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At least 235 records · Page 13

Failure Analysis Study and Long-Term Reliability of Optical Assemblies with End-Face Damage

In June 2005, the NESC received a multi-faceted request to determine the long term reliability of fiber optic termini on the ISS that exhibited flaws not manufactured to best workmanship practices. There was a lack of data related to fiber optic workmanship as it affects the long term reliability of optical fiber assemblies in a harsh environment. A fiber optic defect analysis was requested which would find and/or create various types of chips, spalls, scratches, etc., that were identified by the ISS personnel. Once the defects and causes were identified the next step would be to perform long term reliability testing of similar assemblies with similar defects. The goal of the defect analysis would be for the defects to be observed and documented for deterioration of fiber optic performance. Though this report mostly discusses what has been determined as evidence of poor manufacturing processes, it also concludes the majority of the damage could have been avoided with a rigorous process in place.

Kichak, Robert A.↗

Performance of Compressor of XJ-41-V Turbojet Engine II - Static-Pressure Ratios and Limitation of Maximum Flow at Equivalent Compressor Speed of 8000 rpm

At the request of the Air Material Command, Army Air Forces, an investigation was conducted by the NACA Cleveland laboratory to determine the performance characteristics of the compressor of the XJ-41-V turbojet engine. This report is the second in a series presenting the compressor performance and analysis of flow conditions in the compressor. The static-pressure variation in the direction of flow through the compressor and the location and the cause of the maximum flow restriction at an equivalent speed of 8000 rpm are presented. After the initial runs were reported, the leading edges of the impeller blades and the diffuser surfaces were found to have been roughened by steel particles from a minor failure of auxiliary equipment. The leading edges of the impeller blades were refinished and all high spots resulting from scratches in the diffuser and the accessible parts of the vaned collector passages were removed. The initial overall performance and that obtained with the refinished blades are presented.

Dildine, Dean M.↗

A Study of Transparent Plastics for use on Aircraft, Special Report

Various transparent organic plastics, including both commercially available and experimental materials, have been examined to determine their suitability for use as flexible windshields on aircraft, The properties which have been studied include light transmission, haziness, distortion, resistance to weathering, scratch and indentation hardness, impact strength, dimensional stability, resistance to water and various cleaning fluids, bursting strength at normal and low temperatures, and flammability.

Axilrod, Benjamin M.↗

Using Indium Tin Oxide To Mitigate Dust on Viewing Ports

NASA plans to use a number of onboard viewing ports to measure lunar regolith in situ and to monitor robotic and human activities on the lunar or Martian surface. Because of the size and abundance of dust particles on these bodies, the potential for dust to occlude viewing ports and windows is high enough to threaten system lifetime and reliability, especially when activities rely on relaying video to either a habitat module or controllers on Earth. This project uses a technology being developed by KSC's Electrostatics and Surface Physics Laboratory to remove dust from windowlike surfaces. The technology applies an alternating electric potential to interlaced electrodes. In this application, we use indium tin oxide (ITO) to create various electrode patterns in order to determine the most reliable pattern for dust removal. This technology has application to systems where optical clarity is important. Specifically, this project considers the in situ resource utilization (ISRU) application of a viewing port for Raman spectroscopy, where the electrode pattern on glass would be coated with a scratch-resistant sapphire film (Al2O3).

Source record↗

Use of DSC and DMA to Study Rubber Crystallization as a Possible Cause for a Tear in a Neoprene Glove Used in a Space Shuttle Pressurized Astronaut Suit

