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The continued process development of SiO2 insulators for use in advanced InSb monolithic charge coupled infrared imaging arrays is described. Specific investigations into the use of plasma enhanced chemical vapor deposited (PECVD) SiO2 as a gate insulator for InSb charge coupled devices is discussed, as are investigations of other chemical vapor deposited SiO2 materials.
The present investigation is mainly concerned with a reexamination of the Spacelab payload process. The candidate missions are considered in connection with discipline payloads or laboratories. Attention is given to the Space Biomedical Laboratory (SBL), the Space Plasma Lab (SPL), the Astronomy Research Laboratory (Astro), the Shuttle High Energy Astrophysics Laboratory (SHEAL), the Shuttle Infrared Telescope Facility (SIRTF), the Solar Optical Telescope (SOT), the Materials Sciences Laboratory (MLS), the Environmental Observations Mission (EOM), the Shuttle Radar Lab (SRL), the International Microgravity Laboratory (IML), and the Payload of Opportunity Carrier (POOC). The POOC is a low cost means of placing experiments aboard the Shuttle in the cargo bay.
Thermal stir welding is a new welding process developed at NASA's Marshall Space Flight Center in Huntsville, AL. Thermal stir welding is similar to friction stir welding in that it joins similar or dissimilar materials without melting the parent material. However, unlike friction stir welding, the heating, stirring and forging elements of the process are all independent of each other and are separately controlled. Furthermore, the heating element of the process can be either a solid-state process (such as a thermal blanket, induction type process, etc), or, a fusion process (YG laser, plasma torch, etc.) The separation of the heating, stirring, forging elements of the process allows more degrees of freedom for greater process control. This paper introduces the mechanics of the thermal stir welding process. In addition, weld mechanical property data is presented for selected alloys as well as metallurgical analysis.
Thermal stir welding is a new welding process developed at NASA's Marshall Space Flight Center in Huntsville, AL. Thermal stir welding is similar to friction stir welding in that it joins similar or dissimilar materials without melting the parent material. However, unlike friction stir welding, the heating, stirring and forging elements of the process are all independent of each other and are separately controlled. Furthermore, the heating element of the process can be either a solid-state process (such as a thermal blanket, induction type process, etc), or, a fusion process (YG laser, plasma torch, etc.) The separation of the heating, stirring, forging elements of the process allows more degrees of freedom for greater process control. This paper introduces the mechanics of the thermal stir welding process. In addition, weld mechanical property data is presented for selected alloys as well as metallurgical analysis.
Acquisition of polyimide materials for inter-metal dielectrics was obtained from three vendors, with considerable evaluation conducted on the Dupont PI2550 material. Experimental results indicate this material can be patterned using contact printing to line width far below 0.1 mils. Optimum line width is acquired using plasma etch equipment. Metal lift-off experiments on thermal evaporated films were optimized for application to sputtered deposited films. Alternate metal-lift-off experiments are proposed for future investigation. Dry processing equipment studies and future trends in VLSI fabrication techniques are on-going.
An evaluation of the 20 processes put forth for the liberation of oxygen from lunar materials has resulted in a ranking according to overall feasibility. At this time, the eight processes considered to be the most likely candidates for oxygen production on the moon are: ilmenite reduction with H2, CO, and CH4, glass reduction with H2, molten silicate electrolysis, fluxed molten silicate electrolysis, vapor pyrolysis, and ion plasma pyrolysis.
The Aerospike liquid fueled rocket engine for the X-33 aerospace vehicle consists of several thrust cells, which can comprise as much as 25% of the engine weight. The interior wall of the thrust cell chamber is exposed to high temperature combustion products and must be cooled by using liquid hydrogen. Ultimately, reducing engine weight would increase vehicle performance and allow heavier payload capabilities. Currently, the thrust cell's structural jacket and manifolds are made of stainless steel 347, which can potentially be replaced by a lighter material such as an Aluminum (Al) Metal Matrix Composites (MMC). Up to 50% weight reduction can be expected for each of the thrust cell chambers using particulate SiC reinforced Al MMC. Currently, several Al MMC thrust cell structural jackets have been produced, using cost-effective processes such as gravity casting and plasma spray deposition, to demonstrate MMC technology readiness for NASA's advanced propulsion systems.
