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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS1991

Welding technology transfer task/laser based weld joint tracking system for compressor girth welds

Sensors to control and monitor welding operations are currently being developed at Marshall Space Flight Center. The laser based weld bead profiler/torch rotation sensor was modified to provide a weld joint tracking system for compressor girth welds. The tracking system features a precision laser based vision sensor, automated two-axis machine motion, and an industrial PC controller. The system benefits are elimination of weld repairs caused by joint tracking errors which reduces manufacturing costs and increases production output, simplification of tooling, and free costly manufacturing floor space.

Looney, Alan↗
NASA NTRS1995

Suspension system for gimbal supported scanning payloads

Gimballed scanning devices or instruments are the subject of this invention. Scanning is an important aspect of space science. To achieve a scan pattern some means must be provided which impart to the payload an oscillatory motion. Various forms of machines have been employed for controllably conferring on scanning instruments predetermined scan patterns. They include control moment gyroscopes, reaction wheels, torque motors, reaction control systems, and the like. But rotating unbalanced mass (RUM) devices are a new and efficient way to generate scans in gimballed payloads. RUM devices are superior to previous scanning apparatus, but they require power consuming and frequently complex auxiliary control systems to position and reposition the particular scan pattern relative to a target or a number of targets. Herein the control system is simplified. The most frequently employed method for achieving the various scan patterns is to gimbal the scanning device. Gimbals are suspended in such a way that they can be activated to generate the scan pattern. The suspension means described is for payloads supported in gimbals wherein the payload rotation is restricted by a flex pivot so that the payload oscillates, thereby moving in a scan pattern.

Polites, Michael E.↗
NASA NTRS2004

Distribution of Inclusion-Initiated Fatigue Cracking in Powder Metallurgy Udimet 720 Characterized

In the absence of extrinsic surface damage, the fatigue life of metals is often dictated by the distribution of intrinsic defects. In powder metallurgy (PM) alloys, relatively large defects occur rarely enough that a typical characterization with a limited number of small volume fatigue test specimens will not adequately sample inclusion-initiated damage. Counterintuitively, inclusion-initiated failure has a greater impact on the distribution in PM alloy fatigue lives because they tend to have fewer defects than their cast and wrought counterparts. Although the relative paucity of defects in PM alloys leads to higher mean fatigue lives, the distribution in observed lives tends to be broader. In order to study this important failure initiation mechanism without expending an inordinate number of specimens, a study was undertaken at the NASA Glenn Research Center where known populations of artificial inclusions (seeds) were introduced to production powder. Fatigue specimens were machined from forgings produced from the seeded powder. Considerable effort has been expended in characterizing the crack growth rate from inclusion-initiated cracks in seeded PM alloys. A rotating and translating positioning system, with associated software, was devised to map the surface inclusions in low-cycle fatigue (LCF) test bars and to monitor the crack growth from these inclusions. The preceding graph illustrates the measured extension in fatigue cracks from inclusions on a seeded LCF test bar subjected to cyclic loading at a strain range of 0.8 percent and a strain ratio (max/min) of zero. Notice that the observed inclusions fall into three categories: some do not propagate at all (arrest), some propagate with a decreasing crack growth rate, and a few propagate at increasing rates that can be modeled by fracture mechanics. The following graph shows the measured inclusion-initiated crack growth rates from 10 interrupted LCF tests plotted against stress intensities calculated for semi-elliptical cracks with the observed surface lengths. The expected scatter in the crack growth rates for stress intensity ranges near threshold is observed. These data will be used to help determine the distribution in growth rates of cracks emanating from inclusions as well as the proportion of cracks that arrest under various loading conditions.

Bonacuse, Peter J.↗
NASA NTRS1994

Optically Aligned Drill Press

Precise drill press equipped with rotary-indexing microscope. Microscope and drill exchange places when turret rotated. Microscope axis first aligned over future hole, then rotated out of way so drill axis assumes its precise position. New procedure takes less time to locate drilling positions and produces more accurate results. Apparatus adapted to such other machine tools as milling and measuring machines.

