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NASA NTRS1972

The design and application of an infrared simulator for thermal vacuum testing

An infrared simulator was developed and installed in SIM Chamber A in support of the Apollo lunar-exploration mission thermal vacuum testing. The simulator was designed to provide thermal simulation of the radiation emitted and reflected by the lunar surface incident on the Apollo service module in a 60-mile-altitude lunar orbit. The infrared simulator comprises 18 individually controlled zones that provide the irradiance profiles over a 180 deg arc around the spacecraft, simulating the flux levels of equatorial, polar, and 45 deg lunar orbits.

Skinner, D. J.↗

NASA NTRS2013

Analysis of Water Recovery Rate from the Heat Melt Compactor

Human space missions generate trash with a substantial amount of plastic (20% or greater by mass). The trash also contains water trapped in food residue and paper products and other trash items. The Heat Melt Compactor (HMC) under development by NASA Ames Research Center (ARC) compresses the waste, dries it to recover water and melts the plastic to encapsulate the compressed trash. The resulting waste disk or puck represents an approximately ten-fold reduction in the volume of the initial trash loaded into the HMC. In the current design concept being pursued, the trash is compressed by a piston after it is loaded into the trash chamber. The piston face, the side walls of the waste processing chamber and the end surface in contact with the waste can be heated to evaporate the water and to melt the plastic. Water is recovered by the HMC in two phases. The first is a pre-process compaction without heat or with the heaters initially turned on but before the waste heats up. Tests have shown that during this step some liquid water may be expelled from the chamber. This water is believed to be free water (i.e., not bound with or absorbed in other waste constituents) that is present in the trash. This phase is herein termed Phase A of the water recovery process. During HMC operations, it is desired that liquid water recovery in Phase A be eliminated or minimized so that water-vapor processing equipment (e.g., condensers) downstream of the HMC are not fouled by liquid water and its constituents (i.e., suspended or dissolved matter) exiting the HMC. The primary water recovery process takes place next where the trash is further compacted while the heated surfaces reach their set temperatures for this step. This step will be referred to herein as Phase B of the water recovery process. During this step the waste chamber may be exposed to different selected pressures such as ambient, low pressure (e.g., 0.2 atm), or vacuum. The objective for this step is to remove both bound and any remaining free water in the trash by evaporation. The temperature settings of the heated surfaces are usually kept above the saturation temperature of water but below the melting temperature of the plastic in the waste during this step to avoid any encapsulation of wet trash which would reduce the amount of recovered water by blocking the vapor escape. In this paper, we analyze the water recovery rate during Phase B where the trash is heated and water leaves the waste chamber as vapor, for operation of the HMC in reduced gravity. We pursue a quasi-one-dimensional model with and without sidewall heating to determine the water recovery rate and the trash drying time. The influences of the trash thermal properties, the amount of water loading, and the distribution of the water in the trash on the water recovery rates are determined.

Heat Melt Compactor↗

NASA NTRS2010

Titanium Hydroxide - a Volatile Species at High Temperature

Nguyen, QuynhGiao N.↗

NASA NTRS2010

Selective Functionalization of Carbon Nanotubes: Part II

An alternative method of low-temperature plasma functionalization of carbon nanotubes provides for the simultaneous attachment of molecular groups of multiple (typically two or three) different species or different mixtures of species to carbon nanotubes at different locations within the same apparatus. This method is based on similar principles, and involves the use of mostly the same basic apparatus, as those of the methods described in "Low-Temperature Plasma Functionalization of Carbon Nanotubes" (ARC-14661-1), NASA Tech Briefs, Vol. 28, No. 5 (May 2004), page 45. The figure schematically depicts the basic apparatus used in the aforementioned method, with emphasis on features that distinguish the present alternative method from the other. In this method, one exploits the fact that the composition of the deposition plasma changes as the plasma flows from its source in the precursor chamber toward the nanotubes in the target chamber. As a result, carbon nanotubes mounted in the target chamber at different flow distances (d1, d2, d3 . . .) from the precursor chamber become functionalized with different species or different mixtures of species. In one series of experiments to demonstrate this method, N2 was used as the precursor gas. After the functionalization process, the carbon nanotubes from three different positions in the target chamber were examined by Fourier-transform infrared spectroscopy to identify the molecular groups that had become attached. On carbon nanotubes from d1 = 1 cm, the attached molecular groups were found to be predominantly C-N and C=N. On carbon nanotubes from d2 = 2.5 cm, the attached molecular groups were found to be predominantly C-(NH)2 and/or C=NH2. (The H2 was believed to originate as residual hydrogen present in the nanotubes.) On carbon nanotubes from d3 = 7 cm no functionalization could be detected - perhaps, it was conjectured, because this distance is downstream of the plasma source, all of the free ions and free radicals of the plasma had recombined into molecules.