The Advanced Crew Escape Suit (ACES) is a pressurized suit normally worn by astronauts during launch and landing phases of Space Shuttle operations. In 2008, a large tear (0.5 -1 in. long, between the pinky and ring finger) in the ACES left-hand glove made of neoprene latex rubber was found during training for Shuttle flight STS-124. An investigation to help determine the cause(s) of the glove tear was headed by the NASA Johnson Space Center (JSC) in Houston, Texas. Efforts at JSC to reproduce the actual glove tear pattern by cutting/tearing or rupturing were unsuccessful. Chemical and material property data from JSC such as GC-MS, FTIR, DSC and TGA mostly showed little differences between samples from the torn and control gloves. One possible cause for the glove tear could be a wedding ring/band worn by a male astronaut. Even with a smooth edge, such a ring could scratch the material and initiate the tear observed in the left-hand glove. A decision was later made by JSC to not allow the wearing of such a ring during training or actual flight. Another possible cause for the ACES glove tear is crystallinity induced by strain in the neoprene rubber over a long period of time and use. Neoprene is one several elastomeric materials known to be susceptible to crystallization, and such a process is accelerated with exposure of the material to cold temperatures plus strain. When the temperature is lowered below room temperature, researchers have shown that neoprene crystallization may be maintained at temperatures as high as 45-50 F, with a maximum crystallization rate near 20-25 F (1). A convenient conditioning temperature for inducing neoprene crystallization is a typical freezer that is held near 0 F. For work at the NASA Marshall Space Flight Center (MSFC), samples were cut from several areas/locations (pinky/ring finger crotch, index finger and palm) on each of two pairs of unstrained ACES gloves for DSC and DMA thermal analysis testing. The samples were conditioned in a freezer for various times up to about 14 days. Some rectangular conditioned samples were unstrained, while most were subjected to strains up to 250% with the aid of two slotted aluminum blocks and two aluminum clamps per sample. Trends were observed to correlate DSC data (heat of fusion) and DMA data (linear CTE and stress for iso-strain testing) with: (a) sample location on each glove; and (b) level of strain during conditioning. Control samples cut as is from each glove location were also tested by DSC and DMA.

Wingard, Doug↗

Human Research Program Space Human Factors Engineering (SHFE) Standing Review Panel (SRP)

The Space Human Factors Engineering (SHFE) Standing Review Panel (SRP) evaluated 22 gaps and 39 tasks in the three risk areas assigned to the SHFE Project. The area where tasks were best designed to close the gaps and the fewest gaps were left out was the Risk of Reduced Safety and Efficiency dire to Inadequate Design of Vehicle, Environment, Tools or Equipment. The areas where there were more issues with gaps and tasks, including poor or inadequate fit of tasks to gaps and missing gaps, were Risk of Errors due to Poor Task Design and Risk of Error due to Inadequate Information. One risk, the Risk of Errors due to Inappropriate Levels of Trust in Automation, should be added. If astronauts trust automation too much in areas where it should not be trusted, but rather tempered with human judgment and decision making, they will incur errors. Conversely, if they do not trust automation when it should be trusted, as in cases where it can sense aspects of the environment such as radiation levels or distances in space, they will also incur errors. This will be a larger risk when astronauts are less able to rely on human mission control experts and are out of touch, far away, and on their own. The SRP also identified 11 new gaps and five new tasks. Although the SRP had an extremely large quantity of reading material prior to and during the meeting, we still did not feel we had an overview of the activities and tasks the astronauts would be performing in exploration missions. Without a detailed task analysis and taxonomy of activities the humans would be engaged in, we felt it was impossible to know whether the gaps and tasks were really sufficient to insure human safety, performance, and comfort in the exploration missions. The SRP had difficulty evaluating many of the gaps and tasks that were not as quantitative as those related to concrete physical danger such as excessive noise and vibration. Often the research tasks for cognitive risks that accompany poor task or information design addressed only part, but not all, of the gaps they were programmed to fill. In fact the tasks outlined will not close the gap but only scratch the surface in many cases. In other cases, the gap was written too broadly, and really should be restated in a more constrained way that can be addressed by a well-organized and complementary set of tasks. In many cases, the research results should be turned into guidelines for design. However, it was not clear whether the researchers or another group would construct and deliver these guidelines.

Wichansky, Anna↗

Test Method Variability in Slow Crack Growth Properties of Sealing Glasses

The crack growth properties of several sealing glasses were measured by using constant stress rate testing in ~2 and 95 percent RH (relative humidity). Crack growth parameters measured in high humidity are systematically smaller (n and B) than those measured in low humidity, and crack velocities for dry environments are ~100x lower than for wet environments. The crack velocity is very sensitive to small changes in RH at low RH. Biaxial and uniaxial stress states produced similar parameters. Confidence intervals on crack growth parameters that were estimated from propagation of errors solutions were comparable to those from Monte Carlo simulation. Use of scratch-like and indentation flaws produced similar crack growth parameters when residual stresses were considered.

