world's first orbital Solar Dynamic Power System (SDPS) on the Russian space station Mir. The Solar Dynamic Flight Demonstration (SDFD) program was to operate a nominal 2 kWe SDPS on Mir for a period up to 1-year starting in late 1997. Unfortunately, the SDFD mission was demanifested from the ISS phase 1 shuttle program in early 1996. However, substantial flight hardware and prototypical flight hardware was built including a heat receiver and aperture shield. The aperture shield comprises the front face of the cylindrical cavity heat receiver and is located at the focal plane of the solar concentrator. It is constructed of a stainless steel plate with a 1-m outside diameter, a 0.24-m inside diameter and covered with high-temperature, refractory metal Multi-Foil Insulation (MFI). The aperture shield must minimize heat loss from the receiver cavity, provide a stiff, high strength structure to accommodate shuttle launch loads and protect receiver structures from highly concentrated solar fluxes during concentrator off-pointing events. To satisfy Mir operational safety protocols, the aperture shield was required to accommodate direct impingement of the intensely concentrated solar image for a 1-hour period. To verify thermal-structural durability under the anticipated high-flux, high-temperature loading, an aperture shield test article was constructed and underwent a series of two tests in a large thermal vacuum chamber configured with a reflective, point-focus solar concentrator and a solar simulator. The test article was positioned near the focal plane and exposed to concentrated solar flux for a period of 1-hour. In the first test, a near equilibrium temperature of 1862 K was attained in the center of the shield hot spot. In the second test, with increased incident flux, a near equilibrium temperature of 2072 K was achieved. The aperture shield sustained no visible damage as a result of the exposures. This paper describes the aperture shield thermal-vacuum qualification test program including the test article, test facility, procedures, data collection, test success criteria, results and conclusions.
One of the major problems in the series of ice runs was that the subsurface temperature probes did not function. AIC re-evaluated the design and, after testing several suitable sensors, installed 50 type T thermocouples, each 2 m long. In this design, each thermocouple was soldered to a rectangular copper foil spreader 0.3 com wide by 2.8 cm long to ensure an acute reading. The long rectangular shape was used because it had a large area for good thermal connection to the test material.
The method and apparatus includes a neural network for generating a model of an object in a wind tunnel from performance data on the object. The network is trained from test input signals (e.g., leading edge flap position, trailing edge flap position, angle of attack, and other geometric configurations, and power settings) and test output signals (e.g., lift, drag, pitching moment, or other performance features). In one embodiment, the neural network training method employs a modified Levenberg-Marquardt optimization technique. The model can be generated 'real time' as wind tunnel testing proceeds. Once trained, the model is used to estimate performance features associated with the aircraft given geometric configuration and/or power setting input. The invention can also be applied in other similar static flow modeling applications in aerodynamics, hydrodynamics, fluid dynamics, and other such disciplines. For example, the static testing of cars, sails, and foils, propellers, keels, rudders, turbines, fins, and the like, in a wind tunnel, water trough, or other flowing medium.
Mars is a challenging environment for the use of solar power. The implications of the low temperatures and low light intensity, solar spectrum modified by dust and changing with time of day and year, indirect sunlight, dust storms, deposited dust, wind, and corrosive peroxide-rich soil are discussed with respect to potential photovoltaic power systems. The power systems addressed include a solar-powered rover vehicle and a human base. High transportation costs dictate high efficiency solar cells or alternatively, a 'thin film' solar cell deposited on a lightweight plastic or thin metal foil.
We continue to analyze and interpret data from the MTOF sensor on SoHO, using recently obtained calibration data to improve our understanding of instrument response. We have presented a number of talks demonstrating the excellent instrument resolution and also displaying the temporal behavior of solar wind Fe(sup 54) and Fe(sup 56) isotopes and the element Cr(52). In addition, the isotopic ratios Ne(sup 20)/Ne (sup 22) = (13.8 +/- 0.7) and Ne(sup 20)/Ne(sup 21) = (440 +/- 110) were obtained from MTOF data. These ratios agree with the values obtained from the Apollo foil solar wind experiments and with values which have been derived from measurements on lunar and meteoritic samples.
