Extreme temperature aerospace bearing lubrication systems Final report
Ball bearing endurance tests and lubricant film thickness measurements under conditions of high temperature, pressure, and speed
Peacock, L. A.↗
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Airglow events visible to the naked eye
During IR photographic airglow observations covering several years, three naked-eye events have been recorded. Two of these are moving luminous acoustic-gravity-wave groups of some 10-15-km wavelength, which occur near high lunar tide in the atmosphere. The events appear quickly, endure 0.5-1 h, then fade. Visible photos of two events appear enhanced, while little enhancement is present in the IR photos, although the structures are well correlated. If these events are due to OH, it is suggested that some unrecognized mechanism, perhaps a gravity wave interaction, enhances the visible transitions of the OH over the IR transitions. If the events are due to an unrecognized continuum emitter, perhaps NO, its emission must occur at the same height as the OH. Spectra seem to be the only reasonable approach to solving this problem.
Peterson, A. W.↗
A Compendium of Brazed Microstructures For Fission Power Systems Applications
NASA has been supporting design studies and technology development for fission-based power systems that could provide power to an outpost on the Moon, Mars, or an asteroid. Technology development efforts have included fabrication and evaluation of components used in a Stirling engine power conversion system. This investigation is part of the development of several braze joints crucial for the heat exchanger transfer path from a hot-side heat exchanger to a Stirling engine heat acceptor. Dissimilar metal joints are required to impart both mechanical strength and thermal path integrity for a heater head of interest. Preliminary design work for the heat exchanger involved joints between low carbon stainless steel to Inconel 718, where the 316L stainless steel would contain flowing liquid metal NaK while Inconel 718, a stronger alloy, would be used as structural reinforcement. This paper addressed the long-term microstructural stability of various braze alloys used to join 316L stainless steel heater head to the high conductivity oxygen-free copper acceptor to ensure the endurance of the critical metallic components of this sophisticated heat exchanger. The bonding of the 316L stainless steel heater head material to a copper heat acceptor is required to increase the heat-transfer surface area in contact with flowing He, which is the Stirling engine working fluid.
Locci, Ivan E.↗
Design and evaluation of a toroidal wheel for planetary rovers
The inverted toroidal wheel concept was perceived, mathematically quantified, and experimentally verified. The wheel design has a number of important characteristics, namely; (1) the low footprint pressures required for Mars exploration (0.5 to 1.0 psi); (2) high vehicle weight to wheel weight ratios capable of exceeding 10:1; (3) extremely long cyclic endurances tending towards infinite life; and (4) simplicity of design. The concept, in combination with appropriate materials such as titanium or composites, provides a planetary roving vehicle with a very high degree of exploratory mobility, a substantial savings in weight and a high assurity of mission success. Design equations and computation procedures necessary to formulate an inverted wheel are described in detail.
Koskol, J.↗
Advanced Gear Alloys for Ultra High Strength Applications
Single tooth bending fatigue (STBF) test data of UHS Ferrium C61 and C64 alloys are presented in comparison with historical test data of conventional gear steels (9310 and Pyrowear 53) with comparable statistical analysis methods. Pitting and scoring tests of C61 and C64 are works in progress. Boeing statistical analysis of STBF test data for the four gear steels (C61, C64, 9310 and Pyrowear 53) indicates that the UHS grades exhibit increases in fatigue strength in the low cycle fatigue (LCF) regime. In the high cycle fatigue (HCF) regime, the UHS steels exhibit better mean fatigue strength endurance limit behavior (particularly as compared to Pyrowear 53). However, due to considerable scatter in the UHS test data, the anticipated overall benefits of the UHS grades in bending fatigue have not been fully demonstrated. Based on all the test data and on Boeing s analysis, C61 has been selected by Boeing as the gear steel for the final ERDS demonstrator test gearboxes. In terms of potential follow-up work, detailed physics-based, micromechanical analysis and modeling of the fatigue data would allow for a better understanding of the causes of the experimental scatter, and of the transition from high-stress LCF (surface-dominated) to low-stress HCF (subsurface-dominated) fatigue failure. Additional STBF test data and failure analysis work, particularly in the HCF regime and around the endurance limit stress, could allow for better statistical confidence and could reduce the observed effects of experimental test scatter. Finally, the need for further optimization of the residual compressive stress profiles of the UHS steels (resulting from carburization and peening) is noted, particularly for the case of the higher hardness C64 material.