Salem, J. A.↗

Walking the Walk/Talking the Talk: Mission Planning with Speech-Interactive Agents

The application of simulation technology to mission planning and rehearsal has enabled realistic overhead 2-D and immersive 3-D "fly-through" capabilities that can help better prepare tactical teams for conducting missions in unfamiliar locales. For aircrews, detailed terrain data can offer a preview of the relevant landmarks and hazards, and threat models can provide a comprehensive glimpse of potential hot zones and safety corridors. A further extension of the utility of such planning and rehearsal techniques would allow users to perform the radio communications planned for a mission; that is, the air-ground coordination that is critical to the success of missions such as close air support (CAS). Such practice opportunities, while valuable, are limited by the inescapable scarcity of complete mission teams to gather in space and time during planning and rehearsal cycles. Moreoever, using simulated comms with synthetic entities, despite the substantial training and cost benefits, remains an elusive objective. In this paper we report on a solution to this gap that incorporates "synthetic teammates" - intelligent software agents that can role-play entities in a mission scenario and that can communicate in spoken language with users. We employ a fielded mission planning and rehearsal tool so that our focus remains on the experimental objectives of the research rather than on developing a testbed from scratch. Use of this planning tool also helps to validate the approach in an operational system. The result is a demonstration of a mission rehearsal tool that allows aircrew users to not only fly the mission but also practice the verbal communications with air control agencies and tactical controllers on the ground. This work will be presented in a CAS mission planning example but has broad applicability across weapons systems, missions and tactical force compositions.

Bell, Benjamin↗

Developing a Logistics Data Process for Support Equipment for NASA Ground Operations

The United States NASA Space Shuttle has long been considered an extremely capable yet relatively expensive rocket. A great part of the roughly US $500 million per launch expense was the support footprint: refurbishment and maintenance of the space shuttle system, together with the long list of resources required to support it, including personnel, tools, facilities, transport and support equipment. NASA determined to make its next rocket system with a smaller logistics footprint, and thereby more cost-effective and quicker turnaround. The logical solution was to adopt a standard Logistics Support Analysis (LSA) process based on GEIA-STD-0007 http://www.logisticsengineers.org/may09pres/GEIASTD0007DEXShortIntro.pdf which is the successor of MIL-STD-1388-2B widely used by U.S., NATO, and other world military services and industries. This approach is unprecedented at NASA: it is the first time a major program of programs, Project Constellation, is factoring logistics and supportability into design at many levels. This paper will focus on one of those levels NASA ground support equipment for the next generation of NASA rockets and on building a Logistics Support Analysis Record (LSAR) for developing and documenting a support solution and inventory of resources for. This LSAR is actually a standards-based database, containing analyses of the time and tools, personnel, facilities and support equipment required to assemble and integrate the stages and umbilicals of a rocket. This paper will cover building this database from scratch: including creating and importing a hierarchical bill of materials (BOM) from legacy data; identifying line-replaceable units (LRUs) of a given piece of equipment; analyzing reliability and maintainability of said LRUs; and therefore making an assessment back to design whether the support solution for a piece of equipment is too much work, i.e., too resource-intensive. If one must replace or inspect an LRU too much, perhaps a modification of the design of the equipment can make such operational effort unnecessary. Finally, this paper addresses processes of tying resources to a timeline of tasks performed in ground operations: this enables various overarching analyses, e.g., a summarization of all resources used for a given piece of equipment. Quality Control of data will also be discussed: importing and exporting data from product teams, including spreadsheets-todatabase or data exchange between databases.

