ISM In-Space Manufacturing
Develop and enable the technologies, materials, and processes required to provide affordable, sustainable on-demand manufacturing, recycling, and repair during Exploration Missions.
Elrod, Leigh M.↗
Engineering topics
Hall, Phillip B.
Publications and source records attributed to Hall, Phillip B..
Multi-Center Implementation of NPR 7123.1A: A Collaborative Effort
Collaboration efforts between MSFC and GRC Engineering Directorates to implement the NASA Systems Engineering (SE) Engine have expanded over the past year to include other NASA Centers. Sharing information on designing, developing, and deploying SE processes has sparked further interest based on the realization that there is relative consistency in implementing SE processes at the institutional level. This presentation will provide a status on the ongoing multi-center collaboration and provide insight into how these NPR 7123.1A SE-aligned directives are being implemented and managed to better support the needs of NASA programs and projects. NPR 7123.1A, NASA Systems Engineering Processes and Requirements, was released on March 26, 2007 to clearly articulate and establish the requirements on the implementing organization for performing, supporting, and evaluating SE activities. In early 2009, MSFC and GRC Engineering Directorates undertook a collaborative opportunity to share their research and work associated with developing, updating and revising their SE process policy to comply and align with NPR 7123.1A. The goal is to develop instructions, checklists, templates, and procedures for each of the 17 SE process requirements so that systems engineers will be a position to define work that is process-driven. Greater efficiency and more effective technical management will be achieved due to consistency and repeatability of SE process implementation across and throughout each of the NASA centers. An added benefit will be to encourage NASA centers to pursue and collaborate on joint projects as a result of using common or similar processes, methods, tools, and techniques.
Hall, Phillip B.↗
Improved Apparatus for Testing Monoball Bearings
A desk-sized apparatus for testing monoball bearings and their lubricants offers advantages, relative to prior such apparatuses, of (1) a greater degree of automation and (2) capability of operation under wider and more realistic ranges of test conditions. The ranges of attainable test conditions include load from 100 to greater h than 50,000 lb (445 to greater than 2.22 x 10(exp 5) N), resisting torque up to 30,000 lb-in. (approximately equal to 3,390 N-m), oscillating rotation through an angle as large as 280 degrees, and oscillation frequency from 0 to 6 Hz. With addition of some components and without major modification of the apparatus, it is also possible to perform tests under environmental conditions that include temperature from -320 to 1,000 F (-196 to +538 C), relative humidity from 0 to 100 percent, and either air at ambient pressure, high vacuum, or an atmosphere of monatomic oxygen. In the apparatus (see Figure 1), a monoball bearing specimen is driven in oscillating rotation by a hydraulic rotary actuator through a series of shafts, one of which incorporates a torque meter and one of which is a flexible coupling. The torque meter measures the resisting torque; the flexible coupling accommodates misalignment, wear, and compression of the specimen and ensures equal loading on opposite sides of the monoball. Not shown in the figure is an angular-position sensor that is used for measuring the angle of rotation of the shafts.
Hall, Phillip B.↗
Space Shuttle Body Flap Actuator Bearing Testing For NASA Return to Flight
The Space Shuttle body flap is located beneath the main engine nozzles and is required for proper aerodynamic control during orbital descent. Routine inspection of one of four body flap actuatols found one of the actuator bearings had degraded and blackened balls. A test program was initiated to demonstrate that it is acceptable to operate bearings which are degraded from operation over several flights. This test exposed the bearing to predicted flight axial loads, speeds and temperatures. Testing has been completed, and results indicate the previously flown bearings are acceptable for up to 12 additional missions.
Jett, Timothy R.↗
Dual Use Corrosion Inhibitor and Penetrant for Anomaly Detection in Neutron/X Radiography
A dual purpose corrosion inhibitor and penetrant composition sensitive to radiography interrogation is provided. The corrosion inhibitor mitigates or eliminates corrosion on the surface of a substrate upon which the corrosion inhibitor is applied. In addition, the corrosion inhibitor provides for the attenuation of a signal used during radiography interrogation thereby providing for detection of anomalies on the surface of the substrate.