Adderholdt, Bruce M.↗
NASA NTRS2011

Miniaturized Airborne Imaging Central Server System

In recent years, some remote-sensing applications require advanced airborne multi-sensor systems to provide high performance reflective and emissive spectral imaging measurement rapidly over large areas. The key or unique problem of characteristics is associated with a black box back-end system that operates a suite of cutting-edge imaging sensors to collect simultaneously the high throughput reflective and emissive spectral imaging data with precision georeference. This back-end system needs to be portable, easy-to-use, and reliable with advanced onboard processing. The innovation of the black box backend is a miniaturized airborne imaging central server system (MAICSS). MAICSS integrates a complex embedded system of systems with dedicated power and signal electronic circuits inside to serve a suite of configurable cutting-edge electro- optical (EO), long-wave infrared (LWIR), and medium-wave infrared (MWIR) cameras, a hyperspectral imaging scanner, and a GPS and inertial measurement unit (IMU) for atmospheric and surface remote sensing. Its compatible sensor packages include NASA s 1,024 1,024 pixel LWIR quantum well infrared photodetector (QWIP) imager; a 60.5 megapixel BuckEye EO camera; and a fast (e.g. 200+ scanlines/s) and wide swath-width (e.g., 1,920+ pixels) CCD/InGaAs imager-based visible/near infrared reflectance (VNIR) and shortwave infrared (SWIR) imaging spectrometer. MAICSS records continuous precision georeferenced and time-tagged multisensor throughputs to mass storage devices at a high aggregate rate, typically 60 MB/s for its LWIR/EO payload. MAICSS is a complete stand-alone imaging server instrument with an easy-to-use software package for either autonomous data collection or interactive airborne operation. Advanced multisensor data acquisition and onboard processing software features have been implemented for MAICSS. With the onboard processing for real time image development, correction, histogram-equalization, compression, georeference, and data organization, fast aerial imaging applications, including the real time LWIR image mosaic for Google Earth, have been realized for NASA fs LWIR QWIP instrument. MAICSS is a significant improvement and miniaturization of current multisensor technologies. Structurally, it has a complete modular and solid-state design. Without rotating hard drives and other moving parts, it is operational at high altitudes and survivable in high-vibration environments. It is assembled from a suite of miniaturized, precision-machined, standardized, and stackable interchangeable embedded instrument modules. These stackable modules can be bolted together with the interconnection wires inside for the maximal simplicity and portability. Multiple modules are electronically interconnected as stacked. Alternatively, these dedicated modules can be flexibly distributed to fit the space constraints of a flying vehicle. As a flexibly configurable system, MAICSS can be tailored to interface a variety of multisensor packages. For example, with a 1,024x1,024 pixel LWIR and a 8,984x6,732 pixel EO payload, the complete MAICSS volume is approximately 7x9x11 in. (=18x23x28 cm), with a weight of 25 lb (=11.4 kg).

Sun, Xiuhong↗
NASA NTRS1992

Yarn carrier apparatus for braiding machines and the like

A yarn carrier apparatus particularly suited for use in braiding machinery or the like due to its capability of continuous yarn feeding and retraction of long lengths of yarn. The yarn carrier apparatus comprises a yarn supply spool which is rotatably mounted within the housing, a spring motor also mounted within the housing and operatively connected to the yarn supply spool through a mechanical transmission assembly which is adapted to multiply rotational movement between the first element of the gear assembly operatively connected to the spring motor and the final element of the gear assembly operatively connected to the yarn supply spool. The spring motor is adapted to tension the yarn during both feeding and retraction thereof, and it is further adapted to periodically rotatably slip within the housing and partially unwind so as to allow for continuous withdrawal of a long length of yarn without the spring motor becoming fully wound and preventing further yarn retraction.