Chakrabarti, Suman↗

Handheld White Light Interferometer for Measuring Defect Depth in Windows

Accurate quantification of defects (scratches and impacts) is vital to the certification of flight hardware and other critical components. The amount of damage to a particular component contributes to the performance, reliability, and safety of a system, which ultimately affects the success or failure of a mission or test. The launch-commit criteria on a Space Shuttle Orbiter window are governed by the depth of the defects that are identified by a visual inspection. This measurement of a defect is not easy to obtain given the environment, size of the defect, and location of the window(s). The determination of depth has typically been performed by taking a mold impression and measuring the impression with an optical profiling instrument. Another method of obtaining an estimate of the depth is by using a refocus microscope. To use a refocus microscope, the surface of the glass and bottom of the defect are, in turn, brought into focus by the operator. The amount of movement between the two points corresponds to the depth of the defect. The refocus microscope requires a skilled operator and has been proven to be unreliable when used on Orbiter windows. White light interferometry was chosen as a candidate to replace the refocus microscope. The White Light Interferometer (WLI) was developed to replace the refocus microscope as the instrument used for measuring the depth of defects in Orbiter windows. The WLI consists of a broadband illumination source, interferometer, detector, motion control, displacement sensor, mechanical housing, and support electronics. The illumination source for the WLI is typically a visible light emitting diode (LED) or a near-infrared superluminescent diode (SLD) with power levels of less than a milliwatt. The interferometer is a Michelson configuration consisting of a 1-in. (2.5-cm) cube beam splitter, a 0.5-in. (1.3-cm) optical window as a movable leg (used to closely match the return intensity of the fixed leg from the window), and a mirrored prism to fold the optics into the mechanical housing. The detector may be one of many C-mount CCD (charge-coupled device) cameras. Motion is provided by a commercial nanostepping motor with a serial interface. The displacement sensor is a custom device specifically designed for this application. The mechanical housing and support electronics were designed to integrate the various components into an instrument that could be physically handled by a technician and easily transported.

Youngquist, Robert↗

Portable Handheld Optical Window Inspection Device

The Portable Handheld Optical Window Inspection Device (PHOWID) is a measurement system for imaging small defects (scratches, pits, micrometeor impacts, and the like) in the field. Designed primarily for window inspection, PHOWID attaches to a smooth surface with suction cups, and raster scans a small area with an optical pen in order to provide a three-dimensional image of the defect. PHOWID consists of a graphical user interface, motor control subsystem, scanning head, and interface electronics, as well as an integrated camera and user display that allows a user to locate minute defects before scanning. Noise levels are on the order of 60 in. (1.5 m). PHOWID allows field measurement of defects that are usually done in the lab. It is small, light, and attaches directly to the test article in any orientation up to vertical. An operator can scan a defect and get useful engineering data in a matter of minutes. There is no need to make a mold impression for later lab analysis.

Ihlefeld, Curtis↗

Safe to Fly: Certifying COTS Hardware for Spaceflight

Providing hardware for the astronauts to use on board the Space Shuttle or International Space Station (ISS) involves a certification process that entails evaluating hardware safety, weighing risks, providing mitigation, and verifying requirements. Upon completion of this certification process, the hardware is deemed safe to fly. This process from start to finish can be completed as quickly as 1 week or can take several years in length depending on the complexity of the hardware and whether the item is a unique custom design. One area of cost and schedule savings that NASA implements is buying Commercial Off the Shelf (COTS) hardware and certifying it for human spaceflight as safe to fly. By utilizing commercial hardware, NASA saves time not having to develop, design and build the hardware from scratch, as well as a timesaving in the certification process. By utilizing COTS hardware, the current detailed certification process can be simplified which results in schedule savings. Cost savings is another important benefit of flying COTS hardware. Procuring COTS hardware for space use can be more economical than custom building the hardware. This paper will investigate the cost savings associated with certifying COTS hardware to NASA s standards rather than performing a custom build.

Fichuk, Jessica L.↗

Microencapsulation of Self Healing Agents for Corrosion Control Coatings

Corrosion, the environmentally induced degradation of materials, is a very costly problem that has a major impact on the global economy. Results from a 2-year breakthrough study released in 2002 by the U.S. Federal Highway Administration (FHWA) showed that the total annual estimated direct cost associated with metallic corrosion in nearly every U.S. industry sector was a staggering $276 billion, approximately 3.1% of the nation's Gross Domestic Product (GOP). Corrosion protective coatings are widely used to protect metallic structures from the detrimental effects of corrosion but their effectiveness can be seriously compromised by mechanical damage, such as a scratch, that exposes the metallic substrate. The incorporation of a self healing mechanism into a corrosion control coating would have the potential to significantly increase its effectiveness and useful lifetime. This paper describes work performed to incorporate a number of microcapsule-based self healing systems into corrosion control coatings. The work includes the preparation and evaluation of self-healing systems based on curable epoxy, acrylate, and siloxane resins, as well as, microencapsulated systems based on passive, solvent born, healing agent delivery. The synthesis and optimization of microcapsule-based self healing systems for thin coating (less than 100 micron) will be presented.

