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NASA NTRSDate not supplied

The Impacts of Heating Actuators in Extremely Cold Space Environments

Conventional, grease-lubricated actuators for space mechanisms can achieve long life but must be heated above about 213 K, or -60 °C, to function in extremely cold environments. This paper first overviews a new NASA project that is developing two rotational actuators that can achieve long life without the need for supplemental heating. Then, the impacts of heating conventional, grease-lubricated actuators are studied for operation in a lunar permanently shadowed region. To facilitate the assessment, a novel total efficiency metric is introduced that relates the average power output to the average total power input (i.e., the power to heat plus the power to actuate/rotate). The assessment employs a thermal analysis of the energy required to heat an actuator from a survival temperature of 30 K to 213 K as well as the power required to subsequently maintain 213 K while in an operational state. Two concepts of actuator operation are considered that separately highlight the impacts of warmup heating energy and maintenance heater power. It is shown that in practical situations, the perceived efficiency of an actuator with 100% conventional operating efficiency can reach 10% or lower, particularly when the actuator has a high emissivity and is operated at lower duty cycles for durations less than 10 hours. Other impacts are presented along with a method of mitigating the impacts in some applications.

Extreme Environments↗

NASA NTRS2020

Efficient Thermal Management for Sampling Arm Actuators

An electric actuator incorporating novel features for thermal management is designed and analyzed. Reducing intra-actuator thermal resistance is not only beneficial for cold missions (helping to pre-heat the gearbox) but can also enable high power applications in benign environments. The proposed design increases the thermal conductance between the motor windings and the motor casing by at least two orders of magnitude over the state of practice actuator designs. The design leverages Additive Manufacturing (AM) to integrate a complex 3 dimensional Oscillating Heat Pipe (OHP) directly within the actuator structure. A baseline actuator without this thermal management feature was fabricated. Testing was conducted to evaluate the temperature difference between actuator components at a range of motor winding heat dissipations. An analysis of a proposed revised design incorporating OHPs into the input structure indicated an increase in the effective thermal conductivity of 8 and 22 times for the nominal and start-up modes respectively. In addition, the thermal conductance between the windings and the input structure is increased by a factor of 90, and the thermal conductance between the windings and the gear assembly is increased by a factor of 200 with the proposed design.

Odagiri, Kimihide↗

NASA NTRSDate not supplied

The Impacts of Heating Actuators in Extremely Cold Space Environments

space actuator↗

NASA NTRS2010

Miniature Piezoelectric Shaker for Distribution of Unconsolidated Samples to Instrument Cells

The planned Mars Science Laboratory mission requires inlet funnels for channeling unconsolidated powdered samples from the sampling and sieving mechanisms into instrument test cells, which are required to reduce cross-contamination of the samples and to minimize residue left in the funnels after each sample transport. To these ends, a solid-state shaking mechanism has been created that requires low power and is lightweight, but is sturdy enough to survive launch vibration. The funnel mechanism is driven by asymmetrically mounted, piezoelectric flexure actuators that are out of the load path so that they do not support the funnel mass. Each actuator is a titanium, flextensional piezoelectric device driven by a piezoelectric stack. The stack has Invar endcaps with a half-spherical recess. The Invar is used to counteract the change in stress as the actuators are cooled to Mars ambient temperatures. A ball screw is threaded through the actuator frame into the recess to apply pre-stress, and to trap the piezoelectric stack and endcaps in flexure. During the vibration cycle of the flextensional actuator frame, the compression in the piezoelectric stack may decrease to the point that it is unstressed; however, because the ball joint cannot pull, tension in the piezoelectric stack cannot be produced. The actuators are offset at 120 . In this flight design, redundancy is required, so three actuators are used though only one is needed to assist in the movement. The funnel is supported at three contact points offset to the hexapod support contacts. The actuator surface that does not contact the ring is free to expand. Two other configurations can be used to mechanically tune the vibration. The free end can be designed to drive a fixed mass, or can be used to drive a free mass to excite impacts (see figure). Tests on this funnel mechanism show a high density of resonance modes between 1 and 20 kHz. A subset of these between 9 and 12 kHz was used to drive the CheMin actuators at 7 V peak to peak. These actuators could be driven by a single resonance, or swept through a frequency range to decrease the possibility that a portion of the funnel surface was not coincident with a nodal line (line of no displacement). The frequency of actuation can be electrically controlled and monitored and can also be mechanically tuned by the addition of tuning mass on the free end of the actuator. The devices are solid-state and can be designed with no macroscopically moving parts. This design has been tested in a vacuum at both Mars and Earth ambient temperatures ranging from 30 to 25 C