El-Shiekh, Aly↗
NASA NTRS2012

Mars Science Laboratory Drill

This drill (see Figure 1) is the primary sample acquisition element of the Mars Science Laboratory (MSL) that collects powdered samples from various types of rock (from clays to massive basalts) at depths up to 50 mm below the surface. A rotary-percussive sample acquisition device was developed with an emphasis on toughness and robustness to handle the harsh environment on Mars. It is the first rover-based sample acquisition device to be flight-qualified (see Figure 2). This drill features an autonomous tool change-out on a mobile robot, and novel voice-coil-based percussion. The drill comprises seven subelements. Starting at the end of the drill, there is a bit assembly that cuts the rock and collects the sample. Supporting the bit is a subassembly comprising a chuck mechanism to engage and release the new and worn bits, respectively, and a spindle mechanism to rotate the bit. Just aft of that is a percussion mechanism, which generates hammer blows to break the rock and create the dynamic environment used to flow the powdered sample. These components are mounted to a translation mechanism, which provides linear motion and senses weight-on-bit with a force sensor. There is a passive-contact sensor/stabilizer mechanism that secures the drill fs position on the rock surface, and flex harness management hardware to provide the power and signals to the translating components. The drill housing serves as the primary structure of the turret, to which the additional tools and instruments are attached. The drill bit assembly (DBA) is a passive device that is rotated and hammered in order to cut rock (i.e. science targets) and collect the cuttings (powder) in a sample chamber until ready for transfer to the CHIMRA (Collection and Handling for Interior Martian Rock Analysis). The DBA consists of a 5/8-in. (.1.6- cm) commercial hammer drill bit whose shank has been turned down and machined with deep flutes designed for aggressive cutting removal. Surrounding the shank of the bit is a thick-walled maraging steel collection tube allowing the powdered sample to be augured up the hole into the sample chamber. For robustness, the wall thickness of the DBA was maximized while still ensuring effective sample collection. There are four recesses in the bit tube that are used to retain the fresh bits in their bit box. The rotating bit is supported by a back-to-back duplex bearing pair within a housing that is connected to the outer DBA housing by two titanium diaphragms. The only bearings on the drill in the sample flow are protected by a spring-energized seal, and an integrated shield that diverts the ingested powdered sample from the moving interface. The DBA diaphragms provide radial constraint of the rotating bit and form the sample chambers. Between the diaphragms there is a sample exit tube from which the sample is transferred to the CHIMRA. To ensure that the entire collected sample is retained, no matter the orientation of the drill with respect to gravity during sampling, the pass-through from the forward to the aft chamber resides opposite to the exit tube.

Okon, Avi B.↗
NASA NTRS2012

Investigation of a Moire Based Crack Detection Technique for Propulsion Health Monitoring

The development of techniques for the health monitoring of the rotating components in gas turbine engines is of major interest to NASA s Aviation Safety Program. As part of this on-going effort several experiments utilizing a novel optical Moir based concept along with external blade tip clearance and shaft displacement instrumentation were conducted on a simulated turbine engine disk as a means of demonstrating a potential optical crack detection technique. A Moir pattern results from the overlap of two repetitive patterns with slightly different periods. With this technique, it is possible to detect very small differences in spacing and hence radial growth in a rotating disk due to a flaw such as a crack. The experiment involved etching a circular reference pattern on a subscale engine disk that had a 50.8 mm (2 in.) long notch machined into it to simulate a crack. The disk was operated at speeds up to 12 000 rpm and the Moir pattern due to the shift with respect to the reference pattern was monitored as a means of detecting the radial growth of the disk due to the defect. In addition, blade displacement data were acquired using external blade tip clearance and shaft displacement sensors as a means of confirming the data obtained from the optical technique. The results of the crack detection experiments and its associated analysis are presented in this paper.