Jolley, S. T.↗

Multi-Layer Laminated Thin Films for Inflatable Structures

Special-purpose balloons and other inflatable structures would be constructed as flexible laminates of multiple thin polymeric films interspersed with layers of adhesive, according to a proposal. In the original intended application, the laminate would serve as the envelope of the Titan Aerobot a proposed robotic airship for exploring Titan (one of the moons of Saturn). Potential terrestrial applications for such flexible laminates could include blimps and sails. In the original application, the multi-layered laminate would contain six layers of 0.14-mil (0.0036-mm)-thick Mylar (or equivalent) polyethylene terephthalate film with a layer of adhesive between each layer of Mylar . The overall thickness and areal density of this laminate would be nearly the same as those of 1-mil (0.0254-mm)-thick monolayer polyethylene terephthalate sheet. However, the laminate would offer several advantages over the monolayer sheet, especially with respect to interrelated considerations of flexing properties, formation of pinholes, and difficulty or ease of handling, as discussed next. Most of the damage during flexing of the laminate would be localized in the outermost layers, where the radii of bending in a given bend would be the largest and, hence, the bending stress would be the greatest. The adverse effects of formation of pinholes would be nearly completely mitigated in the laminate because a pinhole in a given layer would not propagate to adjacent layers. Hence, the laminate would tend to remain effective as a barrier to retain gas. Similar arguments can be made regarding cracks: While a crack could form as a result of stress or a defect in the film material, a crack would not propagate into adjacent layers, and the adjacent layer(s) would even arrest propagation of the crack. In the case of the monolayer sheet, surface damage (scratches, dents, permanent folds, pinholes, and the like) caused by handling would constitute or give rise to defects that could propagate through the thickness as cracks or pinholes that would render the sheet less effective or ineffective as a barrier. In contrast, because damage incurred during handling of the laminate would ordinarily be limited to the outermost layers, the barrier properties of the laminate would be less likely to be adversely affected. Therefore, handling of the laminate would be easier because there would be less of a need to exercise care to ensure against surface damage.

Yavrouian, Andre↗

Bubble Departure from Metal-Graphite Composite Surfaces and Its Effects on Pool Boiling Heat Transfer

The formation and growth processes of a bubble in the vicinity of graphite micro-fiber tips on metal-graphite composite boiling surfaces and their effects on boiling behavior are investigated. It is discovered that a large number of micro bubbles are formed first at the micro scratches and cavities on the metal matrix in pool boiling. By virtue of the non-wetting property of graphite, once the growing micro bubbles touch the graphite tips, the micro bubbles are sucked by the tips and merged into larger micro bubbles sitting on the end of the tips. The micro bubbles grow rapidly and coalesce to form macro bubbles, each spanning several tips. The necking process of a detaching macro bubble is analyzed. It is revealed that a liquid jet is produced by sudden break-off of the bubble throat. The composite surfaces not only have higher temperatures in micro- and macrolayers but also make higher frequency of the bubble departure, which increase the average heat fluxes in both the bubble growth stage and in the bubble departure period. Based on these analyses, the enhancement mechanism of pool boiling heat transfer on composite surfaces is clearly revealed.

