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NASA NTRS2012

Friction Pull Plug Welding in Aluminum Alloys

NASA's Marshall Space Flight Center (MSFC) has recently invested much time and effort into the process development of Friction Pull Plug Welding (FPPW). FPPW, is a welding process similar to Friction Push Plug Welding in that, there is a small rotating part (plug) being spun and simultaneously pulled (forged) into a larger part. These two processes differ, in that push plug welding requires an internal reaction support, while pull plug welding reacts to the load externally. FPPW was originally conceived as a post proof repair technique for the Space Shuttle fs External Tank. FPPW was easily selected as the primary weld process used to close out the termination hole on the Constellation Program's ARES I Upper Stage circumferential Self-Reacting Friction Stir Welds (SR-FSW). The versatility of FPPW allows it to also be used as a repair technique for both SR-FSW and Conventional Friction Stir Welds. To date, all MSFC led development has been concentrated on aluminum alloys (2195, 2219, and 2014). Much work has been done to fully understand and characterize the process's limitations. A heavy emphasis has been spent on plug design, to match the various weldland thicknesses and alloy combinations. This presentation will summarize these development efforts including weld parameter development, process control, parameter sensitivity studies, plug repair techniques, material properties including tensile, fracture and failure analysis.

Brooke, Shane A.↗
NASA NTRS2011

Friction Pull Plug Welding in Aluminum Alloys

NASA fs Marshall Space Flight Center (MSFC) has recently invested much time and effort into the process development of Friction Pull Plug Welding (FPPW). FPPW, is a welding process similar to Friction Push Plug Welding in that, there is a small rotating part (plug) being spun and simultaneously pulled (forged) into a larger part. These two processes differ, in that push plug welding requires an internal reaction support, while pull plug welding reacts to the load externally. FPPW was originally conceived as a post proof repair technique for External Tank. FPPW was easily selected as the primary process used to close out the termination hole on the Constellation Program fs ARES I Upper Stage circumferential Self ] Reacting Friction Stir Welds (SR ]FSW). The versatility of FPPW allows it to also be used as a repair technique for both SR ]FSW and Conventional Friction Stir Welds. To date, all MSFC led development has been concentrated on aluminum alloys (2195, 2219, and 2014). Much work has been done to fully understand and characterize the process fs limitations. A heavy emphasis has been spent on plug design, to match the various weldland thicknesses and alloy combinations. This presentation will summarize these development efforts including weld parameter development, process control, parameter sensitivity studies, plug repair techniques, material properties including tensile, fracture and failure analysis.

Brooke, Shane A.↗
NASA NTRS2011

Performance Evaluation of Engineered Structured Sorbents for Atmosphere Revitalization Systems On Board Crewed Space Vehicles and Habitats

Engineered structured (ES) sorbents are being developed to meet the technical challenges of future crewed space exploration missions. ES sorbents offer the inherent performance and safety attributes of zeolite and other physical adsorbents but with greater structural integrity and process control to improve durability and efficiency over packed beds. ES sorbent techniques that are explored include thermally linked and pressure-swing adsorption beds for water-save dehumidification and sorbent-coated metal meshes for residual drying, trace contaminant control, and carbon dioxide control. Results from sub-scale performance evaluations of a thermally linked pressure-swing adsorbent bed and an integrated sub-scale ES sorbent system are discussed.

Howard, David F.↗
NASA NTRS2012

Closing the Seasonal Ocean Surface Temperature Balance in the Eastern Tropical Oceans from Remote Sensing and Model Reanalyses

The Eastern tropical ocean basins are regions of significant atmosphere-ocean interaction and are important to variability across subseasonal to decadal time scales. The numerous physical processes at play in these areas strain the abilities of coupled general circulation models to accurately reproduce observed upper ocean variability. Furthermore, limitations in the observing system of important terms in the surface temperature balance (e.g., turbulent and radiative heat fluxes, advection) introduce uncertainty into the analyses of processes controlling sea surface temperature variability. This study presents recent efforts to close the surface temperature balance through estimation of the terms in the mixed layer temperature budget using state-of-the-art remotely sensed and model-reanalysis derived products. A set of twelve net heat flux estimates constructed using combinations of radiative and turbulent heat flux products - including GEWEX-SRB, ISCCP-SRF, OAFlux, SeaFlux, among several others - are used with estimates of oceanic advection, entrainment, and mixed layer depth variability to investigate the seasonal variability of ocean surface temperatures. Particular emphasis is placed on how well the upper ocean temperature balance is, or is not, closed on these scales using the current generation of observational and model reanalysis products. That is, the magnitudes and spatial variability of residual imbalances are addressed. These residuals are placed into context within the current uncertainties of the surface net heat fluxes and the role of the mixed layer depth variability in scaling the impact of those uncertainties, particularly in the shallow mixed layers of the Eastern tropical ocean basins.