Shen, Tony↗
Development of improved-durability plasma sprayed ceramic coatings for gas turbine engines
As part of a NASA program to reduce fuel consumption of current commercial aircraft engines, methods were investigated for improving the durability of plasma sprayed ceramic coatings for use on vane platforms in the JT9D turbofan engine. Increased durability concepts under evaluation include use of improved strain tolerant microstructures and control of the substrate temperature during coating application. Initial burner rig tests conducted at temperatures of 1010 C (1850 F) indicate that improvements in cyclic life greater than 20:1 over previous ceramic coating systems were achieved. Three plasma sprayed coating systems applied to first stage vane platforms in the high pressure turbine were subjected to a 100-cycle JT9D engine endurance test with only minor damage occurring to the coatings.
Sumner, I. E.↗
Development of improved-durability plasma sprayed ceramic coatings for gas turbine engines
An investigation is reported of improving the durability of plasma sprayed ceramic coatings for the vane platforms in the JT9d turbofan engine. The program aims for reduced fuel consumption of commercial aircraft engines; the use of improved strain tolerant microstructures and control of the substrate temperature during coating application are being evaluated. The initial burner rig tests at temperatures up to 1010 C indicated that improvements in cyclic life greater than 20:1 over previous ceramic coatings were achieved. Three plasma sprayed coating systems applied to first stage vane platforms in the high pressure turbine were subjected to a 1000-cycle JT9D engine endurance test with only minor damage occurring to the coatings.
Sumner, I. E.↗
Endurance tests with large-bore tapered-roller bearings to 2.2 million DN
Endurance life tests were run with standard design and optimized high-speed design 120.65-mm-(4.750-in.-) bore tapered-roller bearings at shaft speeds of 12,500 and 18,500 rpm, respectively. Standard design bearings of vacuum melted AISI 4320 and CBS-1000M, and high-speed design bearings of CBS-1000M and through-hardened AISI M-50 were run under heavy combined radial and thrust load until fatigue failure or until a preset cutoff time of 1100 hours was reached. Standard design bearings made from CBS 1000M material ran to a 10 percent life approximately six times rated catalog life. Twelve identical bearings of AISI 4320 material ran to ten times rated catalog life without failure. Cracking and fracture of the cones of AISI M-50 high-speed design bearings occurred at 18,500 rpm due to high tensile hoop stresses. Four CBS 1000M high-speed design bearings ran to twenty-four times rated catalog life without any spalling, cracking or fracture failures.
Parker, R. J.↗
Dynamic Coupling of Quasi-Electrostatic Thundercloud Fields to the Mesosphere and Lower Ionosphere: Sprites and Jets
Red Sprites and Blue Jets are two different types of recently discovered optical flashes ob- served above large thunderstorm systems. Sprites are luminous glows occurring at altitudes typically ranging from approximately 50 to 90 km. In video they exhibit a red color at their top which gradually changes to blue at lower altitudes. Sprites may occur singly or in clusters of two or more. The lateral extent of "unit" sprites is typically 5-10 km and they endure for several milliseconds. Jets are upward moving (approximately 100 km/s) highly collimated beams of luminosity, emanating from the tops of thunderclouds, extending up to approximately 50 km altitude and exhibiting a primarily blue color. We propose that sprites result from large electric field transients capable of causing electron heating, breakdown ionization and excitation of optical emissions at mesospheric altitudes following the removal of thundercloud charge by a cloud-to-ground discharge. Depending on the history of charge accumulation and removal, and the distribution of ambient atmospheric conductivity, the breakdown region may have the shape of vertically oriented ionization column(s). Results of a two-dimensional and self consistent quasi-electrostatic (QE) model indicate that most of the observed features of sprites can be explained in terms of the formation and self-driven propagation of streamer type channels of breakdown ionization. Comparison of the optical emission intensities of the 1st and 2nd positive bands of N2, Meinel and 1st negative bands of N2(+) and the 1st negative band of O2(+) demonstrates that the 1st positive band of N2 is the dominant optical emission in the altitude range approximately 50-90 km, which accounts for the observed red color of sprites. Optical emissions of the 1st and 2nd positive bands of N2 occur in carrot-like vertical structures with typical transverse dimension approximately 5-10 km which can span an altitude range from approximately 80 km to well below approximately 50 km. The appearance of optical emissions associated with sprites can be delayed in time (approximately 1-20 ms) with respect to the causative cloud to ground discharge. Theoretical model results are found to be in good agreement with recent video, photometric and spectral measurements of sprites.