Sherrit, Stewart↗

NASA NTRS2000

Demonstration of Plasma Arc Environmental Technology Applications for the Demilitrization of DOD Stockpiles

Since 1989 the US Army Construction Engineering Research Laboratories (USACERL) have been active participants in the research and development towards establishing Plasma Arc Technology (PAT) as an efficient, economical, and safe hazardous waste immobilization tool. A plasma torch capable of generating high temperatures makes this technology a viable and powerful tool for the thermal destruction of various military industrial waste streams into an innocuous ceramic material no longer requiring hazardous waste landfill disposal. The emerging plasma environmental thermal treatment process has been used to safely and efficiently meet the waste disposal needs for various demilitarized components disposal needs, such as: (1) pyrotechnic smoke assemblies, (2) thermal batteries, (3) proximity fuses, (4) cartridge actuated devices (CADs), and (5) propellant actuated devices (PADs). MSE Technology Applications, Inc., (MSE) has proposed and fabricated a Mobile Plasma Treatment System to be a technology demonstrator for pilotscale mobile plasma waste processing. The system is capable of providing small-scale waste remediation services, and conducting waste stream applicability demonstrations. The Mobile Plasma Treatment System's innovative concept provides the flexibility to treat waste streams at numerous sites and sites with only a limited quantity of waste, yet too hazardous to transport to a regional fixed facility. The system was designed to be operated as skid mounted modules; consisting of a furnace module, controls module, offgas module, and ancillary systems module. All system components have been integrated to be operated from a single control station with both semi-continuous feeding and batch slag-pouring capability.

Smith, Ed↗

NASA NTRS2004

Programmable 2-D Addressable Cryogenic Aperture Masks

We are developing a two-dimensional array of square microshutters (programmable aperture mask) for a multi-object spectrometer for the James Webb Space Telescope (JWST). This device will provide random access selection of the areas in the field to be studied. The device is in essence a close packed array of square slits, each of which can be opened independently to select areas of the sky for detailed study.The device is produced using a 100-micron thick silicon wafer as a substrate with 0.5-micron thick silicon nitride shutters on top of it. Silicon nitride has been selected as the blade and flexure material because its stiffness allows thinner and lighter structures than single crystal Si, the chief alternative, and because of its ease of manufacture. The 100 micron silicon wafer is backetched in a high aspect ratio Deep Reactive Ion Etching (Deep RIE) to leave only a support grid for the shutters and the address electronics. The shutter actuation is done magnetically whereas addressing is electrostatic. 128x128 format microshutter arrays have been produced. Their operation has been demostarted on 32x32 subarrays. Good reliability of the fabrication process and good quality of the microshutters has been achieved. The mechanical behavior and optical performance of the fabricated arrays at cryogenic temperature are being studied.