Roberts, J. Brent↗
NASA NTRS2012

Burning Questions in Gravity-Dependent Combustion Science

Building upon a long history of spaceflight and ground based research, NASA's Combustion Science program has accumulated a significant body of accomplishments on the ISS. Historically, NASAs low-gravity combustion research program has sought: to provide a more complete understanding of the fundamental controlling processes in combustion by identifying simpler one-dimensional systems to eliminate the complex interactions between the buoyant flow and the energy feedback to the reaction zone to provide realistic simulation of the fire risk in manned spacecraft and to enable practical simulation of the gravitational environment experienced by reacting systems in future spacecraft. Over the past two decades, low-gravity combustion research has focused primarily on increasing our understanding of fundamental combustion processes (e.g. droplet combustion, soot, flame spread, smoldering, and gas-jet flames). This research program was highly successful and was aided by synergistic programs in Europe and in Japan. Overall improvements were made in our ability to model droplet combustion in spray combustors (e.g. jet engines), predict flame spread, predict soot production, and detect and prevent spacecraft fires. These results provided a unique dataset that supports both an active research discipline and also spacecraft fire safety for current and future spacecraft. These experiments have been conducted using the Combustion Integrated Rack (CIR), the Microgravity Science Glovebox and the Express Rack. In this paper, we provide an overview of the earlier space shuttle experiments, the recent ISS combustion experiments in addition to the studies planned for the future. Experiments in combustion include topics such as droplet combustion, gaseous diffusion flames, solid fuels, premixed flame studies, fire safety, and super critical oxidation processes.

Urban, David↗
NASA NTRS2012

Automatic Facial Expression Recognition and Operator Functional State

The prevalence of human error in safety-critical occupations remains a major challenge to mission success despite increasing automation in control processes. Although various methods have been proposed to prevent incidences of human error, none of these have been developed to employ the detection and regulation of Operator Functional State (OFS), or the optimal condition of the operator while performing a task, in work environments due to drawbacks such as obtrusiveness and impracticality. A video-based system with the ability to infer an individual's emotional state from facial feature patterning mitigates some of the problems associated with other methods of detecting OFS, like obtrusiveness and impracticality in integration with the mission environment. This paper explores the utility of facial expression recognition as a technology for inferring OFS by first expounding on the intricacies of OFS and the scientific background behind emotion and its relationship with an individual's state. Then, descriptions of the feedback loop and the emotion protocols proposed for the facial recognition program are explained. A basic version of the facial expression recognition program uses Haar classifiers and OpenCV libraries to automatically locate key facial landmarks during a live video stream. Various methods of creating facial expression recognition software are reviewed to guide future extensions of the program. The paper concludes with an examination of the steps necessary in the research of emotion and recommendations for the creation of an automatic facial expression recognition program for use in real-time, safety-critical missions

Blanson, Nina↗
NASA NTRS2013

The Value of Workmanship Standards: What we Want, What we Ask For, What we Get

The Workmanship Standards serve to force positive outcomes rather than to depend only on finding and repairing defects. The Workmanship requirements address all avenues that can introduce defects or allow them to exist at the next level of integration: design, materials, processes, process control, screening.

Plante, Jeannette↗
NASA NTRS2012

Identification of Time-Varying Pilot Control Behavior in Multi-Axis Control Tasks

Recent developments in fly-by-wire control architectures for rotorcraft have introduced new interest in the identification of time-varying pilot control behavior in multi-axis control tasks. In this paper a maximum likelihood estimation method is used to estimate the parameters of a pilot model with time-dependent sigmoid functions to characterize time-varying human control behavior. An experiment was performed by 9 general aviation pilots who had to perform a simultaneous roll and pitch control task with time-varying aircraft dynamics. In 8 different conditions, the axis containing the time-varying dynamics and the growth factor of the dynamics were varied, allowing for an analysis of the performance of the estimation method when estimating time-dependent parameter functions. In addition, a detailed analysis of pilots adaptation to the time-varying aircraft dynamics in both the roll and pitch axes could be performed. Pilot control behavior in both axes was significantly affected by the time-varying aircraft dynamics in roll and pitch, and by the growth factor. The main effect was found in the axis that contained the time-varying dynamics. However, pilot control behavior also changed over time in the axis not containing the time-varying aircraft dynamics. This indicates that some cross coupling exists in the perception and control processes between the roll and pitch axes.