For the past several years, NASA's Marshall Space Flight Center (MSFC) has been working with Plasma Processes, Inc. (PPI) to fabricate combustion chamber liners using the Vacuum Plasma Spray (VPS) process. Multiple liners of a variety of shapes and sizes have been created. Each liner has been fabricated with GRCop-84 (a copper alloy with chromium and niobium) and a functional gradient coating (FGC) on the hot wall. While the VPS process offers versatility and a reduced fabrication schedule, the material system created with VPS allows the liners to operate at higher temperatures, with maximum blanch resistance and improved cycle life. A subscal unit (5K lbf thrust class) is being cycle tested in a LOX/Hydrogen thrust chamber assembly at MSFC. To date, over 75 hot-fire tests have been accumulated on this article. Tests include conditions normally detrimental to conventional materials, yet the VPS GRCop-84 liner has yet to show any signs of degradation. A larger chamber (15K lbf thrust class) has also been fabricated and is being prepared for hot-fire testing at MSFC near the end of 2003. Linear liners have been successfully created to further demonstrate the versatility of the process. Finally, scale up issues for the VPS process are being tackled with efforts to fabricate a full size, engine class liner. Specifically, a liner for the SSME's Main Combustion Chamber (MCC) has recently been attempted. The SSME size was chosen for convenience, since its design was readily available and its size was sufficient to tackle specific issues. Efforts to fabricate these large liners have already provided valuable lessons for using this process for engine programs. The material quality for these large units is being evaluated with destructive analysis and these results will be available by the end of 2003.
Advanced multi-component, low conductivity oxide thermal barrier coatings have been developed using an approach that emphasizes real-time monitoring of thermal conductivity under conditions that are engine-like in terms of temperatures and heat fluxes. This is in contrast to the traditional approach where coatings are initially optimized in terms of furnace and burner rig durability with subsequent measurement in the as-processed or furnace-sintered condition. The present work establishes a laser high-heat-flux test as the basis for evaluating advanced plasma-sprayed and electron beam-physical vapor deposited (EB-PVD) thermal barrier coatings under the NASA Ultra-Efficient Engine Technology (UEET) Program. The candidate coating materials for this program are novel thermal barrier coatings that are found to have significantly reduced thermal conductivities and improved thermal stability due to an oxide-defect-cluster design. Critical issues for designing advanced low conductivity coatings with improved coating durability are also discussed.
We investigate how the radio emission of a pulsar interacts with plasma derived from a stellar companion. Various physical mechanisms that can cause radio pulse eclipse are discussed, and predictions are made for the polarization properties of the emergent radio wave. We consider eclipses by a wind from the stellar companion, by a stellar magnetosphere, or by material entrained in the pulsar wind. Eclipses due to refraction require either a relatively high plasma density or a sharp edge to the plasma distribution. The conditions that must prevail for free-free absorption to be effective in eclipsing a radio beam are also outlined. Pulse smearing may be important at higher frequencies; related eclipse mechanisms include pulse spreading due to a rapidly changing electron column, and scattering by Langmuir turbulence. The high brightness temperature radio beam can generate its own plasma turbulence via a number of nonlinear parametric instabilities, such as the instability associated with stimulated Raman scattering. When the plasma turbulence is heavily damped, the radio bean can still undergo induced Compton scattering. Stimulated scattering effects such as these are very sensitive to the presence of narrow-band substructure in the pulsar radio emission. Finally, we consider the possibility that plasma derived from a stellar companion may mix with the relativistic pulsar wind and cause cyclotron absorption at low radio frequencies. Even if the cyclotron optical depth is small, fluctuations in the emergent polarization of the radio beam on the timescale of a few seconds are a very sensitive probe of the spatial structure of the magnetic field in the pulsar wind. The current observational properties of two known eclipsing pulsar systems, PSR 1957+20 and PSR 1744-24A, are used to construct tentative eclipse models. The favored model for PSR 1957+20 is cyclotron or synchrotron absorption by plasma embedded in the pulsar wind combined with pulse smearing at high frequency, and the favored model for PSR 1744-24A is backscattering off plasma turbulence generated by the stimulated Raman scattering parametric instability. Pulsar eclipses promise to provide a good diagnostic of pulsar winds and possible of the pulse emission mechanism.
Sunlight is dispersed over a diffraction grating formed on the surface of a conducting film on a substrate. The angular dispersion controls the effective grating period so that a matching spectrum of surface plasmons is excited for parallel processing on the conducting film. The resulting surface plasmons carry energy to an array of inelastic tunnel diodes. This solar energy converter does not require different materials for each frequency band, and sunlight is directly converted to electricity in an efficient manner by extracting more energy from the more energetic photons.
Emerging magnetic flux plays an important role in the development of active regions on the sun and, perhaps, in the subsequent activation of flares. However, the energy input that produces preflare brightenings and flares probably does not come from the flux emergence itself but from one or more associated energy-releasing processes - likely candidates include magnetic reconnection and various current-driven plasma micro-instabilities. Here the interplay between the changing physical characteristics of an emerging magnetic-flux tube and the onset and evolution of a representative 'bump-on-tail' plasma current-driven instability is investigated. The microinstability heats the ambient material, thus changing the macroscopic characteristics of the plasma in which the model and current-driven instability occurs.
