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All sourcesNASA NTRSDOE OSTI
NASA NTRS2008

The Manufacturing Process for the NASA Composite Crew Module Demonstration Structure

This paper will describe the approaches and methods selected in fabrication of a carbon composite demonstration structure for the Composite Crew Module (CCM) Program. The program is managed by the NASA Safety and Engineering Center with participants from ten NASA Centers and AFRL. Multiple aerospace contractors are participating in the design development, tooling and fabrication effort as well. The goal of the program is to develop an agency wide design team for composite habitable spacecraft. The specific goals for this development project are: a).To gain hands on experience in design, building and testing a composite crew module. b) To validate key assumptions by resolving composite spacecraft design details through fabrication and testing of hardware. This abstract is based on Preliminary Design data..The final design will continue to evolve through the fall of 2007 with fabrication mostly completed by conference date. From a structures perspective, the.CCM can be viewed as a pressure module with variable pressure time histories and a series of both impact and quasi-static, high intensity point, line, and area distributed loads. The portion of the overall space vehicle being designed and. fabricated by the CCM team is just the pressure module and primary loading points. The heaviest point loads are applied and distributed to the pressure module at.an aluminum Service Module/Alternate Launch Abort System (SM/ALAS) fittings and at Main and Drogue Chute fittings. Significant line loads with metal to metal impact is applied at.the Lids ring. These major external point and line loads as well as pressure impact loads (blast and water landing) are applied to the lobed floor though the reentry shield and crushable materials. The pressure module is divided into upper and lower. shells that mate together with a bonded belly band splice joint to create the completed structural assembly. The benefits of a split CCM far outweigh the risks of a joint. These benefits include lower tooling cost and less manufacturing risk. Assembly of the top and bottom halves of the pressure shell will allow access to the interior of the shell throughout remaining fabrication sequence and can also potentially permit extensive installation of equipment and .crew facilities prior to final assembly of the two shell halves. A Pi pre-form is a woven carbon composite material which is provided in pre-impregnated form and frozen for long term storage. The cross-section shape allows the top of the pi to be bonded to a flat or curved surface with a second flat plate composite section bonded between two upstanding legs of the Pi. One of the regions relying on the merits of the Pi pre-form is the backbone. All connections among plates of the backbone structure, including the upper flanges, and to the lobe base of the pressure shell are currently joined by Pi pre-forms. The intersection of backbone composite plates is formed by application of two Pi pre-forms, top flanges and lobed surfaces are bonded with one Pi pre-form. The process of applying the pre-impregnated pi-preform will be demonstrated to include important steps like surface preparation, forming, application of pressure dams, vacuum bagging for consolidation, and curing techniques. Chopped carbon fiber tooling was selected over other traditional metallic and carbon fiber tooling. The requirement of schedule and cost economy for a moderate reuse cure tool warranted composite tooling options. Composite tooling schedule duration of 18 weeks compared favorably against other metallic tooling including invar tooling. Composite tooling also shows significant cost savings over low CTE metallic options. The composite tooling options were divided into two groups and the final decision was based on the cost, schedule, tolerance, temperature, and reuse requirements.

Pelham, Larry↗
NASA NTRS1992

Fast plasmoid formation in double arcades

The evolution of two neighboring nonsymmetric arcades with footpoint shearing profiles which can change in time is simulated in order to investigate the quasi-static evolution of a double arcade system. It is found that rapid forced reconnection can take place repeatedly, forming a series of plasmoids. A two-arcade system laterally confined by surrounding fluxes can develop instability with nonsymmetric footpoint shear, but the instability is significantly lower in comparison with the case in which the system is confined by a 'hard box' or periodic boundary conditions. The fast plasmoid formation process due to asymmetry switching is not due to the presence of simulation walls. The behavior of double arcades with asymmetry switching is described using equilibrium bifurcation diagrams with footpoint shear and degree of asymmetry, as two independent control parameters.