Kutyrev, A. S.↗

NASA NTRS2003

Commercialization of NASA's High Strength Cast Aluminum Alloy for High Temperature Applications

In this paper, the commercialization of a new high strength cast aluminum alloy, invented by NASA-Marshall Space Flight Center, for high temperature applications will be presented. Originally developed to meet U.S. automotive legislation requiring low- exhaust emission, the novel NASA aluminum alloy offers dramatic improvement in tensile and fatigue strengths at elevated temperatures (450 F-750 F), which can lead to reducing part weight and cost as well as improving performance for automotive engine applications. It is an ideal low cost material for cast components such as pistons, cylinder heads, cylinder liners, connecting rods, turbo chargers, impellers, actuators, brake calipers and rotors. NASA alloy also offers greater wear resistance, dimensional stability, and lower thermal expansion compared to conventional aluminum alloys, and the new alloy can be produced economically from sand, permanent mold and investment casting. Since 2001, this technology was licensed to several companies for automotive and marine internal combustion engines applications.

Lee, Jonathan A.↗

NASA NTRS2007

JWST Lightweight Mirror TRL-6 Results

Mirror technology for a Primary Mirror Segment Assembly (PMSA) is a system of components: reflective coating; polished optical surface; mirror substrate; actuators, mechanisms and flexures; and reaction structure. The functional purpose of a PMSA is to survive launch, deploy and align itself to form a 25 square meter collecting area 6.5 meter diameter primary mirror with a 131 nm rms wavefront error at temperatures less than 50K and provide stable optical performance for the anticipated thermal environment. At the inception of JWST in 1996, such a capability was at a Technology Readiness Level (TRL) of 3. A highly successful technology development program was initiated including the Sub-scale Beryllium Mirror Demonstrator (SBMD) and Advanced Mirror System Demonstrator (AMSD) projects. These projects along with flight program activities have matured mirror technology for JWST to TRL-6. A directly traceable prototype (and in some cases the flight hardware itself) has been built, tested and operated in a relevant environment.

Stahl, H. Philip↗

NASA NTRS2002

Heated Surface Temperatures Measured by Infrared Detector in a Cascade Environment

Investigators have used infrared devices to accurately measure heated surface temperatures. Several of these applications have been for turbine heat transfer studies involving film cooling and surface roughness, typically, these measurements use an infrared camera positioned externally to the test section. In cascade studies, where several blades are used to ensure periodic flow, adjacent blades block the externally positioned camera's views of the test blade. To obtain a more complete mapping of the surface temperatures, researchers at the NASA Glenn Research Center fabricated a probe with an infrared detector to sense the blade temperatures. The probe size was kept small to minimize the flow disturbance. By traversing and rotating the probe, using the same approach as for total pressure surveys, one can find the blade surface temperatures. Probe mounted infrared detectors are appropriate for measuring surface temperatures where an externally positioned infrared camera is unable to completely view the test object. This probe consists of a 8-mm gallium arsenide (GaAs) lens mounted in front of a mercury-cadmium-zinc-tellurium (HgCdZnTe) detector. This type of photovoltaic detector was chosen because of its high sensitivity to temperature when the detector is uncooled. The particular application is for relatively low surface temperatures, typically ambient to 100 C. This requires a detector sensitive at long wavelengths. The detector is a commercial product enclosed in a 9-mm-diameter package. The GaAs lens material was chosen because of its glass-like hardness and its good long-wavelength transmission characteristics. When assembled, the 6.4-mm probe stem is held in the traversing actuator. Since the entire probe is above the measurement plane, the flow field disturbance in the measurement plane is minimized. This particular probe body is somewhat wider than necessary, because it was designed to have replaceable detectors and lenses. The signal for the detector is fed through the hollow probe body. The detector's signal goes to an externally mounted preamplifier. The detector assembly, along with a preamplifier, is calibrated as a function of the surface temperature for various detector temperatures. The output voltage is a function of both the detector and object temperatures.