Meyyappan, Meyya↗

NASA NTRS1990

Transatmospheric vehicle research

Research was conducted into the alternatives to the supersonic combustion ramjet (scramjet) engine for hypersonic flight. A new engine concept, the Oblique Detonation Wave Engine (ODWE) was proposed and explored analytically and experimentally. Codes were developed which can couple the fluid dynamics of supersonic flow with strong shock waves, with the finite rate chemistry necessary to model the detonation process. An additional study was conducted which compared the performance of a hypersonic vehicle powered by a scramjet or an ODWE. Engineering models of the overall performances of the two engines are included. This information was fed into a trajectory program which optimized the flight path to orbit. A third code calculated the vehicle size, weight, and aerodynamic characteristics. The experimental work was carried out in the Ames 20MW arc-jet wind tunnel, focusing on mixing and combustion of fuel injected into a supersonic airstream. Several injector designs were evaluated by sampling the stream behind the injectors and analyzing the mixture with an on-line mass spectrometer. In addition, an attempt was made to create a standing oblique detonation wave in the wind tunnel using hydrogen fuel. It appeared that the conditions in the test chamber were marginal for the generation of oblique detonation waves.

Adelman, Henry G.↗

NASA NTRS1993

Chamber free fusion welding root side purging method and apparatus

A method and apparati are presented for non-chamber root side purging in fusion welding of oxygen reactive metals which require that the molten weld zone and local solid areas of the weld seam remaining at high temperatures be shielded from normal atmosphere to prevent degradation of the welded area. The apparati provide an inert atmosphere to the root side of a weld joint through a porous medium whereby the jet-like thrust of the plasma arc actually draws the continuously supplied inert atmosphere into the path of the molten or high temperature solid weld zone. The porous medium is configured so it can be placed at the borders of the weld seam and substantially parallel to the seam without restricting the view of the root side of the seam. The inert gas is dispersed evenly through the porous media and across the weld seam, at the point of arc penetration and in front of and behind the arc. The apparati can be constructed so as to limit the amount of inert gas flow and can be mobile and travel synchronously with the welding arc.

Mcgee, William F.↗

NASA NTRS1995

Chamber free fusion welding root side purging method and apparatus

Dailey, J. R.↗

NASA NTRS1998

Results From Mars Show Electrostatic Charging of the Mars Pathfinder Sojourner Rover

