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Miniaturized Reverse-Operation Differential Thermal Expansion (DTE) Thermal Switch (MINI-ROD-TSW)
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Soft Spherical Tensegrity Robot Design Using Rod-Centered Actuation and Control
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Extended Stroke and Miniaturized Reverse-Operation DTE Thermal Switches
This paper describes two advanced thermal switches under development that are offshoots of the recently flight-qualified 2500:1 reverse-operation differential thermal expansion (DTE) thermal switch (ROD-TSW). The first is the extended stroke ROD-TSW (ES-ROD-TSW) while the second is the miniaturized ROD-TSW (mini-ROD-TSW). Each employs multiple diametrically nested DTE stages in contrast to the single-stage ROD-TSW. The ES-ROD-TSW employs two stages and a negative CTE material known as Allvar and its main purpose is to extend its stroke for use in non-vacuum planetary environments. The mini-ROD-TSW employs four stages to miniaturize its size for use in compact lunar instruments and rovers. The ES-ROD-TSW was TVAC tested at JPL and its ON/OFF ratio is 13000:1 based on a measured ON conductance of 6.89 W/K and a calculated OFF conductance of 0.00053 W/K. The mini-ROD-TSW is targeted to have an ON conductance of 1.5 W/K and an OFF conductance of 0.0015 W/K, both verified by analysis. Test verification of the mini-ROD-TSW remains to be carried out. The paper will provide design/performance details of each device.
Finite Element Analysis of MEMS Devices
A side-slide actuator and a corrugated diaphragm actuator will be analyzed and optimized this summer. Coupled electrostatic and fluid analyses will also be initiated. Both the side-slide actuator and the corrugated diaphragm actuator will be used to regulate the flow of fuel in a jet engine. Many of the side-slide actuators will be placed on top of a fuel injector that is still in the developmental stage as well. The corrugated diaphragm actuator will also be used to regulate the flow of fuel in fuel injectors. A comparative analysis of the performance matrix of both actuators will be conducted. The side-slide actuator uses the concept of mechanical advantage to regulate the flow of fuel using electrostatic forces. It is made from Nickel, Silicon Carbide, and thin layers of Oxide. The slider will have a hole in the middle that will allow fuel to pass through the hole underneath it. The goal is to regulate the flow of fuel through the inlet. This means that the actuator needs to be designed so that when a voltage is applied to the push rod, the slider will deflect in the x-direction and be able to completely block the inlet and no fuel can pass through. Different voltage levels will be tested. The parameters that are being optimized are the thickness of the diaphragm, what kind of corrugation the diaphragm should have, the length, width, and thickness of the push rod, and what design should be used to return the slider. The current possibilities for a return rod are a built in spring on the slider, a return rod that acts like a spring, or a return rod that is identical to the push rod. The final actuator design should have a push rod that has rotational motion and no translation motion, a push rod thickness that prevents warping due to the slider, and a large ratio of the displacement on the bottom of the push rod to displacement on the top of the push rod. The corrugated diaphragm actuator was optimized last winter and this summer will be spent completing the optimization of the coupled electrostatic and fluid flow parameters. It was found that Nickel is the best material to use for the diaphragm because it has a higher yield strength and allows for a larger stress, deflection and applied pressure. The parameters that were optimized were the wavelength and thickness of the diaphragm.