Pasko, Victor Petrovich↗
Manifold Integrated Pyrovalve
The Manifold Integrated Pyrovalve (MI-PV) provides a state-of-the-art, low mass, low volume, normally-closed (NC) pyrotechnic isolation valve configuration which is optimized for small free-flier applications. Small scale free-flier (e.g. CubeSat) applications require high pressure fluid isolation valves with leak rates low enough to endure long pad stays, and often have severe mass and volume limitations. The MI-PV utilizes a unique configuration where the shear section and the pyrotechnic ram assembly (PRA) are installed directly into a ported gas manifold, allowing elimination of heavy fluid fittings and connections. This configuration can be readily scaled and adapted to the needs of other long duration missions.
valve pyrovalve pyrotechnic↗
Thin Thermal-Insulation Blankets for Very High Temperatures
Thermal-insulation blankets of a proposed type would be exceptionally thin and would endure temperatures up to 2,100 C. These blankets were originally intended to protect components of the NASA Solar Probe spacecraft against radiant heating at its planned closest approach to the Sun (a distance of 4 solar radii). These blankets could also be used on Earth to provide thermal protection in special applications (especially in vacuum chambers) for which conventional thermal-insulation blankets would be too thick or would not perform adequately.
Choi, Michael K.↗
Thin Thermal-Insulation Blankets for Very High Temperatures
Thermal-insulation blankets of a proposed type would be exceptionally thin and would endure temperatures up to 2,100 C. These blankets were originally intended to protect components of the NASA Solar Probe spacecraft against radiant heating at its planned closest approach to the Sun (a distance of 4 solar radii). These blankets could also be used on Earth to provide thermal protection in special applications (especially in vacuum chambers) for which conventional thermal-insulation blankets would be too thick or would not perform adequately. A blanket according to the proposal (see figure) would be made of molybdenum, titanium nitride, and carbon- carbon composite mesh, which melt at temperatures of 2,610, 2,930, and 2,130 C, respectively. The emittance of molybdenum is 0.24, while that of titanium nitride is 0.03. Carbon-carbon composite mesh is a thermal insulator. Typically, the blanket would include 0.25-mil (.0.00635-mm)-thick hot-side and cold-side cover layers of molybdenum. Titanium nitride would be vapor-deposited on both surfaces of each cover layer. Between the cover layers there would be 10 inner layers of 0.15-mil (.0.0038-mm)-thick molybdenum with vapor-deposited titanium nitride on both sides of each layer. The thickness of each titanium nitride coat would be about 1,000 A. The cover and inner layers would be interspersed with 0.25-mil (0.00635-mm)-thick layers of carbon-carbon composite mesh. The blanket would have total thickness of 4.75 mils (approximately equal to 0.121 mm) and an areal mass density of 0.7 kilograms per square meter. One could, of course, increase the thermal- insulation capability of the blanket by increasing number of inner layers (thereby unavoidably increasing the total thickness and mass density).
Choi, Michael K.↗
Multidisciplinary Probabilistic Heat Transfer/Structural Analysis Code Developed: NESTEM
High-Speed Civil Transport (HSCT) engine combustor liners are subjected to complex thermal environments and have to endure these for thousands of hours with assured reliability. In the past, several deterministic analyses have been performed, including detailed heat transfer analyses to obtain thermal profiles and deterministic stress analyses to identify critical locations of high stresses. Actual rig tests also have been performed for segments by simulating these loading situations as closely as possible. However, it is well known that many uncertainties exist in loading (primarily thermal loads due to heat transfer), boundary conditions (end fixity unknowns), and material properties (moduli, thermal-expansion coefficients, and conductivities). The present in-house effort at the NASA Lewis Research Center is directed toward accounting for these in a formal way to assess the performance of liner components under complex and uncertain loading conditions as well as subject to other geometry- and material-related uncertainties.