Chao, David F.↗

Microscope Cells Containing Multiple Micromachined Wells

Tech Briefs, May 2003 19 Manufacturing Microscope Cells Containing Multiple Micromachined Wells The cost per cell has been reduced substantially. John H. Glenn Research Center, Cleveland, Ohio An improved design for multiple-well microscope cells and an associated improved method of fabricating them have been devised. [As used here, "well" denotes a cavity that has a volume of about 1 or 2 L and that is used to hold a sample for examination under a microscope. As used here, "cell" denotes a laminate, based on a standard 1- by 3-in. (2.54- by 7.62-cm) microscope slide, that comprises (1) the slide as the lower layer, (2) an intermediate layer that contains holes that serve as the wells, and (3) a top layer that either consists of, or is similar to, a standard microscope-slide cover slip.] The improved design and method of fabrication make it possible to increase (relative to a prior design and method of fabrication) the number of wells per cell while reducing the fabrication loss and reducing the cost per cell to about one-tenth of the prior value. In the prior design and method, the slide, well, and cover-slip layers were made from silicate glass. The fabrication of each cell was a labor-intensive process that included precise cutting and grinding of the glass components, fusing of the glass components, and then more grinding and polishing to obtain desired dimensions. Cells of the prior design were expensive and fragile, the rate of loss in fabrication was high, and the nature of the glass made it difficult to increase the number of cells per well. Efforts to execute alternative prior designs in plastic have not yielded satisfactory results because, for typical applications, plastics are not sufficiently thermally or chemically stable, not sufficiently optically clear, and/or not hard enough to resist scratching. The figure depicts a cell of the present improved type. The slide and cover-slip layers are made of a low-thermal-expansion glass (Pyrex(TradeMark) or equivalent) and the intermediate (well layer) is made of SiO2 - a combination of materials that results in a laminate stronger than one made from layers of silicate glass. Before the layers are assembled into the laminate, the SiO2 layer is micromachined to form the wells plus shallow grooves that, when subsequently covered with the cover slip, become capillary channels that are used to fill the wells with samples. The micromachining is accomplished by use of the same patterning and etching techniques used to fabricate microelectromechanical systems (MEMS).

Turner, Walter↗

Predicting the Blast of Lunar Soil Under a Rocket's Exhaust Jet

The blast of lunar soil represents a problem for the future missions planned for the moon. When the lander approached the ground during the Apollo missions, huge showers of dust particles were sent in all directions at extremely high velocities - including upwards towards the landing spacecraft. This represents a clear danger to the lander because the loss of visibility and the damage that can be produced to the vehicle itself. If there had been equipment on the ground, these showers of particles would have created a sand blasting effect over the equipment, possibly damaging optics and contaminating the equipment and depending on the size and velocity of the particles maybe even more extensive damage as the particles penetrated the outer surface of the equipment. Since the there is no air on the moon to slow down the particles, they can travel large distances at high speeds, in fact in some instances they can reach near escape velocity and go into an orbit around the moon and come all the way back to almost the same point where they were at the beginning; meaning that some of the lunar dust that came up during landing will shower back over the site. Once on the surface, the extremely fine dust had a habit of getting itself everywhere. During the Apollo missions it not only covered the astronauts' suits, but managed to work its way inside, damaging airtight joints and scratching up glass visors. The dust found its way inside the spacecraft, contaminating the floor and electronic systems inside, clogging air filters in the process. This is due to the fact that the lunar soil is extremely cohesive. The Lunar soil causes all of the same problems as sand does on Earth but unlike sand particles on Earth, which have smooth spherical shapes, the dust on the Moon is more like small particles of glass with sharper edges since there is no erosion on the lunar surface. During the Apollo missions the dust problem did not cause a big problem due to the fact of the length of duration of the missions. But as NASA plans to have long term missions to the moon the dust problem becomes an issue, due to multiple landings and the equipment that will be accumulated on the site. In order to mitigate these problems it is needed first to understand the physics of the problem in order to find the most suitable solution to protect equipment and vehicles during the next lunar missions..

Diaz, Carlos J. Sanchez↗

Examination of Relationship Between Photonic Signatures and Fracture Strength of Fused Silica Used in Orbiter Windows

A commercially available grey-field polariscope (GFP) instrument for photoelastic examination is used to assess impact damage inflicted upon the outermost pane of the orbiter windows. Four categories of damage: hyper-velocity impacts that occur during space-flight (HVI); hypervelocity impacts artificially made at the Hypervelocity Impact Technology Facility (HIT-F); impacts made by larger objects falling onto the pane surface to simulate dropped items on the window during service/storage of vehicle (Bruises); and light scratches from dull objects designed to mimic those that might occur by dragging a dull object across the glass surface (Chatter Checks) are examined. The damage sites are cored from fused silica window carcasses, examined with the GFP and other methodologies, and broken using the ASTM Standard C1499-09 to measure the fracture strength. A correlation is made between the fracture strength and damage-site measurements including geometrical measurements and GFP measurements of photoelastic retardation (stress patterns) surrounding the damage sites. An analytical damage model to predict fracture strength from photoelastic retardation measurements is presented and compared with experimental results.

Yost, William T.↗