Finn, J. M.↗
NASA NTRS1994

Modeling time-dependent corrosion fatigue crack propagation in 7000 series aluminum alloys

Stress corrosion cracking and corrosion fatigue experiments were conducted with the susceptible S-L orientation of AA7075-T651, immersed in acidified and inhibited NaCl solution, to provide a basis for incorporating environmental effects into fatigue crack propagation life prediction codes such as NASA FLAGRO. This environment enhances da/dN by five to ten-fold compared to fatigue in moist air. Time-based crack growth rates from quasi-static load experiments are an order of magnitude too small for accurate linear superposition prediction of da/dN for loading frequencies above 0.001 Hz. Alternate methods of establishing da/dt, based on rising-load or ripple-load-enhanced crack tip strain rate, do not increase da/dt and do not improve linear superposition. Corrosion fatigue is characterized by two regimes of frequency dependence; da/dN is proportional to f(exp -1) below 0.001 Hz and to F(exp 0) to F(exp -0.1) for higher frequencies. Da/dN increases mildly both with increasing hold-time at K(sub max) and with increasing rise-time for a range of loading waveforms. The mild time-dependence is due to cycle-time-dependent corrosion fatigue growth. This behavior is identical for S-L nd L-T crack orientations. The frequency response of environmental fatigue in several 7000 series alloys is variable and depends on undefined compositional or microstructural variables. Speculative explanations are based on the effect of Mg on occluded crack chemistry and embritting hydrogen uptake, or on variable hydrogen diffusion in the crack tip process zone. Cracking in the 7075/NaCl system is adequately described for life prediction by linear superposition for prolonged load-cycle periods, and by a time-dependent upper bound relationship between da/dN and delta K for moderate loading times.

Mason, Mark E.↗
NASA NTRS2015

Dynamic Characterization of Galfenol

A novel and precise characterization of the constitutive behavior of solid and laminated research-grade, polycrystalline Galfenol (Fe81:6Ga18:4) under under quasi-static (1 Hz) and dynamic (4 to 1000 Hz) stress loadings was recently conducted by the authors. This paper summarizes the characterization by focusing on the experimental design and the dynamic sensing response of the solid Galfenol specimen. Mechanical loads are applied using a high frequency load frame. The dynamic stress amplitude for minor and major loops is 2.88 and 31.4 MPa, respectively. Dynamic minor and major loops are measured for the bias condition resulting in maximum, quasi-static sensitivity. Three key sources of error in the dynamic measurements are accounted for: (1) electromagnetic noise in strain signals due to Galfenol's magnetic response, (2) error in load signals due to the inertial force of fixturing, and (3) time delays imposed by conditioning electronics. For dynamic characterization, strain error is kept below 1.2 % of full scale by wiring two collocated gauges in series (noise cancellation) and through lead wire weaving. Inertial force error is kept below 0.41 % by measuring the dynamic force in the specimen using a nearly collocated piezoelectric load washer. The phase response of all conditioning electronics is explicitly measured and corrected for. In general, as frequency increases, the sensing response becomes more linear due to an increase in eddy currents. The location of positive and negative saturation is the same at all frequencies. As frequency increases above about 100 Hz, the elbow in the strain versus stress response disappears as the active (soft) regime stiffens toward the passive (hard) regime.

Dynamic sensing↗
NASA NTRS1994

Analysis of DE-1 PWI electric field data

The measurement of low frequency electric field oscillations may be accomplished with the Plasma Wave Instrument (PWI) on DE 1. Oscillations at a frequency around 1 Hz are below the range of the conventional plasma wave receivers, but they can be detected by using a special processing of the quasi-static electric field data. With this processing it is also possible to determine if the electric field oscillations are predominately parallel or perpendicular to the ambient magnetic field. The quasi-static electric field in the DE 1 spin/orbit plane is measured with a long-wire 'double probe'. This antenna is perpendicular to the satellite spin axis, which in turn is approximately perpendicular to the geomagnetic field in the polar magnetosphere. The electric field data are digitally sampled at a frequency of 16 Hz. The measured electric field signal, which has had phase reversals introduced by the rotating antenna, is multiplied by the sine of the rotation angle between the antenna and the magnetic field. This is called the 'perpendicular' signal. The measured time series is also multiplied with the cosine of the angle to produce a separate 'parallel' signal. These two separate time series are then processed to determine the frequency power spectrum.