Zaal, Peter M. T.↗
NASA NTRS2013

Supersonic Retropulsion Surface Preparation of Carbon Fiber Reinforced Epoxy Composites for Adhesive Bonding

Surface preparation is widely recognized as a key step to producing robust and predictable bonds in a precise and reproducible manner. Standard surface preparation techniques, including grit blasting, manual abrasion, and peel ply, can lack precision and reproducibility, which can lead to variation in surface properties and subsequent bonding performance. The use of a laser to ablate composite surface resin can provide an efficient, precise, and reproducible means of preparing composite surfaces for adhesive bonding. Advantages include elimination of physical waste (i.e., grit media and sacrificial peel ply layers that ultimately require disposal), reduction in process variability due to increased precision (e.g. increased reproducibility), and automation of surface preparation, all of which improve reliability and process control. This paper describes a Nd:YAG laser surface preparation technique for composite substrates and the mechanical performance and failure modes of bonded laminates thus prepared. Additionally, bonded specimens were aged in a hot, wet environment for approximately one year and subsequently mechanically tested. The results of a one year hygrothermal aging study will be presented.

Palmieri, Frank L.↗
NASA NTRS2013

Combined Cycle Engine Large-Scale Inlet for Mode Transition Experiments: System Identification Rack Hardware Design

The System Identification (SysID) Rack is a real-time hardware-in-the-loop data acquisition (DAQ) and control instrument rack that was designed and built to support inlet testing in the NASA Glenn Research Center 10- by 10-Foot Supersonic Wind Tunnel. This instrument rack is used to support experiments on the Combined-Cycle Engine Large-Scale Inlet for Mode Transition Experiment (CCE‒ LIMX). The CCE‒LIMX is a testbed for an integrated dual flow-path inlet configuration with the two flow paths in an over-and-under arrangement such that the high-speed flow path is located below the lowspeed flow path. The CCE‒LIMX includes multiple actuators that are designed to redirect airflow from one flow path to the other; this action is referred to as "inlet mode transition." Multiple phases of experiments have been planned to support research that investigates inlet mode transition: inlet characterization (Phase-1) and system identification (Phase-2). The SysID Rack hardware design met the following requirements to support Phase-1 and Phase-2 experiments: safely and effectively move multiple actuators individually or synchronously; sample and save effector control and position sensor feedback signals; automate control of actuator positioning based on a mode transition schedule; sample and save pressure sensor signals; and perform DAQ and control processes operating at 2.5 KHz. This document describes the hardware components used to build the SysID Rack including their function, specifications, and system interface. Furthermore, provided in this document are a SysID Rack effectors signal list (signal flow); system identification experiment setup; illustrations indicating a typical SysID Rack experiment; and a SysID Rack performance overview for Phase-1 and Phase-2 experiments. The SysID Rack described in this document was a useful tool to meet the project objectives.

Thomas, Randy↗
NASA NTRS2013

Manufacture of Lunar Regolith Simulants

The manufacture of lunar regolith simulants can use many technologies unfamiliar to the aerospace industry. Many of these technologies are extensively used in the mining industry. Rock crushing, grinding, process control as a function of particle size, as well as other essential concepts are explained here. Notes are provided on special considerations necessary, given the unusual nature of the desired final product. For example, wet grinding, which is an industry norm, can alter the behavior of simulant materials. As the geologic materials used for simulants can contain minerals such as quartz and pyrite, guidance is provided regarding concepts, risks, measurement, and handling. Extractive metallurgy can be used to produce high-grade components for subsequent manufacture, reducing the compromises inherent in using just rock. Several of the components needed in simulants such as glasses, agglutinates, and breccias are simply not available or not reasonably matched by existing terrestrial resources. Therefore, techniques to produce these in useful quantities were developed and used. Included in this list is the synthesis of specific minerals. The manufacture of two simulants, NU-LHT-1M and NU-LHT-2M, is covered in detail.