Indirect evidence (dust accumulation) has been obtained indicating that the Mars Pathfinder rover, Sojourner, experienced electrostatic charging on Mars. Lander camera images of the Sojourner rover provide distinctive evidence of dust accumulation on rover wheels during traverses, turns, and crabbing maneuvers. The sol 22 (22nd Martian "day" after Pathfinder landed) end-of-day image clearly shows fine red dust concentrated around the wheel edges with additional accumulation in the wheel hubs. A sol 41 image of the rover near the rock "Wedge" (see the next image) shows a more uniform coating of dust on the wheel drive surfaces with accumulation in the hubs similar to that in the previous image. In the sol 41 image, note particularly the loss of black-white contrast on the Wheel Abrasion Experiment strips (center wheel). This loss of contrast was also seen when dust accumulated on test wheels in the laboratory. We believe that this accumulation occurred because the Martian surface dust consists of clay-sized particles, similar to those detected by Viking, which have become electrically charged. By adhering to the wheels, the charged dust carries a net nonzero charge to the rover, raising its electrical potential relative to its surroundings. Similar charging behavior was routinely observed in an experimental facility at the NASA Lewis Research Center, where a Sojourner wheel was driven in a simulated Martian surface environment. There, as the wheel moved and accumulated dust (see the following image), electrical potentials in excess of 100 V (relative to the chamber ground) were detected by a capacitively coupled electrostatic probe located 4 mm from the wheel surface. The measured wheel capacitance was approximately 80 picofarads (pF), and the calculated charge, 8 x 10(exp -9) coulombs (C). Voltage differences of 100 V and greater are believed sufficient to produce Paschen electrical discharge in the Martian atmosphere. With an accumulated net charge of 8 x 10(exp -9) C, and average arc time of 1 msec, arcs can also occur with estimated arc currents approaching 10 milliamperes (mA). Discharges of this magnitude could interfere with the operation of sensitive electrical or electronic elements and logic circuits. Sojourner rover wheel tested in laboratory before launch to Mars. Before launch, we believed that the dust would become triboelectrically charged as it was moved about and compacted by the rover wheels. In all cases observed in the laboratory, the test wheel charged positively, and the wheel tracks charged negatively. Dust samples removed from the laboratory wheel averaged a few ones to tens of micrometers in size (clay size). Coarser grains were left behind in the wheel track. On Mars, grain size estimates of 2 to 10 mm were derived for the Martian surface materials from the Viking Gas Exchange Experiment. These size estimates approximately match the laboratory samples. Our tentative conclusion for the Sojourner observations is that fine clay-sized particles acquired an electrostatic charge during rover traverses and adhered to the rover wheels, carrying electrical charge to the rover. Since the Sojourner rover carried no instruments to measure this mission's onboard electrical charge, confirmatory measurements from future rover missions on Mars are desirable so that the physical and electrical properties of the Martian surface dust can be characterized. Sojourner was protected by discharge points, and Faraday cages were placed around sensitive electronics. But larger systems than Sojourner are being contemplated for missions to the Martian surface in the foreseeable future. The design of such systems will require a detailed knowledge of how they will interact with their environment. Validated environmental interaction models and guidelines for the Martian surface must be developed so that design engineers can test new ideas prior to cutting hardware. These models and guidelines cannot be validated without actual flighata. Electrical charging of vehicles and, one day, astronauts moving across the Martian surface may have moderate to severe consequences if large potential differences develop. The observations from Sojourner point to just such a possibility. It is desirable to quantify these results. The various lander/rover missions being planned for the upcoming decade provide the means for doing so. They should, therefore, carry instruments that will not only measure vehicle charging but characterize all the natural and induced electrical phenomena occurring in the environment and assess their impact on future missions.

Kolecki, Joseph C.↗

NASA NTRS2002

Vacuum Arc Vapor Deposition Method and Apparatus for Applying Identification Symbols to Substrates

An apparatus for applying permanent markings onto products using a Vacuum Arc Vapor Deposition (VAVD) marker by accelerating atoms or molecules from a vaporization source onto a substrate to form human and/or machine-readable part identification marking that can be detected optically or via a sensing device like x-ray, thermal imaging, ultrasound, magneto-optic, micro-power impulse radar, capacitance, or other similar sensing means. The apparatus includes a housing with a nozzle having a marking end. A chamber having an electrode, a vacuum port and a charge is located within the housing. The charge is activated by the electrode in a vacuum environment and deposited onto a substrate at the marking end of the nozzle. The apparatus may be a hand-held device or be disconnected from the handle and mounted to a robot or fixed station.

Harry F Schramm↗

NASA NTRS1981

Vapor phase diamond growth technology

Ion beam deposition chambers used for carbon film generation were designed and constructed. Features of the developed equipment include: (1) carbon ion energies down to approx. 50 eV; (2) in suit surface monitoring with HEED; (3) provision for flooding the surface with ultraviolet radiation; (4) infrared laser heating of substrate; (5) residual gas monitoring; (6) provision for several source gases, including diborane for doping studies; and (7) growth from either hydrocarbon source gases or from carbon/argon arc sources. Various analytical techniques for characterization of from carbon/argon arc sources. Various analytical techniques for characterization of the ion deposited carbon films used to establish the nature of the chemical bonding and crystallographic structure of the films are discussed. These include: H2204/HN03 etch; resistance measurements; hardness tests; Fourier transform infrared spectroscopy; scanning auger microscopy; electron spectroscopy for chemical analysis; electron diffraction and energy dispersive X-ray analysis; electron energy loss spectroscopy; density measurements; secondary ion mass spectroscopy; high energy electron diffraction; and electron spin resonance. Results of the tests are summarized.