Murthy, Pappu L. N.↗
The Idyllic Workplace
How many of us have worked in organizations where the discipline was so rigid and unyielding that it would send even a Marine Corps Drill Instructor screaming into the night? How many of us have worked in organizations where sightings of senior management were sporadic and rare, and any other interactions were by appointment only? Or, how many of us have worked in organizations where your role, absent specific direction, was to be seldom seen and rarely heard? And how many of us have worked in organizations where seemingly light itself was not permitted to escape without the acquiescence and approval of the director? Sadly, there are organizations that embody some of these conditions, and the resultant adverse effects on employee productivity, creativity and morale are profound. But what if you could work in an organization in which there was little hierarchy, where rank and seniority played no part, where there were no closed meetings or doors, where everyone knows what was expected of them, and where creativity was not only tolerated but encouraged and celebrated? Was there ever such a place? There was, and it was known as NASA's Space Station Task Force. I was fortunate enough to work there for a time, and I would like to tell you how this organization with few apparent rules led to incredibly high levels of employee satisfaction and fulfillment, and yielded work products of enduring quality. On May 20, 1982, NASA Administrator James M. Beggs established the Space Station Task Force under the direction of John D. Hodge. The Task Force was charged with the responsibility for "the development of the programmatic aspects of a Space Station as they evolve, including mission analysis, requirements definition and program management," and was authorized to draw on Space Station activities at the NASA Program Offices and Field Centers. No additional conditions or directions were provided. Hodge knew that in order to accomplish the job he had been given, he was going to have to obtain the services of the "best and the brightest" and facilitate the unleashing of the full force of their creative capabilities. In order to avoid the stultifying effects of a typical hierarchical organization, he set up a loosely structured, horizontal organization with only one supervisor of record - himself. He populated this organization with detailees from Headquarters, the field Centers and the Jet Propulsion Lab, thereby assuring himself of the political and technical expertise with which to deal with Congress and the bureaucracy, and conduct the required engineering studies and analyses.
Schoenfelder, Tony E.↗
Design of Long-Endurance Unmanned Airplanes Incorporating Solar and Fuel Cell Propulsion
Preliminary performance analysis and conceptual design are described for a class of unmanned airplanes possessing multi-day endurance capability. A mixed-mode electric power system incorporates solar cells for daytime energy production and a non-regenerative H2-02 fuel cell to supply energy for night flight. The power system provides energy for all onboard systems, including propulsion., payload, and avionics. Excess solar energy is available during significant portions of the day, and may be used for climbing, maneuvering, or payload functions. By jettisoning fuel cell reactant product (water) during flight, vehicle endurance may be increased under certain conditions. Empirical structure sizing algorithms are combined with low-Reynolds number aerodynamics algorithms to estimate airplane size and geometry to meet prescribed mission requirements. Initial calculations for summertime, high-altitude flight (above 40,000 ft (12 km)) at moderate latitude (31 deg N) indicate that mission endurance of several days may be possible for configurations having wing loadings on the order of 0.9 to 1.3 lb/ft(exp 2). These aircraft tend to be somewhat smaller than solar-powered aircraft previously conceived for multi-month endurance utilizing regenerative fuel cell systems for night flight.