Weimer, Daniel↗
NASA NTRS1996

Studies of Westward Electrojets and Field-Aligned Currents in the Magnetotail During Substorms: Implications for Magnetic Field Models

This section outlines those tasks undertaken in the final year that contribute integrally to the overarching project goals. Fast, during the final year, it is important to note that the project benefited greatly with the addition of a Boston University graduate student, Ms. Karen Hirsch. Jointly, we made substantial progress on the development of and improvements to magnetotail magnetic field and plasma models. The ultimate aim of this specific task was to assess critically the utility of such models for mapping low-altitude phenomena into the magnetotail (and vice-versa). The bulk of this effort centered around the finite-width- magnetotail convection model developed by and described by Spence and Kivelson (J. Geophys. Res., 98, 15,487, 1993). This analytic, theoretical model specifies the bulk plasma characteristics of the magnetotail plasma sheet (number density, temperature, pressure) across the full width of the tail from the inner edge of the plasma sheet to lunar distances. Model outputs are specified by boundary conditions of the source particle populations as well as the magnetic and electric field configuration. During the reporting period, we modified this code such that it can be interfaced with the auroral particle precipitation model developed by Dr. Terry Onsager. Together, our models provide a simple analytic specification of the equatorial distribution of fields and plasma along with their low-altitude consequences. Specifically, we have built a simple, yet powerful tool which allows us to indirectly 'map' auroral precipitation signatures (VDIS, inverted-V's, etc.) measured by polar orbiting spacecraft in the ionosphere, to the magnetospheric equatorial plane. The combined models allow us to associate latitudinal gradients measured in the ion energy fluxes at low-altitudes with the large-scale pressure gradients in the equatorial plane. Given this global, quasi-static association, we can then make fairly strong statements regarding the location of discrete features in the context of the global picture. We reported on our initial study at national and international meetings and published the results of our predictions of the low-altitude signatures of the plasma sheet. In addition, the PI was invited to contribute a publication to the so-called 'Great Debate in Space Physics' series that is a feature of EOS. The topic was on the nature of magnetospheric substorms. Specific questions of the when and where a substorm occurs and the connection between the auroral and magnetospheric components were discussed in that paper. This paper therefore was derived exclusively from the research supported by this grant. Attachment: Empirical modeling of the quite time nightside magnetosphere.' 'CRRES observations of particle flux dropout event.' The what, where, when, and why of magnetospheric substorm triggers'. and 'Low altitude signature of the plasma sheet: model prediction of local time dependence'.

Spence, Harlan E.↗
NASA NTRS1994

Evolutionary sequences of very hot, low-mass, accreting white dwarfs with application to symbiotic variables and ultrasoft/supersoft low-luminosity x-ray sources

We present the first detailed model results of quasi-static evolutionary sequences of very hot low-mass white dwarfs accreting hydrogen-rich material at rates between 1 x 10(exp -7) and 1 x 10(exp -9) solar mass/yr. Most of the sequences were generated from starting models whose core thermal structures were not thermally relaxed in the thermal pulse cycle-averaged sense of an asymptotic giant branch stellar core. Hence, the evolution at constant accretion rate was not invariably characterized by series of identical shell flashes. Sequences exhibiting stable steady state nuclear burning at the accretion supply rate as well as sequences exhibiting recurrent thermonuclear shell flashes are presented and discussed. In some cases, the white dwarf accretors remain small (less than 10(exp 11) cm) and very hot even during the shell flash episode. They then experience continued but reduced hydrogen shell burning during the longer quiescent intervals while their surface temperatures increase both because of compressional heating and envelope structure readjustment in response to accretion over thousands of years. Both accretion and continued hydrogen burning power these models with luminosities of a few times 10(exp 37) ergs/s. We suggest that the physical properties of these model sequences are of considerable relevance to the observed outburst and quiescent behavior of those symbiotic variables and symbiotic novae containing low-mass white dwarfs. We also suggest that our models are relevant to the observational characteristics of the growing class of low-luminosity, supersoft/ultrasoft X-ray sources in globular clusters, and the Magellanic Clouds.