Angus, J. C.↗

NASA NTRS1980

Experimental results on plasma interactions with large surfaces at high voltages

Multikilowatt power levels for future payloads can be more efficiently generated using solar arrays operating in the kilovolt range. This implies that large areas of the array at high operating voltages will be exposed to the space plasma environment. The resulting interactions of these high voltage surfaces with space plasma environments can seriously impact the performance of the satellite system. The plasma-surface interaction phenomena were studied in tests performed in two separate vacuum chambers, a 4.6 m diameter by 19.2 long chamber and a 20 m diameter by 27.4 m long chamber. The generated plasma density was approximately 1x10 to the 4th power/cu cm. Ten solar array panels, each with areas of 1400 sq cm were used in the tests. Nine of the solar panels were tested as a composite unit in the form of a 3x3 solar panel matrix. The results from all the tests confirmed small sample tests results: insulators were found to enhance the plasma coupling current for high positive bias and arcing was found to occur at high negative bias.

Grier, N. T.↗

NASA NTRS1995

Spectral Changes in Metal Halide and High-pressure Sodium Lamps Equipped with Electronic Dimming

Electronic dimming of high-intensity discharge lamps offers control of photosynthetic photon flux (PPF) but is often characterized as causing significant spectral changes. Growth chambers with 400-W metal halide (MH) and high-pressure sodium (HPS) lamps were equipped with a dimmer system using silicon-controlled rectifiers (SCR) as high-speed switches. Phase control operation turned the line power off for some period of the alternating current cycle. At full power, the electrical input to HPS and MH lamps was 480 W (root mean squared) and could be decreased to 267 W and 428 W, respectively, before the arc was extinguished. Concomitant with this decrease in input power, PPF decreased by 60% in HPS and 50% in MH. The HPS lamp has characteristic spectral peaks at 589 and 595 nm. As power to the HPS lamps was decreased, the 589-nm peak remained constant while the 595-nm peak decreased, equaling the 589-nm peak at 345-W input, and the 589-nm peak was almost absent at 270-W input. The MH lamp has a broader spectral output but also has a peak at 589 nm and another smaller peak at 545 nm. As input power to the MH lamps decreased, the peak at 589 diminished to equal the 545-nm peak. As input power approached 428 W, the 589-nm peak shifted to 570 nm. While the spectrum changed as input power was decreased in the MH and HPS lamps, the phytochrome equilibrium ratio (P(sub fr):P(sub tot)) remains unchanged for both lamp types.

Bubenheim, David L.↗

NASA NTRS1995

Spectral Changes in Metal Halide and High-Pressure Sodium Lamps Equipped with Electronic Dimming

Electronic dimming of high-intensity discharge lamps offers control of Photosynthetic Photon Flux (PPF) but is often characterized as causing significant spectral changes. Growth chambers with 400-W Metal Halide (MH) and High-Pressure Sodium (HPS) lamps were equipped with a dimmer system using Silicon-Controlled Rectifiers (SCR) as high-speed switches. Phase control operation turned the line power off for some period of the alternating current cycle. At full power, the electrical input to HPS and MH lamps was 480 W (root mean squared) and could be decreased to 267 W and 428 W, respectively, before the arc was extinguished. Concomitant with this decrease in input power, PPF decreased by 60% in HPS and 50% in MH. The HPS lamp has characteristic spectral peaks at 589 and 595 nm. As power to the HPS lamps was decreased, the 589-nm peak remained constant while the 595-nm peak decreased, equaling the 589-nm peak at 345-W input, and 589-nm peak was almost absent at 270-W input. The MH lamp has a broader spectral output but also has a peak at 589 nm and another smaller peak at 545 nm. As input power approached 428 W, the 589-nm peak shifted to 570 nm. While the spectrum changed as input power was decreased in the MH and HPS lamps, the phytochrome equilibrium ratio (P(sub ft):P(sub tot)) remains unchanged for both lamp types.