Validation of an Accurate Three-Dimensional Helical Slow-Wave Circuit Model
The helical slow-wave circuit embodies a helical coil of rectangular tape supported in a metal barrel by dielectric support rods. Although the helix slow-wave circuit remains the mainstay of the traveling-wave tube (TWT) industry because of its exceptionally wide bandwidth, a full helical circuit, without significant dimensional approximations, has not been successfully modeled until now. Numerous attempts have been made to analyze the helical slow-wave circuit so that the performance could be accurately predicted without actually building it, but because of its complex geometry, many geometrical approximations became necessary rendering the previous models inaccurate. In the course of this research it has been demonstrated that using the simulation code, MAFIA, the helical structure can be modeled with actual tape width and thickness, dielectric support rod geometry and materials. To demonstrate the accuracy of the MAFIA model, the cold-test parameters including dispersion, on-axis interaction impedance and attenuation have been calculated for several helical TWT slow-wave circuits with a variety of support rod geometries including rectangular and T-shaped rods, as well as various support rod materials including isotropic, anisotropic and partially metal coated dielectrics. Compared with experimentally measured results, the agreement is excellent. With the accuracy of the MAFIA helical model validated, the code was used to investigate several conventional geometric approximations in an attempt to obtain the most computationally efficient model. Several simplifications were made to a standard model including replacing the helical tape with filaments, and replacing rectangular support rods with shapes conforming to the cylindrical coordinate system with effective permittivity. The approximate models are compared with the standard model in terms of cold-test characteristics and computational time. The model was also used to determine the sensitivity of various circuit parameters including typical manufacturing dimensional tolerances and support rod permittivity. By varying the circuit parameters of an accurate model using MAFIA, these sensitivities can be computed for manufacturing concerns, and design optimization previous to fabrication, thus eliminating the need for costly experimental iterations. Several variations were made to a standard helical circuit using MAFIA to investigate the effect that variations on helical tape and support rod width, metallized loading height and support rod permittivity, have on TWT cold-test characteristics.
Contactless heater floating zone refining and crystal growth
Floating zone refining or crystal growth is carried out by providing rapid relative rotation of a feed rod and finish rod while providing heat to the junction between the two rods so that significant forced convection occurs in the melt zone between the two rods. The forced convection distributes heat in the melt zone to allow the rods to be melted through with a much shorter melt zone length than possible utilizing conventional floating zone processes. One of the rods can be rotated with respect to the other, or both rods can be counter-rotated, with typical relative rotational speeds of the rods ranging from 200 revolutions per minute (RPM) to 400 RPM or greater. Zone refining or crystal growth is carried out by traversing the melt zone through the feed rod.
High-Powered, Ultrasonically Assisted Thermal Stir Welding
This method is a solid-state weld process capable of joining metallic alloys without melting. The weld workpieces to be joined by thermal stir welding (TSW) are drawn, by heavy forces, between containment plates past the TSW stir tool that then causes joining of the weld workpiece. TSW is similar to friction stir welding (FSW) in that material is heated into a plastic state (not melted) and stirred using a stir rod. The FSW pin tool is an integrated geometrical structure consisting of a large-diameter shoulder, and a smaller-diameter stir pin protruding from the shoulder. When the pin is plunged into a weld workpiece, the shoulder spins on the surface of the weld workpiece, thus inducing frictional heat into the part. The pin stirs the fraying surfaces of the weld joint, thus joining the weld workpiece into one structure. The shoulder and stir pin of the FSW pin tool must rotate together at a desired rotational speed. The induced frictional energy control and stir pin control of the pin tool cannot be de-coupled. The two work as one integrated unit. TSW, on the other hand, de-couples the heating and stirring of FSW, and allows for independent control of each process element. A uniquely designed induction coil heats the weld workpiece to a desired temperature, and once heated, the part moves into a stir rod whose RPM is also independently controlled. As the weld workpiece moves into the stir rod, the piece is positioned, or sandwiched, between upper and lower containment plates. The plate squeezes together, thus compressing the upper and lower surfaces of the weld workpiece. This compressive force, also called consolidation force, consolidates the plastic material within the weld nugget material as it is being stirred by the stir rod. The stir rod is positioned through the center of the top containment plate and protrudes midway through the opposite lower containment plate where it is mechanically captured. The upper and lower containment plates are separated by a distance equal to the thickness of the material being welded. The TSW process can be significantly improved by reducing the draw forces. This can be achieved by reducing the friction forces between the weld workpieces and the containment plates. High-power ultrasonic (HPU) vibrations of the containment plates achieve friction reduction in the TSW process. Furthermore, integration of the HPU energy into the TSW stir rod can increase tool life of the stir rod, and can reduce shear forces to which the stir rod is subjected during the welding process. TSW has been used to successfully join 0.500-in (≈13-mm) thick commercially pure (CP) titanium, titanium 6AL- 4V, and titanium 6AL-4V ELI in weld joint lengths up to 9 ft (≈2.75-m) long. In addition, the TSW process was used to fabricate a sub-scale hexagonally shaped gun turret component for the U.S. Navy. The turret is comprised of six 0.5000-in (≈13-mm) thick angled welds. Each angled weld joint was prepared by machining the mating surfaces to 120deg. The angled weld joint was then fixtured using an upper and lower containment plate of the same geometry of the angled weld joint. The weld joint was then stirred by the stir rod as it and the upper and lower containment plates traverse through the angled joint prep.