In this work a preliminary study of the vacuum evaporation of silicon extracted from the lunar regolith has been undertaken. An electron gun vacuum evaporation system has been adapted for this purpose. Following the calibration of the system using ultra high purity silicon deposited on Al coated glass substrates, thin films of lunar Si were evaporated on a variety of crystalline substrates as well as on glass and lightweight 1 mil (25 microns) Al foil. Extremely smooth and featureless films with essentially semiconducting properties were obtained. Optical absorption analysis sets the bandgap (about 1.1 eV) and the refractive index (n=3.5) of the deposited thin films close to that of crystalline silicon. Secondary ion mass spectroscopy and energy dispersive spectroscopy analysis indicated that these films are essentially comparable to high purity silicon and that the evaporation process resulted in a substantial reduction of impurity levels. All layers exhibited a p-type conductivity suggesting the presence of a p-type dopant in the fabricated layers. While the purity of the 'lunar waste material' is below that of the 'microelectronic-grade silicon', the vacuum evaporated material properties seems to be adequate for the fabrication of average performance Si-based devices such as thin film solar cells. Taking into account solar cell thickness requirements (greater than 10 microns) and the small quantities of lunar material available for this study, solar cell fabrication was not possible. However, the high quality of the optical and electronic properties of evaporated thin films was found to be similar to those obtained using ultra-high purity silicon suggest that thin film solar cell production on the lunar surface with in situ resource utilization may be a viable approach for electric power generation on the moon.
This report describes an analytical and experimental investigation of AeroVironment's Quasi-Bipolar battery concept. The modelling/battery design part of the study demonstrates that there is a trade-off between thermal and specified electrical performance. Even so, quasi-bipolar batteries can be designed, with ten times better thermal uniformity, that meet or exceed current state-of-the-art hybrid-electric vehicle battery pack performance, even using the same active materials. The thermal uniformity, power, and energy for these quasi-bipolar battery packs is projected to be very good. The experimental part of the investigation demonstrates the concept of the quasi-bipolar plate applied to a lead foil current collector wrapping around two sides of an inexpensive plastic film core. Approximately 50 quasi-biplate samples were fabricated using a hot laminating press. Hot lamination with "texture" between the plastic and lead shows some promise as a low cost method for fabricating the plates. Five of these plates were assembled into two cells plus one two-cell battery. Data from these test cells were compared with existing data for similar true bipolar batteries. The positive side of the plates exhibited corrosion where not protected by the active material.
The Long Duration Exposure Facility (LDEF) materials were useful for testing technical concepts that needed to be validated for the Cosmic Dust Collector Facility (CDCF) - a large instrument that was under study for inclusion on the upcoming Space Station. As it turned out, CDCF, which was approved at one point as an external payload, was ultimately canceled due to the scaling back of the Space Station capabilities. However, the study of cosmic dust is still a field of great interest for NASA, being the crucial part of at least one experiment that is still being considered for a Discovery mission. The optimum analysis of hypervelocity impacts is thus a continuing NASA concern. Two experiments, AO187-1 and AO187-2 were explicitly designed to measure the flux and composition of dust particles impacting LDEF. The former consisted of flat targets of Au and Al while the second comprised a set of 237 "capture cells" using Ge target plates covered by thin (2.5 microns) metallized plastic foils. The spacecraft maintained a constant orientation with respect to its velocity vector thereby defining leading and trailing edges that faced respectively into and away from the direction of motion. Both AO187-1 and AO187-2 had detectors on both the leading and trailing edges of LDEF. It was expected that interplanetary dust particles would dominate impacts on the trailing edge while the leading edge would be exposed to both cosmic dust and particles of orbital manmade debris. In AO187-1, the compositions of the impactors was determined by SEM-EDS techniques; in AO187-2 a sensitive surface analysis technique - SIMS - was used to determine both elemental and (some) isotopic compositions. In the initial analysis of AO187-2, it was found that SIMS was more sensitive for the analysis of thin impact debris layers than SEM-EDS. The present grant was made to determine if SIMS analysis could also be applied to impacts recorded in the Au surfaces of AO187-1. Success would extend the analysis of AO187-1 and would also contribute important technical information for the design of future cosmic dust space missions. The results obtained with this grant are incorporated in the attached paper presented at the Third LDEF Symposium and are briefly summarized here. In addition, we comment on the potential implications of this work for future research.