Bubenheim, David L.↗

NASA NTRS2011

The Development of a CO2 Test Capability in the NASA JSC ARCJet for Mars Reentry Simulation

The Atmospheric Reentry Materials and Structures Evaluation Facility (ARMSEF) located at NASA Johnson Space Center is used for simulating the extreme environment experienced upon reentry for the development and certification of thermal protection systems (TPS). The facility supports a large variety of programs and was heavily leveraged for the certification and operational support of the TPS for the Orbiter and, more recently, the development of the heat shield for CEV. This paper will provide more detail into the heritage of the facility. Unique attributes of the facility include a modular aerodynamically stabilized arc heater and independently controlled O2 and N2 for the test gases. When combining the O2 and N2 in a 23:77 mass ratio respectively the Earth s atmosphere is accurately simulated and via modification of this ratio the investigation of the effects of atomic oxygen on a material s response is possible. In the summer of 2010 a development effort was started to add CO2 as a third independently controlled test gas such that, when combined with N2, opens up the possibility of accurately simulating a Martian reentry environment. This paper will discuss the test facility, especially the arc heater, in more detail. Initial testing involved relatively low concentrations of CO2 combined with N2 for the primary purpose of gathering data to answer two pressing safety concerns. The first being the rate of production of carbon monoxide (CO) within the ejector vacuum system. The main concern was that CO can be flammable and possibly explosive at high enough concentrations and pressures. The hazard control during the development phase involved the use of injecting N2 inside the test chamber diffuser to dilute and reduce the concentration of any and all CO present. A residual gas analyzer (RGA) was used to determine the relative amount of CO in the exhaust gas and provide a conversion rate of CO2 to CO. This paper will discuss in more detail the results of the RGA data and the calculated conversion rate. The second safety concern addressed is the possible formation of hydrogen cyanide (HCN) and cyanide (CN). HCN would primarily be present in the cooling water while the CN would most probably condense onto the interior surfaces of the test chamber. Water samples and wipes of the test chamber surfaces were analyzed by an industrial hygienist for the presence of HCN and CN. His paper will discuss these results in more detail. Throughout this development effort measurements of the CO2:N2 flowfield were made with heat flux and pressure probes and with laser induced fluorescence (LIF) of the atomic oxygen. This paper will discuss these results

DelPapa, Steven V.↗

NASA NTRS2004

RFID and Memory Devices Fabricated Integrally on Substrates

Electronic identification devices containing radio-frequency identification (RFID) circuits and antennas would be fabricated integrally with the objects to be identified, according to a proposal. That is to say, the objects to be identified would serve as substrates for the deposition and patterning of the materials of the devices used to identify them, and each identification device would be bonded to the identified object at the molecular level. Vacuum arc vapor deposition (VAVD) is the NASA derived process for depositing layers of material on the substrate. This proposal stands in contrast to the current practice of fabricating RFID and/or memory devices as wafer-based, self-contained integrated-circuit chips that are subsequently embedded in or attached to plastic cards to make smart account-information cards and identification badges. If one relies on such a chip to store data on the history of an object to be tracked and the chip falls off or out of the object, then one loses both the historical data and the means to track the object and verify its identity electronically. Also, in contrast is the manufacturing philosophy in use today to make many memory devices. Today s methods involve many subtractive processes such as etching. This proposal only uses additive methods, building RFID and memory devices from the substrate up in thin layers. VAVD is capable of spraying silicon, copper, and other materials commonly used in electronic devices. The VAVD process sprays most metals and some ceramics. The material being sprayed has a very strong bond with the substrate, whether that substrate is metal, ceramic, or even wood, rock, glass, PVC, or paper. An object to be tagged with an identification device according to the proposal must be compatible with a vacuum deposition process. Temperature is seldom an issue as the substrate rarely reaches 150 F (66 C) during the deposition process. A portion of the surface of the object would be designated as a substrate for the deposition of the device. By use of a vacuum arc vapor deposition apparatus, a thin electrically insulating film would first be deposited on the substrate. Subsequent layers of materials would then be deposited and patterned by use of known integrated-circuit fabrication techniques. The total thickness of the deposited layers could be much less than the 100- m thickness of the thinnest state-of-the-art self-contained microchips. Such a thin deposit could be readily concealed by simply painting over it. Both large vacuum chambers for production runs and portable hand-held devices for in situ applications are available.