D.L. Rickman↗
NASA NTRS2014

Analyzing Source Apportioned Methane in Northern California During DISCOVER-AQ-CA Using Airborne Measurements and Model Simulations

This study analyzes source apportioned methane (CH4) emissions and atmospheric concentrations in northern California during the Discover-AQ-CA field campaign using airborne measurement data and model simulations. Source apportioned CH4 emissions from the Emissions Database for Global Atmospheric Research (EDGAR) version 4.2 were applied in the 3-D chemical transport model GEOS-Chem and analyzed using airborne measurements taken as part of the Alpha Jet Atmospheric eXperiment over the San Francisco Bay Area (SFBA) and northern San Joaquin Valley (SJV). During the time period of the Discover-AQ-CA field campaign EDGAR inventory CH4 emissions were 5.30 Gg/day (Gg 1.0 109 grams) (equating to 1.9 103 Gg/yr) for all of California. According to EDGAR, the SFBA and northern SJV region contributes 30 of total emissions from California. Source apportionment analysis during this study shows that CH4 concentrations over this area of northern California are largely influenced by global emissions from wetlands and local/global emissions from gas and oil production and distribution, waste treatment processes, and livestock management. Model simulations, using EDGAR emissions, suggest that the model under-estimates CH4 concentrations in northern California (average normalized mean bias (NMB) -5 and linear regression slope 0.25). The largest negative biases in the model were calculated on days when hot spots of local emission sources were measured and atmospheric CH4 concentrations reached values 3.0 parts per million (model NMB -10). Sensitivity emission studies conducted during this research suggest that local emissions of CH4 from livestock management processes are likely the primary source of the negative model bias. These results indicate that a variety, and larger quantity, of measurement data needs to be obtained and additional research is necessary to better quantify source apportioned CH4 emissions in California and further the understanding of the physical processes controlling them.

Methane↗
NASA NTRS2014

The Lunar Atmosphere and Dust Environment Explorer (LADEE): Initial Science Results

On September 6, 2013, a nearperfect launch of the first Minotaur V rocket successfully carried NASA's Lunar Atmosphere and Dust Environment Explorer (LADEE) into a higheccentricity geocentric orbit. The launch, from NASA's Wallops Flight Facility in Virginia, was visible from much of the eastern seaboard. Over the next 30 days, LADEE performed three phasing orbits, with near-perfect maneuvers that placed apogee at ever higher altitudes in preparation for rendezvous with the Moon. LADEE arrived at the Moon on October 6, 2013, during the government shutdown. LADEE's science objectives are twofold: (1) Determine the composition of the lunar atmosphere, investigate processes controlling its distribution and variability, including sources, sinks, and surface interactions; (2) Characterize the lunar exospheric dust environment, measure its spatial and temporal variability, and effects on the lunar atmosphere, if any.

LADEE↗
NASA NTRS2014

Early Results from the Lunar Atmosphere and Dust Environment Explorer (LADEE)

On 6 September, 2013, a near-perfect launch of the first Minotaur V rocket successfully carried NASA's Lunar Atmosphere and Dust Environment Explorer (LADEE) into a high-eccentricity geocentric orbit. After 30 days of phasing, LADEE arrived at the Moon on 6 October, 2013. LADEE's science objectives are twofold: (1) Determine the composition of the lunar atmosphere, investigate processes controlling its distribution and variability, including sources, sinks, and surface interactions; (2) Characterize the lunar exospheric dust environment, measure its spatial and temporal variability, and effects on the lunar atmosphere, if any. After a successful commissioning phase, the three science instruments have made systematic observations of the lunar dust and exospheric environment. These include initial observations of argon, neon and helium exospheres, and their diurnal variations; the lunar micrometeoroid impact ejecta cloud and its variations; spatial and temporal variations of the sodium exosphere; and the search for sunlight extinction caused by dust. LADEE also made observations of the effects of the Chang'e 3 landing on 14 December 2013.

lunar exospheric environment↗
NASA NTRS2014

Additive Manufacturing: Ensuring Quality for Spacecraft Applications

Reliable manufacturing requires that material properties and fabrication processes be well defined in order to insure that the manufactured parts meet specified requirements. While this issue is now relatively straightforward for traditional processes such as subtractive manufacturing and injection molding, this capability is still evolving for AM products. Hence, one of the principal challenges within AM is in qualifying and verifying source material properties and process control. This issue is particularly critical for applications in harsh environments and demanding applications, such as spacecraft.