The vacuum plasma spray process (VPS) has been developed by NASA and Rocketdyne for a variety of applications on liquid fuel rocket engines, including the Space Shuttle Main Engine. These applications encompass thermal barrier coatings which are thermal shock resistant for turbopump blades and nozzles; bond coatings for cryogenic titanium components; wear resistant coatings and materials; high conductivity copper, NaRloy-Z, combustion chamber liners, and structural nickel base material, Inconel 718, for nozzle and combustion chamber support jackets.
Ferrofluids offered vast-problem solving potential. Under license for the NASA technology, Dr. Ronald Moskowitz and Dr. Ronald Rosensweig formed Ferrofluids Corporation. First problem they found a solution for was related to the manufacture of semiconductor "chips" for use in electronic systems. They developed a magnetic seal composed of ferrofluid and a magnetic circuit. Magnetic field confines the ferrofluid in the regions between the stationary elements and the rotary shaft of the seal. Result is a series of liquid barriers that totally bar passage of contaminants. Seal is virtually wear-proof and has a lifetime measured in billions of shaft revolutions. It has reduced maintenance, minimizes "downtime" of production equipment, and reduces the cost of expensive materials that had previously been lost through seal failures. Products based on ferrofluid are exclusion seals for computer disc drives and inertia dampers for stepper motors. Uses are performance-improving, failure-reducing coolants for hi-fi loudspeakers. Other applications include analytical instrumentation, medical equipment, industrial processes, silicon crystal growing furnaces, plasma processes, fusion research, visual displays, and automated machine tools.
In a qualification life test of a Hall thruster it was found that the erosion of the acceleration channel practically stopped after approx 5,600 h. Numerical simulations using a two-dimensional axisymmetric plasma solver with a magnetic field-aligned mesh reveal that when the channel receded from its early-in-life to its steady-state configuration the following changes occurred near the wall: (1) reduction of the electric field parallel to the wall that prohibited ions from acquiring significant impact kinetic energy before entering the sheath, (2) reduction of the potential fall in the sheath that further diminished the total energy ions gained before striking the material, and (3) reduction of the ion number density that decreased the flux of ions to the wall. All these changes, found to have been induced by the magnetic field, constituted collectively an effective shielding of the walls from any significant ion bombardment. Thus, we term this process in Hall thrusters "magnetic shielding."
A 2 1/2-dimensional, cylindrically symmetric particle in cell program is used to simulate the interaction of a plasma with a positively biased disk covered by a dielectric material (Kapton). Several runs using different combinations of bias voltages and secondary electron yields are discussed. Special attention is paid to the role of the secondaries as the dielectric surface changes from a negative potential to become increasingly positive. This is termed the 'snapover' process. The contribution due to secondaries is examined by plotting the distribution (number versus position) of the particles emitted by the impacting on the dielectric. These plots show that secondaries are drawn back into the dielectric as well as the conductor in the case of snapover. Mechanisms and experimental implications for these particular distributions are discussed.
The emergence of commercial quantities of BNNTs facilitates the exploration of structural material applications. BNNT-reinforced composites must exhibit extraordinary mechanical properties in order to justify the cost premium. Prevailing theory indicates that suitable BNNTs must possess an aspect ratio (AR= length/diameter) approaching 10,000 to provide effective discontinuous reinforcement under tensile loading. A survey of commercial products shows that although the quantities are sufficient, lots of uniform morphology are unavailable. Therefore, the opportunity exists to supplement procedures either during synthesis operations or post-synthesis processing in order to deliver homogeneous batches of high AR BNNTs. An assessment of relevant technologies reveals established methods compatible with sorting of BNNTs by physical dimensions, i.e., size and/or shape. Electrostatic fractionation emerges as the leading candidate, with the potential to isolate high-purity, low-defect, high AR product. The adaptation of existing equipment to the handling of fibrous particulate on the nanoscale will be paramount to success. Although currently focused on BNNTs, the concepts outlined may be applied to nanotubes synthesized from any organic or inorganic compounds. This survey sets the stage for delivering reproducible lots of BNNTs that satisfy the dimensional requirements for use in acreage structural materials.
The theory that polycyclic aromatic hydrocarbons (PAHs) are a constituent of the interstellar medium, and a source of the IR emission bands at 3.3, 6.2, 7.7, 8.6, and 11.3 microns is being studied using PAH containing acid insoluble residue of the Orgueil CI meteorite and coal tar. FTIR spectra of Orgueil PAH material that has undergone thermal treatment, and a solvent insoluble fraction of coal tar that has been exposed to hydrogen plasma are presented. The UV excided luminescence spectrum of a solvent soluble coal tar film is also shown. Comparison of the lab measurements with observations appears to support the interstellar PAH theory, and shows the process of dehydrogenation expected to take place in the interstellar medium.