Quasi-containerless glass formation method and apparatus
Glass rods or fibers are prepared from a polycrystalline rod by heating a short section of the rod in a first furnace to form a molten zone of the rod, heating a second short section of the rod in a second furnace to form a second molten zone and gradually moving the furnaces apart from one another to form an elongated molten float zone, which is cooled in its midsection to produce a glass rod between the molten zones. In another embodiment a single moving furnace assembly and a precursor rod with compositional gradient sections, are used, and the moving furnace traverses the rod so that the molten portion is drawn out to a degree whereby a fiber of ultrapure glass is formed.
Test fixture for determination of energy absorbing capabilities of composite materials
The present invention provides a fixture for supporting an elongated specimen for crush testing. The fixture comprises a base plate, four guiding rods, a sliding plate, four support rods and two collars. The guiding rods connect to the base plate and extend in a direction substantially perpendicular to the base plate. The sliding plate has linear bearings which encircle the guiding rods and enable translation of the sliding plate along the axis of each guiding rod. The four supporting rods mount to the base plate and also extend in a direction substantially perpendicular to the base plate. Each support rod has a keyway for a wedge which contacts the elongated specimen and holds the specimen in place during crushing. Each collar lies above the sliding plate and holds a pair of support rods on their ends opposite the ends connected to the base plate. A spherical bearing sits on top of the sliding plate and transfers an applied load to the sliding plate, which moves downward and crushes the elongated specimen.
Test Fixture for Determination of Energy Absorbing Capabilities of Composite Materials
The present invention provides a fixture for supporting an elongated specimen for crush testing. The fixture comprises a base plate. four guiding rods, a sliding plate, four support rods and two collars. The guiding rods connect to the base plate and extend in a direction substantially perpendicular to the base plate. The sliding plate has linear bearings which encircle the guiding rods and enable translation of the sliding plate along the axis of each guiding rod. The four supporting rods mount to the base plate and also extend in a direction substantially perpendicular to the base plate. Each support rod has a keyway for a wedge which contacts the elongated specimen and holds the specimen in place during crushing. Each collar lies above the sliding plate and holds a pair of support rods on their ends opposite the ends connected to the base plate. A spherical bearing sits on top of the sliding plate and transfers an applied load to the sliding plate, which moves downward and crushes the elongated specimen.
Miniature quadrupole mass spectrometer array
The present invention provides a minature quadrupole mass spectrometer array for the separation of ions, comprising a first pair of parallel, planar, nonmagnetic conducting rods each having an axis of symmetry, a second pair of planar, nonmagnetic conducting rods each having an axis of symmetry parallel to said first pair of rods and disposed such that a line perpendicular to each of said first axes of symmetry and a line perpendicular to each of said second axes of symmetry bisect each other and form a generally 90 degree angle. A nonconductive top positioning plate is positioned generally perpendicular to the first and second pairs of rods and has an aperture for ion entrance along an axis equidistant from each axis of symmetry of each of the parallel rods, a nonconductive bottom positioning plate is generally parallel to the top positioning plate and has an aperture for ion exit centered on an axis equidistant from each axis of symmetry of each of the parallel rods, means for maintaining a direct current voltage between the first and second pairs of rods, and means for applying a radio frequency voltage to the first and second pairs of rods.