Sion, Edward M.↗
NASA NTRS1989

Redistribution in astrophysically important hydrogen lines

Under typical solar chromospheric conditions for hydrogen radiators, strong collisions due to both electrons and ions are well separated in time, so that a binary collision theory for collisional redistribution is applicable. However, a simple impact approximation may not be used, but rather a unified type theory is required in which frequency dependent line shape parameters are used to describe both impact and quasi-static regions of the spectrum. In addition, correlated terms which describe absorption and emission during a collision are important, and, in fact, without correlated terms describing both transfer of excitation and emission during the same collision unphysical predictions (such as negative intensities) would be obtained. In this paper theory is specifically developed for the coupled Lyman-alpha, Lyman-beta, Hydrogen-alpha system, and equations of statistical equilibrium and absorption and emission coefficients are given. All correlated events are examined and emission during a collision is found to be important in the line wings. Stimulated emission and absorption is also included within a broadband approximation. The major approximation is to ignore lower state interaction. It is found that for Lyman-beta Raman-coupling with Hydrogen-alpha occurs and the overall scattering of radiation in the line wings is mostly coherent. In contrast, for Hydrogen-alpha, incoherent redistribution due to lower state radiative decay (which occurs even in the absence of collisions) is found to dominate the coherent scattering. Finally, in the Lyman series the dominant incoherent contribution is associated with cascade transitions and inelastic collisions between different principal quantum states.

Cooper, J.↗
NASA NTRSDate not supplied

Quantifying Leak Rates and Vacuum Impact on Granular Soil Column Pneumatic Seal

Introduction: All In-Situ Resource Utilization (ISRU) regolith reactor systems that aim to extract gases or vapors must maintain a seal along the flow path of the regolith from the inlet hopper to where extracted gases or vapors are generated. Using a column of regolith at the inlet has been proposed as an alternative to systems using series of mechanical valves to reduce mass and complexity. Preliminary investigations into the use of regolith itself as a barrier to escaping fluids have been conducted, which this research seeks to expand upon. Different vertical regolith simulant plug diameters and heights were tested under vacuum with dry nitrogen to observe leak rates and approximate steady state pressure gradient equilibria. The effect of absolute ambient pressure was also studied by repeating tests at incremental pressures ranging from 10e-5 Torr up to 1 atm to corroborate ambient bench tests from previous work. The impact of regolith dynamics was addressed to emulate continuous-feed regolith reaction processes by measuring leak rates through continuously draining simulant columns. OB-1 lunar highlands regolith simulant was used. Experimental Setup: Regolith simulant columns were constructed using a motorized butterfly valve separating upper acrylic tubes of various diameters from a larger, lower aluminum pipe plenum (See Figure 1). The butterfly valve was cracked open such that gas could freely pass through whereas regolith would bridge and stay suspended as a cohesive plug above in the acrylic portion. These assemblies were loaded into a vacuum chamber, and a compressed dry nitrogen line was routed into the lower plenum. Pressure transducers measured the absolute pressure of the lower plenum, which was compared to absolute chamber pressure to monitor the pressure gradient across the regolith simulant. A precision mass flow controller enabled fine control of plenum pressure. The plenum pressure was quasi-statically increased to set points informed by previous work [1] before shutting off the gas supply to allow the now pressurized gas volume to dissipate through the simulant into the chamber in what was referred to as a ‘leak test.’ In a separate set of tests, the pressure was allowed to quasi-statically build until visual disturbances in the soil were observed via remote camera feeds. Initial leak rate tests were repeated on the disturbed soil to observe changes in leak rates between initial as-poured and post-bubbling soil conditions. This test schedule was applied to simulant columns of three different diameters (approximately 2, 4, and 6 inches) as well as two different heights (around 8 and 16 inches) and was repeated at least three times for each configuration. Plenums were also pressurized while the butterfly valves were opened slightly further to facilitate slow, controlled, constant flowrate draining of the simulant to observe the impact that continuous-feed systems might have on leak rate through the regolith column. Finally, the regolith columns were reset and refilled and static leak rate tests were repeated approximately every decade in ambient pressure from 10e-5 Torr up to ambient conditions to observe the impact of transitioning out of the molecular flow regime on regolith column seal performance. Analysis: Trends with respect to each factor examined were constructed and reported alongside commentary on the most likely responsible physical phenomena. Confidence intervals were applied to the predictive findings of the data by quantifying instrumentation error and accounting for probabilistic impacts of curve fitting the generic exponential function onto pressure decay data. The leak rate is assumed directly proportional to the exponential term coefficient, while the steady-state static pressure gradient is assumed to be the asymptotic limit of each curve fit. Finally, a generic model developed by Ogino et al. [2] and later tuned for ambient testing was re-tuned using vacuum data to estimate leak rates on the lunar surface. Results: Pressure decay rates decreased up to 27-fold under vacuum when compared to ambient pressure, as shown in Figure 2. Simulant column diameter was found to exponentially correlate to both regolith column leak rate and steady-state equilibrium pressure delta. Height was found to be linearly related to leak rate –doubling the regolith column height consistently yielded around a 40% reduction in leak rate. Dynamic regolith draining was found to slightly increase leak rate, although to a lower degree than expected. Conclusion: Because of the transition into molecular gas flow through regolith, vacuum testing is required to properly estimate performance. Regolith columns should be designed as narrow as possible to avoid bridging and minimize leak rate, and as tall as is feasible to both further reduce leak rate and to help prevent bubbling, which has been shown to degrade the quality of the regolith seal. Disrupted soil was found to exhibit higher leak rates than pristine, as-poured soil, indicating the need to consider the impact of recovery from depressurization events. Regolith columns appear equally feasible for both dosed and continuous-feed reactors.