Woike, Mark R.↗
NASA NTRSDate not supplied

Sliding Mode Transient Scaling Controller for Gas Turbine Engine Emulation on an Electric Machine

The testing of hybrid-electric aircraft propulsion system components and control strategies has dictated the need for a low-cost gas turbine engine (GTE) emulation testbed. Within that testbed, electric machines (EMs) are used to emulate the dynamics of a GTE. GTE mathematical models are used to provide control torque commands to EMs. Most GTEs operate at much higher power levels than commercially available EMs. Therefore, the transient shaft dynamics of the GTE must be scaled appropriately. The sliding mode controller being presented here aims to deliver a control torque to an electric machine with a fixed inertia that will allow it to mimic the response of a GTE with a different inertia. This solution provides an easily scalable and tunable transient emulation method without having to scale the GTE mathematical model and/or add inertia to the physical EM shaft. This controller has been proven in simulation to produce nearly identical transient rotational speed response to a reference GTE shaft model which has a large difference in rotational inertia compared to the motor. Also, the inherent robustness of the sliding mode control scheme results in negligible changes in performance for large amounts of parameter uncertainty while minimizing high frequency fluctuations in the control signal.

sliding mode↗
NASA NTRS1980

Miniature motor-driven instrument valve

Valve consists of small geared reversible motor, operated by momentary contact closure, which drives shaft with O-rings placed to seal selected ports. Shaft rotates and also moves axially, causing ports to be alternately connected and disconnected. Electrical control of valve is provided by limit switches and relays. Design has advantage over other available valves: less precision machining of parts is required; machining operations are less expensive. Seals are made with O-rings, which are easily replaceable and inexpensive; valve uses less power. It can be used in any application requiring pilot valves for control devices.

Minkin, H. L.↗
NASA NTRS1993

Machine Cleans And Degreases Without Toxic Solvents

Appliance uses hot water and biodegradable chemicals to degrease and clean hardware. Spray chamber essentially industrial-scale dishwasher. Front door tilts open, and hardware to be cleaned placed on basket-like tray. During cleaning process, basket-like tray rotates as high-pressure "V" jets deliver steam, hot water, detergent solution, and rust inhibitor as required.

Gurguis, Kamal S.↗
NASA NTRS1978

Shock tube and shock wave research; Proceedings of the Eleventh International Symposium, University of Washington, Seattle, Wash., July 11-14, 1977

Papers are presented on the applications of shock-wave technology to the study of hydrodynamics, the use of the pressure-wave machine for charging diesel engines, and measurements of the heat-transfer rate in gas-turbine components. Consideration is given to shock propagation along 90-degree bends, the explosive dissemination of liquids, and rotational and vibrational relaxation behind weak shock waves in water vapor. Shock phenomena associated with expansion flows are described and stratospheric-related research using the shock tube is outlined. Attention is given to shock-wave ignition of magnesium powders, Mach reflection and boundary layers, and transition in the shock-induced unsteady boundary layer on a flat plate. Shock-tube measurements of induction and post-induction rates for low-Btu gas mixtures are presented and shock-initiated ignition in COS-N2O-Ar mixtures is described. Cluster growth rates in supersaturated lead vapor are presented and a study of laser-induced plasma motion in a solenoidal magnetic field is reviewed.

Ahlborn, B.↗
NASA NTRS1987

Flexible Coupling With Centering Device

Misaligned machine shafts operating at low speeds coupled with cheap, simple mechanism made in part from wire rope. Wire rope bends to accommodate angular and lateral misalignments and dampens vibrations that accompany, or caused by, rotation of shafts.

Kerley, James↗
NASA NTRS2004

Vibration-Based Method Developed to Detect Cracks in Rotors During Acceleration Through Resonance

In recent years, there has been an increasing interest in developing rotating machinery shaft crack-detection methodologies and online techniques. Shaft crack problems present a significant safety and loss hazard in nearly every application of modern turbomachinery. In many cases, the rotors of modern machines are rapidly accelerated from rest to operating speed, to reduce the excessive vibrations at the critical speeds. The vibration monitoring during startup or shutdown has been receiving growing attention (ref. 1), especially for machines such as aircraft engines, which are subjected to frequent starts and stops, as well as high speeds and acceleration rates. It has been recognized that the presence of angular acceleration strongly affects the rotor's maximum response to unbalance and the speed at which it occurs. Unfortunately, conventional nondestructive evaluation (NDE) methods have unacceptable limits in terms of their application for online crack detection. Some of these techniques are time consuming and inconvenient for turbomachinery service testing. Almost all of these techniques require that the vicinity of the damage be known in advance, and they can provide only local information, with no indication of the structural strength at a component or system level. In addition, the effectiveness of these experimental techniques is affected by the high measurement noise levels existing in complex turbomachine structures. Therefore, the use of vibration monitoring along with vibration analysis has been receiving increasing attention.