Miniature quadrupole mass spectrometer array
The present invention provides a minature quadrupole mass spectrometer array for the separation of ions, comprising a first pair of parallel, planar, nonmagnetic conducting rods each having an axis of symmetry, a second pair of planar, nonmagnetic conducting rods each having an axis of symmetry parallel to said first pair of rods and disposed such that a line perpendicular to each of said first axes of symmetry and a line perpendicular to each of said second axes of symmetry bisect each other and form a generally 90 degree angle. A nonconductive top positioning plate is positioned generally perpendicular to the first and second pairs of rods and has an aperture for ion entrance along an axis equidistant from each axis of symmetry of each of the parallel rods, a nonconductive bottom positioning plate is generally parallel to the top positioning plate and has an aperture for ion exit centered on an axis equidistant from each axis of symmetry of each of the parallel rods, means for maintaining a direct current voltage between the first and second pairs of rods, and means for applying a radio frequency voltage to the first and second pairs of rods.
Nuclear thermionic converter
Efficient nuclear reactor thermionic converter units are described which can be constructed at low cost and assembled in a reactor which requires a minimum of fuel. Each converter unit utilizes an emitter rod with a fluted exterior, several fuel passages located in the bulges that are formed in the rod between the flutes, and a collector receiving passage formed through the center of the rod. An array of rods is closely packed in an interfitting arrangement, with the bulges of the rods received in the recesses formed between the bulges of other rods, thereby closely packing the nuclear fuel. The rods are constructed of a mixture of tungsten and thorium oxide to provide high power output, high efficiency, high strength, and good machinability.
Sound shield
An improved test section for a supersonic or hypersonic wind tunnel is disclosed wherein the model tested is shielded from the noise normally radiated by the turbulent tunnel wall boundary layer. A vacuum plenum surrounds spaced rod elements making up the test chamber to extract some of the boundary layer as formed along the rod elements during a test to thereby delay the tendency of the rod boundary layers to become turbulent. Novel rod construction involves bending each rod slightly prior to machining the bent area to provide a flat segment on each rod for connection with the flat entrance fairing. Rods and fairing are secured to provide a test chamber incline on the order of 1 deg outward from the noise shield centerline to produce up to 65% reduction of the root mean square (rms) pressure over previously employed wind tunnel test sections at equivalent Reynolds numbers.
Automatic compression adjusting mechanism for internal combustion engines
Means for controlling the compression pressure in an internal combustion engine having one or more cylinders and subject to widely varying power output requirements are provided. Received between each crank pin and connecting rod is an eccentric sleeve selectively capable of rotation about the crank pin and/or inside the rod and for latching with the rod to vary the effective length of the connecting rod and thereby the clearance volume of the engine. The eccentric normally rotates inside the connecting rod during the exhaust and intake strokes but a latching pawl carried by the eccentric is movable radially outwardly to latch the rod and eccentric together during the compression and power strokes. A control valve responds to intake manifold pressure to time the supply of hydraulic fluid to move the latch-pawl outwardly, varying the effective rod length to maintain a substantially optimum firing chamber pressure at all intake manifold pressures.
Liquid encapsulated float zone process and apparatus
The process and apparatus for growing crystals using float zone techniques are described. A rod of crystalline materials is disposed in a cylindrical container, leaving a space between the rod and container walls. This space is filled with an encapsulant, selected to have a slightly lower melting point than the crystalline material. The rod is secured to a container end cap at one end and to a shaft at its other end. A piston slides over the rod and provides pressure to prevent loss of volatile components upon melting of the rod. Prior to melting the rod the container is first heated to melt the encapsulant, with any off-gas from this step being vented to a cavity behind the piston. The piston moves slightly forward owing to volume change upon melting of the encapsulant, and the vent passageway is closed. The container is then moved longitudinally through a heated zone to progressively melt sections of the rod as in conventional float zone processes. The float zone technique may be used in the microgravity environment of space.
Method of making single crystal fibers
Single crystal fibers are made from miniature extruded ceramic feed rods. A decomposable binder is mixed with powders to inform a slurry which is extruded into a small rod which may be sintered, either in air or in vacuum, or it may be used in the extruded and dried condition. A pair of laser beams focuses onto the tip of the rod to melt it thereby forming a liquid portion. A single crystal seed fiber of the same material as the feed rod contacts this liquid portion to establish a zone of liquid material between the feed rod and the single crystal seed fiber. The feed rod and the single crystal feed fiber are moved at a predetermined speed to solidify the molten zone onto the seed fiber while simultaneously melting additional feed rod. In this manner a single crystal fiber is formed from the liquid portion.