ISRU↗
NASA NTRSDate not supplied

Extinction of the Stagnation Point Diffusion Flame: Effect of Conductive Heat Loss into Solid Interior

The flammability boundary of a solid is U-shaped with the ordinate as ambient oxygen percentage (or total pressure) and the abscissa represents flow velocity, gravity level, stretch rate, etc. The left side of the flammability boundary is the quenching branch, and the right side is the blow-off branch. Quenching is due to a weak flame whose heat release from combustion cannot overcome the excessive heat losses from, for example, radiation. Blow-off is due to a short gas residence time that is smaller than the chemical reaction time (traditionally referred to as the small Damköhler number effect). For thick solids, the heat conduction into the solid interior has a long transient after ignition before the solid temperature reaches the steady state. During this slow transient, there is excessive (i.e. more than that at the steady state) gas phase heat conduction into the solid interior. From the viewpoint of the quasi-static gaseous flame, this is an additional heat loss that will affect the gas flame's flammability. In this work, a previously developed one-dimensional axisymmetric stagnation-point diffusion flame model is extended to account for the excessive heat loss into the solid beyond the steady burning state. A non-dimensional excessive conductive heat loss parameter Ψ is defined in the paper to account for the transient solid effect. For each Ψ, the gas phase is considered reaching a quasi-steady state. Extensive numerical computations have been performed to determine the extinction boundary and the characteristics of near-limit flames. The U-shaped flammability boundary is now a series of boundaries with Ψ as a parameter. Flame structures under the same environment condition but with different Ψ are compared. For a given oxygen ambient, the extinction boundary Ψ vs stretch rate is an inverted U-shape. The boundary consists of a blowoff branch and a radiative quenching branch. Extensive computed data including flame and pyrolysis temperatures, burning rate, flame standoff distance, species concentration, and reaction rate are presented along the extinction boundaries. Heat balance analysis is performed for both the gas phase and the gas-solid interface. Along the extinction boundary, the relative importance of conduction, convection, radiation, and chemical reaction are analyzed in detail.

Stagnation point diffusion flame↗