Sawicki, Jerzy T.↗
NASA NTRS1981

Economics of ingot slicing with an internal diameter saw for low-cost solar cells

Slicing of silicon ingots using diamond impregnated internal diameter blade saws has been a standard technology of the semiconductor industry. This paper describes work on improvements to this technology for 10 cm diameter ingot slicing. Ingot rotation, dynamic blade edge control with feedback, mechanized blade dressing and development of thinner blades are the approaches tried. A comparison of the results for wafering with and without ingot rotation is also made. A sensitivity analysis of the major cost elements in wafering is performed for 10 cm diameter ingot and extended to the 15 cm diameter ingot case. Various parameter values such as machine cost, feed rate and consumable materials cost are identified both for single and multiple ingot slicing.

Daud, T.↗
NASA NTRS1992

Tool For Making Curved Holes

Tool for use in electrical-discharge machining (EDM) guides EDM electrode in making curved holes. Guide rod fits in slot in arm, which moves through arc. Motion drives electrode into workpiece along desired curved path. Electrode burns into workpiece while arm rotates on spindle. Discharge cuts hole of same radius of curvature.

Allard, Robert↗
NASA NTRS1999

Development of a Revolutionary High Speed Spindle

This report presents the development of a hydraulic motor driven spindle system to be employed for high speed machining of composite materials and metals. The spindle system is conceived to be easily retrofitted into conventional milling machines. The need for the hydraulic spindle arises because of the limitations placed on conventional electric motor driven spindles by the low cutting power and the presence of vibrational phenomena associated with voltage frequency at high rotational speeds. Also, the electric motors are usually large and expensive when power requirements are moderately high. In contrast, hydraulic motor driven spindles promise a distinct increase in spindle life over the conventional electric motor driven spindles. In this report, existing technologies applicable to spindle holder for severe operating conditions were reviewed, conceptual designs of spindle holder system were developed and evaluated, and a detailed design of an acceptable concept was conducted. Finally, a rapid prototype of the design was produced for design evaluation.

Agba, Emmanuel I.↗
NASA NTRS2015

Anomalous Cases of Astronaut Helmet Detection

An astronaut's helmet is an invariant, rigid image element that is well suited for identification and tracking using current machine vision technology. Future space exploration will benefit from the development of astronaut detection software for search and rescue missions based on EVA helmet identification. However, helmets are solid white, except for metal brackets to attach accessories such as supplementary lights. We compared the performance of a widely used machine vision pipeline on a standard-issue NASA helmet with and without affixed experimental feature-rich patterns. Performance on the patterned helmet was far more robust. We found that four different feature-rich patterns are sufficient to identify a helmet and determine orientation as it is rotated about the yaw, pitch, and roll axes. During helmet rotation the field of view changes to frames containing parts of two or more feature-rich patterns. We took reference images in these locations to fill in detection gaps. These multiple feature-rich patterns references added substantial benefit to detection, however, they generated the majority of the anomalous cases. In these few instances, our algorithm keys in on one feature-rich pattern of the multiple feature-rich pattern reference and makes an incorrect prediction of the location of the other feature-rich patterns. We describe and make recommendations on ways to mitigate anomalous cases in which detection of one or more feature-rich patterns fails. While the number of cases is only a small percentage of the tested helmet orientations, they illustrate important design considerations for future spacesuits. In addition to our four successful feature-rich patterns, we present unsuccessful patterns and discuss the cause of their poor performance from a machine vision perspective. Future helmets designed with these considerations will enable automated astronaut detection and thereby enhance mission operations and extraterrestrial search and rescue.

Dolph, Chester↗