Boyle, Robert J.↗

NASA NTRS2007

NASA Tech Briefs, July 2007

Topics covered include: Miniature Intelligent Sensor Module; "Smart" Sensor Module; Portable Apparatus for Electrochemical Sensing of Ethylene; Increasing Linear Dynamic Range of a CMOS Image Sensor; Flight Qualified Micro Sun Sensor; Norbornene-Based Polymer Electrolytes for Lithium Cells; Making Single-Source Precursors of Ternary Semiconductors; Water-Free Proton-Conducting Membranes for Fuel Cells; Mo/Ti Diffusion Bonding for Making Thermoelectric Devices; Photodetectors on Coronagraph Mask for Pointing Control; High-Energy-Density, Low-Temperature Li/CFx Primary Cells; G4-FETs as Universal and Programmable Logic Gates; Fabrication of Buried Nanochannels From Nanowire Patterns; Diamond Smoothing Tools; Infrared Imaging System for Studying Brain Function; Rarefying Spectra of Whispering-Gallery-Mode Resonators; Large-Area Permanent-Magnet ECR Plasma Source; Slot-Antenna/Permanent-Magnet Device for Generating Plasma; Fiber-Optic Strain Gauge With High Resolution And Update Rate; Broadband Achromatic Telecentric Lens; Temperature-Corrected Model of Turbulence in Hot Jet Flows; Enhanced Elliptic Grid Generation; Automated Knowledge Discovery From Simulators; Electro-Optical Modulator Bias Control Using Bipolar Pulses; Generative Representations for Automated Design of Robots; Mars-Approach Navigation Using In Situ Orbiters; Efficient Optimization of Low-Thrust Spacecraft Trajectories; Cylindrical Asymmetrical Capacitors for Use in Outer Space; Protecting Against Faults in JPL Spacecraft; Algorithm Optimally Allocates Actuation of a Spacecraft; and Radar Interferometer for Topographic Mapping of Glaciers and Ice Sheets.

Source record↗

NASA NTRS1995

Active Flow Control: Instrumentation Automation and Experimental Technique

In investigating the potential of a new actuator for use in an active flow control system, several objectives had to be accomplished, the largest of which was the experimental setup. The work was conducted at the NASA Langley 20x28 Shear Flow Control Tunnel. The actuator named Thunder, is a high deflection piezo device recently developed at Langley Research Center. This research involved setting up the instrumentation, the lighting, the smoke, and the recording devices. The instrumentation was automated by means of a Power Macintosh running LabVIEW, a graphical instrumentation package developed by National Instruments. Routines were written to allow the tunnel conditions to be determined at a given instant at the push of a button. This included determination of tunnel pressures, speed, density, temperature, and viscosity. Other aspects of the experimental equipment included the set up of a CCD video camera with a video frame grabber, monitor, and VCR to capture the motion. A strobe light was used to highlight the smoke that was used to visualize the flow. Additional effort was put into creating a scale drawing of another tunnel on site and a limited literature search in the area of active flow control.

Gimbert, N. Wes↗

NASA NTRS2008

Method for Thermal Spraying of Coatings Using Resonant-Pulsed Combustion

A method has been devised for high-volume, high-velocity surface deposition of protective metallic coatings on otherwise vulnerable surfaces. Thermal spraying is used whereby the material to be deposited is heated to the melting point by passing through a flame. Rather than the usual method of deposition from the jet formed from the combustion products, this innovation uses non-steady combustion (i.e. high-frequency, periodic, confined bursts), which generates not only higher temperatures and heat transfer rates, but exceedingly high impingement velocities an order of magnitude higher than conventional thermal systems. Higher impingement rates make for better adhesion. The high heat transfer rates developed here allow the deposition material to be introduced, not as an expensive powder with high surface-area-to-volume, but in convenient rod form, which is also easier and simpler to feed into the system. The nonsteady, resonant combustion process is self-aspirating and requires no external actuation or control and no high-pressure supply of fuel or air. The innovation has been demonstrated using a commercially available resonant combustor shown in the figure. Fuel is naturally aspirated from the tank through the lower Tygon tube and into the pulsejet. Air for starting is ported through the upper Tygon tube line. Once operation commences, this air is no longer needed as additional air is naturally aspirated through the inlet. A spark plug on the device is needed for starting, but the process carries on automatically as the operational device is resonant and reignites itself with each 220-Hz pulse.