Hall, Phillip B.↗
Environmentally Compatible Vapor-Phase Corrosion Inhibitor for Space Shuttle Hardware
USA-SRB Element is responsible for the assembly and refurbishment of the non-motor components of the SRB as part of Space Shuttle. Thrust Vector Control (TVC) frames structurally support components of the TVC system located in the aft skirt of the SRB. TVC frames are exposed to the seacoast environment after refurbishment and, also, to seawater immersion after splashdown, and during tow-back to CCAFS-Hangar AF refurbishment facilities. During refurbishment operations it was found that numerous TVC frames were experiencing internal corrosion and coating failures, both from salt air and seawater intrusions. Inspectors using borescopes would visually examine the internal cavities of the complicated aluminum alloy welded tubular structure. It was very difficult for inspectors to examine cavity corners and tubing intersections and particularly, to determine the extent of the corrosion and coating anomalies. Physical access to TVC frame internal cavities for corrosion removal and coating repair was virtually impossible, and an improved method using a Liquid (water based) Vapor-phase Corrosion Inhibitor (LVCI) for preventing initiation of new corrosion, and mitigating and/or stopping existing corrosion growth was recommended in lieu of hazardous paint solvents and high VOC / solvent based corrosion inhibitors. In addition, the borescopic inspection method used to detect corrosion, and/or coating anomalies had severe limitations because of part geometry, and an improved non-destructive inspection (NDI) method using Neutron Radiography (N-Ray) was also recommended.
Novak, Howard L.↗
Corrosion Inhibitors as Penetrant Dyes for Radiography
Liquid/vapor-phase corrosion inhibitors (LVCIs) have been found to be additionally useful as penetrant dyes for neutron radiography (and perhaps also x-radiography). Enhancement of radiographic contrasts by use of LVCIs can reveal cracks, corrosion, and other defects that may be undetectable by ultrasonic inspection, that are hidden from direct optical inspection, and/or that are difficult or impossible to detect in radiographs made without dyes.
Novak, Howard L.↗
Environmentally Compatible Vapor-Phase Corrosion Inhibitor for Space Shuttle Hardware
USA-SRB Element is responsible for the assembly and refurbishment of the non-motor components of the SRB as part of Space Shuttle. Thrust Vector Control (TVC) frames structurally support components of the TVC system located in the aft skirt of the SRB (Solid Rocket Booster). TVC frames are exposed to the seacoast environment after refurbishment and, also, to seawater immersion after splashdown, and during tow-back to CCAFS-Hangar AF refurbishment facilities. During refurbishment operations it was found that numerous TVC frames were experiencing internal corrosion and coating failures, both from salt air and seawater intrusions. Inspectors using borescopes would visually examine the internal cavities of the complicated aluminum alloy welded tubular structure. It was very difficult for inspectors to examine cavity corners and tubing intersections and particularly. to determine the extent of the corrosion and coating anomalies. Physical access to TVC frame internal cavities for corrosion removal and coating repair was virtually impossible, and an improved method using a Liquid (water based) Vapor-phase Corrosion Inhibitor (LVCI) for preventing initiation of new corrosion, and mitigating and/or stopping existing corrosion growth was recommended in lieu of hazardous paint solvents and high VOC/solvent based corrosion inhibitors. In addition, the borescopic inspection method used to detect corrosion, and/or coating anomalies had severe limitations because of part geometry, and an improved non-destructive inspection (NDI) method using Neutron Radiography (N-Ray) was also recommended.
Novak, Howard L.↗
Environmentally Compatible Vapor-Phase Corrosion Inhibitor for Space Shuttle Hardware
USA-SRB Element is responsible for the assembly and refurbishment of the non-motor components of the SRB as part of Space Shuttle. Thrust Vector Control (TVC) frames structurally support components of the TVC system located in the aft skirt of the SRB. TVC frames are exposed to the seacoast environment after refurbishment and, also, to seawater immersion after splashdown, and during tow-back to CCAFS-Hangar AF refurbishment facilities. During refurbishment operations it was found that numerous TVC frames were experiencing internal corrosion and coating failures, both from salt air and seawater intrusions. Inspectors using borescopes would visually examine the internal cavities of the complicated aluminum alloy welded tubular structure. It was very difficult for inspectors to examine cavity corners and tubing intersections and particularly, to determine the extent of the corrosion and coating anomalies. Physical access to TVC frame internal cavities for corrosion removal and coating repair was virtually impossible, and an improved method using a Liquid (water based) Vapor-phase Corrosion Inhibitor (LVCI) for preventing initiation of new corrosion, and mitigating and/or stopping existing corrosion growth was recommended in lieu of hazardous paint solvents and high VOC/solvent based corrosion inhibitors. In addition, the borescopic inspection method used to detect corrosion, and/or coating anomalies had severe limitations because of part geometry, and an improved non-destructive inspection (NDI) method using Neutron Radiography (N-Ray) was also recommended.