Youngblood, James W.↗
Development of a Contingency Gas Analyzer for the Orion Crew Exploration Vehicle
NASA's experience with electrochemical sensors in a hand-held toxic gas monitor serves as a basis for the development of a fixed on-board instrument, the Contingency Gas Analyzer (CGA), for monitoring selected toxic combustion products as well as oxygen and carbon dioxide on the Orion Crew Exploration Vehicle (CEV). Oxygen and carbon dioxide are major components of the cabin environment and accurate measurement of these compounds is critical to maintaining a safe working environment for the crew. Fire or thermal degradation events may produce harmful levels of toxic products, including carbon monoxide (CO), hydrogen cyanide (HCN), and hydrogen chloride (HCl) in the environment. These three components, besides being toxic in their own right, can serve as surrogates for a panoply of hazardous combustion products. On orbit monitoring of these surrogates provides for crew health and safety by indicating the presence of toxic combustion products in the environment before, during and after combustion or thermal degradation events. Issues identified in previous NASA experiences mandate hardening the instrument and components to endure the mechanical and operational stresses of the CEV environment while maintaining high analytical fidelity. Specific functional challenges involve protecting the sensors from various anticipated events- such as rapid pressure changes, low cabin pressures, and extreme vibration/shock exposures- and extending the sensor lifetime and calibration periods far beyond the current state of the art to avoid the need for on-orbit calibration. This paper focuses on lessons learned from the earlier NASA hardware, current testing results, and engineering solutions to the identified problems. Of particular focus will be the means for protecting the sensors, addressing well known cross-sensitivity issues and the efficacy of a novel self monitoring mechanism for extending sensor calibration periods.
Niu, Bill↗
Characterizing Wheel-Soil Interaction Loads Using Meshfree Finite Element Methods: A Sensitivity Analysis for Design Trade Studies
A wheel experiencing sinkage and slippage events poses a high risk to planetary rover missions as evidenced by the mobility challenges endured by the Mars Exploration Rover (MER) project. Current wheel design practice utilizes loads derived from a series of events in the life cycle of the rover which do not include (1) failure metrics related to wheel sinkage and slippage and (2) performance trade-offs based on grouser placement/orientation. Wheel designs are rigorously tested experimentally through a variety of drive scenarios and simulated soil environments; however, a robust simulation capability is still in development due to myriad of complex interaction phenomena that contribute to wheel sinkage and slippage conditions such as soil composition, large deformation soil behavior, wheel geometry, nonlinear contact forces, terrain irregularity, etc. For the purposes of modeling wheel sinkage and slippage at an engineering scale, meshfree nite element approaches enable simulations that capture su cient detail of wheel-soil interaction while remaining computationally feasible. This study implements the JPL wheel-soil benchmark problem in the commercial code environment utilizing the large deformation modeling capability of Smooth Particle Hydrodynamics (SPH) meshfree methods. The nominal, benchmark wheel-soil interaction model that produces numerically stable and physically realistic results is presented and simulations are shown for both wheel traverse and wheel sinkage cases. A sensitivity analysis developing the capability and framework for future ight applications is conducted to illustrate the importance of perturbations to critical material properties and parameters. Implementation of the proposed soil-wheel interaction simulation capability and associated sensitivity framework has the potential to reduce experimentation cost and improve the early stage wheel design proce
terramechanics↗
Exercise countermeasures for bed-rest deconditioning
The purpose for this 30-day bed rest study was to investigate the effects of short-term, high intensity isotonic and isokinetic exercise training on maintenance of working capacity (peak oxygen uptake), muscular strength and endurance, and on orthostatic tolerance, posture and gait. Other data were collected on muscle atrophy, bone mineralization and density, endocrine analyses concerning vasoactivity and fluid-electrolyte balance, muscle intermediary metabolism, and on performance and mood of the subjects. It was concluded that: The subjects maintained a relatively stable mood, high morale, and high esprit de corps throughout the study. Performance improved in nearly all tests in almost all the subjects. Isotonic training, as opposed to isokinetic exercise training, was associated more with decreasing levels of psychological tension, concentration, and motivation; and improvement in the quality of sleep. Working capacity (peak oxygen uptake) was maintained during bed rest with isotonic exercise training; it was not maintained with isokinetic or no exercise training. In general, there was no significant decrease in strength or endurance of arm or leg muscles during bed rest, in spite of some reduction in muscle size (atrophy) of some leg muscles. There was no effect of isotonic exercise training on orthostasis, since tilt-table tolerance was reduced similarly in all three groups following bed rest. Bed rest resulted in significant decreases of postural stability and self-selected step length, stride length, and walking velocity, which were not influenced by either exercise training regimen. Most pre-bed rest responses were restored by the fourth day of recovery.
Greenleaf, John↗