Additive Manufacturing↗
NASA NTRS2014

Nondestructive Evaluation Techniques for Development and Characterization of Carbon Nanotube Based Superstructures

Recently, multiple commercial vendors have developed capability for the production of large-scale quantities of high-quality carbon nanotube sheets and yarns. While the materials have found use in electrical shielding applications, development of structural systems composed of a high volume fraction of carbon nanotubes is still lacking. A recent NASA program seeks to address this by prototyping a structural nanotube composite with strength-toweight ratio exceeding current state-of-the-art carbon fiber composites. Commercially available carbon nanotube sheets, tapes, and yarns are being processed into high volume fraction carbon nanotube-polymer nanocomposites. Nondestructive evaluation techniques have been applied throughout this development effort for material characterization and process control. This paper will report on the progress of these efforts, including magnetic characterization of residual catalyst content, Raman scattering characterization of nanotube diameter, defect ratio, and nanotube strain, and polarized Raman scattering for characterization of nanotube alignment.

Wincheski, Buzz↗
NASA NTRS2014

Intercomparison of Large-Eddy Simulations of Arctic Mixed-Phase Clouds: Importance of Ice Size Distribution Assumptions

Large-eddy simulations of mixed-phase Arctic clouds by 11 different models are analyzed with the goal of improving understanding and model representation of processes controlling the evolution of these clouds. In a case based on observations from the Indirect and Semi-Direct Aerosol Campaign (ISDAC), it is found that ice number concentration, Ni, exerts significant influence on the cloud structure. Increasing Ni leads to a substantial reduction in liquid water path (LWP), in agreement with earlier studies. In contrast to previous intercomparison studies, all models here use the same ice particle properties (i.e., mass-size, mass-fall speed, and mass-capacitance relationships) and a common radiation parameterization. The constrained setup exposes the importance of ice particle size distributions (PSDs) in influencing cloud evolution. A clear separation in LWP and IWP predicted by models with bin and bulk microphysical treatments is documented and attributed primarily to the assumed shape of ice PSD used in bulk schemes. Compared to the bin schemes that explicitly predict the PSD, schemes assuming exponential ice PSD underestimate ice growth by vapor deposition and overestimate mass-weighted fall speed leading to an underprediction of IWP by a factor of two in the considered case. Sensitivity tests indicate LWP and IWP are much closer to the bin model simulations when a modified shape factor which is similar to that predicted by bin model simulation is used in bulk scheme. These results demonstrate the importance of representation of ice PSD in determining the partitioning of liquid and ice and the longevity of mixed-phase clouds.

clouds↗
NASA NTRS2015

Assessing Air-Sea Interaction in the Evolving NASA GEOS Model

In order to understand how the climate responds to variations in forcing, one necessary component is to understand the full distribution of variability of exchanges of heat and moisture between the atmosphere and ocean. Surface heat and moisture fluxes are critical to the generation and decay of many coupled air-sea phenomena. These mechanisms operate across a number of scales and contain contributions from interactions between the anomalous (i.e. non-mean), often extreme-valued, flux components. Satellite-derived estimates of the surface turbulent and radiative heat fluxes provide an opportunity to assess results from modeling systems. Evaluation of only time mean and variability statistics, however only provides limited traceability to processes controlling what are often regime-dependent errors. This work will present an approach to evaluate the representation of the turbulent fluxes at the air-sea interface in the current and evolving Goddard Earth Observing System (GEOS) model. A temperature and moisture vertical profile-based clustering technique is used to identify robust weather regimes, and subsequently intercompare the turbulent fluxes and near-surface parameters within these regimes in both satellite estimates and GEOS-driven data sets. Both model reanalysis (MERRA) and seasonal-to-interannual coupled GEOS model simulations will be evaluated. Particular emphasis is placed on understanding the distribution of the fluxes including extremes, and the representation of near-surface forcing variables directly related to their estimation. Results from these analyses will help identify the existence and source of regime-dependent biases in the GEOS model ocean surface turbulent fluxes. The use of the temperature and moisture profiles for weather-state clustering will be highlighted for its potential broad application to 3-D output typical of model simulations.

Clayson, Carol Anne↗