Novak, Howard L.↗
Development and Implementation of Environmentally Compatible Solid Film Lubricants
Multi-body launch vehicles require the use of Solid Film Lubricants (SFLs) to allow for unrestricted relative motion between structural assemblies and components during lift-off and ascent into orbit. The Space Shuttle Solid Rocket Booster (SRB), uses a dual coat, ceramic-bonded high temperature SFL in several locations such as restraint hardware between the SRB aft skirt and the Mobile Launch Platform (MLP), the aft SRB/External Tank (ET) attach struts, and the forward skirt SRB/ET attach ball assembly. Future launch systems may require similar applications of SFLs for attachment and restraint hardware. A family of environmentally compatible non-lead/antimony bearing alternative SFLs have been developed including a compatible repair material. In addition, commercial applications for SFLs on transportation equipment, all types of lubricated fasteners, and energy related equipment allow for wide usage's of these new lubricants. The new SFLs trade named BOOSTERLUBE is a family of single layer thin film (0.001 inch maximum) coatings that are a unique mixture of non-hazardous pigments in a compatible resin system that allows for low temperature curing (450 F). Significant savings in energy and processing time as well as elimination of hazardous material usage and disposal would result from the non-toxic one-step SFL application. Compatible air-dry field repair lubricants will help eliminate disassembly of launch vehicle restraint hardware during critical time sensitive assembly operations.
Novak, Howard L.↗
Development and Implementation of Environmentally Compatible Solid Film Lubricants
Multi-body launch vehicles require the use of Solid Film Lubricants (SFLS) to allow for unrestricted relative motion between structural assemblies and components during lift-off and ascent into orbit. The Space Shuttle Solid Rocket Booster (SRB), uses a dual coat, ceramic-bonded high temperature SFL in several locations such as restraint hardware between the SRB aft skirt and the Mobile Launch Platform (MLP), the aft SRB/External Tank (ET) attach struts, and the forward skirt SRB/ET attach ball assembly. Future launch systems may require similar applications of SFLs for attachment and restraint hardware. A family of environmentally compatible non-lead/antimony bearing alternative SFLs have been developed including a compatible repair material. In addition, commercial applications for SFLs on transportation equipment, all types of lubricated fasteners, and energy related equipment allow for wide usage's of these new lubricants. The new SFLs trade named BOOSTERLUBE is a family of single layer thin film (0.001 inch maximum) coatings that are a unique mixture of non-hazardous pigments in a compatible resin system that allows for low temperature curing (450F). Significant savings in energy and processing time as well as elimination of hazardous material usage and disposal would result from the non-toxic one-step SFL application. Compatible air-dry field repair lubricants will help eliminate disassembly of launch vehicle restraint hardware during critical time sensitive assembly operations.
Novak, Howard L.↗
Development and Implementation of Environmentally Compatible Solid Film Lubricants
Multi-body launch vehicles require the use of Solid Film Lubricants (SFLs) to allow for unrestricted relative motion between structural assemblies and components during lift off and ascent into orbit. The Space Shuttle Solid Rocket Booster (SRB), uses a dual coat, ceramic-bonded high temperature SFL in several locations such as restraint hardware between the SRB aft skirt and the Mobile Launch Platform (MLP), the aft SRB/External Tank (ET) attach struts, and the forward skirt SRB/ET attach ball assembly. The proposed National Launch System (NLS) may require similar applications of SFLs for attachment and restraint hardware. A family of environmentally compatible nonlead/antimony bearing alternative SFLs have been developed including a compatible repair material. In addition, commercial applications for SFLs on transportation equipment, all types of lubricated fasteners, and energy related equipment allow for wide usage of these new lubricants. The new SFLs named BOOSTERLUBE is a family of single layer thin film (0.001 inch maximum) coatings that are a unique mixture of non-hazardous pigments in a compatible resin system that allows for low temperature curing (450 F). Significant savings in energy and processing time as well as elimination of hazardous material usage and disposal would result from the non-toxic onestep SFL application. Compatible air-dry field repair lubricants will help eliminate disassembly of launch vehicle restraint hardware during critical time sensitive assembly operations.
Novak, Howard L.↗