Paxson, Daniel E.↗

NASA NTRS2000

Validation of High Displacement Piezoelectric Actuator Finite Element Models

The paper presents the results obtained by using NASTRAN(Registered Trademark) and ANSYS(Regitered Trademark) finite element codes to predict doming of the THUNDER piezoelectric actuators during the manufacturing process and subsequent straining due to an applied input voltage. To effectively use such devices in engineering applications, modeling and characterization are essential. Length, width, dome height, and thickness are important parameters for users of such devices. Therefore, finite element models were used to assess the effects of these parameters. NASTRAN(Registered Trademark) and ANSYS(Registered Trademark) used different methods for modeling piezoelectric effects. In NASTRAN(Registered Trademark), a thermal analogy was used to represent voltage at nodes as equivalent temperatures, while ANSYS(Registered Trademark) processed the voltage directly using piezoelectric finite elements. The results of finite element models were validated by using the experimental results.

Taleghani, B. K.↗

NASA NTRS1995

Thermal Switch for Satellite Temperature Control

An active radiator tile (ART) thermal valve has been fabricated using silicon micromachining. Intended for orbital satellite heat control applications, the operational principal of the ART is to control heat flow between two thermally isolated surfaces by bring the surfaces into intimate mechanical contact using electrostatic actuation. Prototype devices have been tested in a vacuum and demonstrate thermal actuation voltages as low as 40 volts, very good thermal insulation in the OFF state, and a large increase in radiative heat flow in the ON state. Thin, anodized aluminum was developed as a coating for high infrared emissivity and high solar reflectance.

Ziad, H.↗

NASA NTRS2010

Ultrasonic/Sonic Drill for High Temperature Application

Venus is one of the many significant scientific targets for NASA. New rock sampling tools with the ability to be operated at high temperatures of the order of 460 deg C are required for surface in-situ sampling/analysis missions. Piezoelectric materials such as LiNbO? crystals and Bismuth Titanate are potentially operational at the temperature range found on the surface of Venus. A study of the feasibility of producing piezoelectric drills for a temperature up to 500 deg C was conducted. The study includes investigation of the high temperature properties of piezoelectric crystals and ceramics with different formulas and doping. Several prototypes of Ultrasonic/Sonic Drill/Corers (USDC) driven by transducers using the high temperate piezoelectric ceramics and single LiNbO? crystal were fabricated. The transducers were analyzed by scanning the impedance at room temperature and 500 deg C under both low and high voltages. The drilling performances were tested at temperature up to 500 deg C. Preliminary results were previously reported [Bao et al, 2009]. In this paper, the progress is presented and the future works for performance improvements are discussed.