Schramm, Harry F.↗

NASA NTRS1974

Acceleration processes in the quasi-steady magnetoplasmadynamic discharge

The flow field characteristics within the discharge chamber and exhaust of a quasi-steady magnetoplasmadynamic (MPD) arcjet were examined to clarify the nature of the plasma acceleration process. The observation of discharge characteristics unperturbed by insulator ablation and terminal voltage fluctuations, first requires the satisfaction of three criteria: the use of refractory insulator materials; a mass injection geometry tailored to provide propellant to both electrode regions of the discharge; and a cathode of sufficient surface area to permit nominal MPD arcjet operation for given combinations of arc current and total mass flow. The axial velocity profile and electromagnetic discharge structure were measured for an arcjet configuration which functions nominally at 15.3 kA and 6 g/sec argon mass flow. An empirical two-flow plasma acceleration model is advanced which delineates inner and outer flow regions and accounts for the observed velocity profile and calculated thrust of the accelerator.

Boyle, M. J.↗

NASA NTRS1983

Electron beam charging and arc discharging of spacecraft insulating materials

Samples of Mylar and Teflon film were exposed to combinations of monoenergetic electron and lithium ion fluxes in various ratios. The samples' discharge rates and strengths were found to diminish as the ion proportion increased. Various types of capacitors were exposed in air to beta irradiation from a 100 mCie Strontium-90 radioisotope source located at distances ranging from 2 cm to 5 cm from the capacitors. In these preliminary experiments, no evidence of spontaneous electrical breakdown was noted, nor was any change in RF impedance detectable using the available instrumentation. A decrease in DC resistance was noted, apparently due to radiation-induced conductivity. A cylindrical glass vacuum chamber is being assembled. Its inside dimensions are 44 cm diameter by 100 cm length. All necessary associated components and instruments have been acquired, including electron and ion guns, Trek surface potential probe and turbo-molecular pump. A mass-spectrometer detector for leaks and evolved gases will be ordered shortly.

Balmain, K. G.↗

NASA NTRS2015

Printing Outside the Box: Additive Manufacturing Processes for Fabrication of Large Aerospace Structures

To achieve NASA's mission of space exploration, innovative manufacturing processes are being applied to the fabrication of propulsion elements. Liquid rocket engines (LREs) are comprised of a thrust chamber and nozzle extension as illustrated in figure 1 for the J2X upper stage engine. Development of the J2X engine, designed for the Ares I launch vehicle, is currently being incorporated on the Space Launch System. A nozzle extension is attached to the combustion chamber to obtain the expansion ratio needed to increase specific impulse. If the nozzle extension could be printed as one piece using free-form additive manufacturing (AM) processes, rather than the current method of forming welded parts, a considerable time savings could be realized. Not only would this provide a more homogenous microstructure than a welded structure, but could also greatly shorten the overall fabrication time. The main objective of this study is to fabricate test specimens using a pulsed arc source and solid wire as shown in figure 2. The mechanical properties of these specimens will be compared with those fabricated using the powder bed, selective laser melting technology at NASA Marshall Space Flight Center. As printed components become larger, maintaining a constant temperature during the build process becomes critical. This predictive capability will require modeling of the moving heat source as illustrated in figure 3. Predictive understanding of the heat profile will allow a constant temperature to be maintained as a function of height from substrate while printing complex shapes. In addition, to avoid slumping, this will also allow better control of the microstructural development and hence the properties. Figure 4 shows a preliminary comparison of the mechanical properties obtained.

Babai, Majid↗