Piezoelectric Drill↗

NASA NTRS2009

NASA Tech Briefs, March 2009

Topics covered include: Improved Instrument for Detecting Water and Ice in Soil; Real-Time Detection of Dust Devils from Pressure Readings; Determining Surface Roughness in Urban Areas Using Lidar Data; DSN Data Visualization Suite; Hamming and Accumulator Codes Concatenated with MPSK or QAM; Wide-Angle-Scanning Reflectarray Antennas Actuated by MEMS; Biasable Subharmonic Membrane Mixer for 520 to 600 GHz; Hardware Implementation of Serially Concatenated PPM Decoder; Symbolic Processing Combined with Model-Based Reasoning; Presentation Extensions of the SOAP; Spreadsheets for Analyzing and Optimizing Space Missions; Processing Ocean Images to Detect Large Drift Nets; Alternative Packaging for Back-Illuminated Imagers; Diamond Machining of an Off-Axis Biconic Aspherical Mirror; Laser Ablation Increases PEM/Catalyst Interfacial Area; Damage Detection and Self-Repair in Inflatable/Deployable Structures; Polyimide/Glass Composite High-Temperature Insulation; Nanocomposite Strain Gauges Having Small TCRs; Quick-Connect Windowed Non-Stick Penetrator Tips for Rapid Sampling; Modeling Unsteady Cavitation and Dynamic Loads in Turbopumps; Continuous-Flow System Produces Medical-Grade Water; Discrimination of Spore-Forming Bacilli Using spoIVA; nBn Infrared Detector Containing Graded Absorption Layer; Atomic References for Measuring Small Accelerations; Ultra-Broad-Band Optical Parametric Amplifier or Oscillator; Particle-Image Velocimeter Having Large Depth of Field; Enhancing SERS by Means of Supramolecular Charge Transfer; Improving 3D Wavelet-Based Compression of Hyperspectral Images; Improved Signal Chains for Readout of CMOS Imagers; SOI CMOS Imager with Suppression of Cross-Talk; Error-Rate Bounds for Coded PPM on a Poisson Channel; Biomorphic Multi-Agent Architecture for Persistent Computing; and Using Covariance Analysis to Assess Pointing Performance.

Source record↗

NASA NTRS1994

System Would Regulate Low Gas Pressure

System intended to maintain gases in containers at pressures near atmospheric. Includes ballast volume in form of underinflated balloon that communicates with working volume. Balloon housed in rigid chamber not subjected to extremes of temperature of working volume. Pressure in chamber surrounding balloon regulated at ambient atmospheric pressure or at constant small differential pressure above or below ambient. Expansion and contraction of balloon accommodates expansion or contraction of gas during operational heating or cooling in working volume, maintaining pressure in working volume at ambient or constant differential above or below ambient. Gas lost from system due to leakage or diffusion, low-pressure sensor responds, signaling valve actuators to supply more gas to working volume. If pressure rises too high, overpressure relief valve opens before excessive pressure damages system.

Frazer, Robert E.↗

NASA NTRS2005

Utilizing Radioisotope Power System Waste Heat for Spacecraft Thermal Management

An advantage of using a Radioisotope Power System (RPS) for deep space or planetary surface missions is the readily available waste heat, which can be used for a number of beneficial purposes including: maintaining electronic components within a controlled temperature range, warming propulsion tanks and mobility actuators, and maintaining liquid propellants above their freezing temperature. Previous missions using Radioisotope Thermoelectric Generators (RTGs) dissipated large quantities of waste heat due to the low efficiency of the thermoelectric conversion technology. The next generation RPSs, such as the 110-Watt Stirling Radioisotope Generator (SRG110) will have higher conversion efficiencies, thereby rejecting less waste heat at a lower temperature and may require alternate approaches to transferring waste heat to the spacecraft. RTGs, with efficiencies of ~6 to 7 percent, reject their waste heat at the relatively high heat rejection temperature of 200 C. This is an advantage when rejecting heat to space; however, transferring heat to the internal spacecraft components requires a large and heavy radiator heat exchanger. At the same time, sensitive spacecraft instruments must be shielded from the thermal radiation of the RTG. The SRG110, with an efficiency around 22 percent and 50 C nominal housing surface temperature, can readily transfer the available waste heat directly via heat pipes, thermal straps, or fluid loops. The lower temperatures associated with the SRG110 avoid the chances of overheating other scientific components, eliminating the need for thermal shields. This provides the spacecraft designers more flexibility when locating the generator for a specific mission. A common misconception with high-efficiency systems is that there is not enough waste heat for spacecraft thermal management. This paper will dispel this misconception and investigate the use of a high-efficiency SRG110 for spacecraft thermal management and outline potential methods of waste heat utilization in several conceptual missions (Lunar Rover, Mars Rover, and Titan Lander). The advantages associated with the SRG110 as they relate to ease of assembly, less complex interfaces, and overall mass savings for a spacecraft will be highlighted.

Pantano, David R.↗