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NASA NTRS2002

ASK Magazine

What makes a successful team? In this issue our contributors look closely at the subject and come up with several answers. Working on team chemistry is the "Activation Energy" Dr. Owen Gadeken's story is about. Scott Cameron thinks it's getting to know people one to one. Tony Maturo says it's getting the most out of your support staff. Dr. Michael Hecht finds the best people he can and build the team around their talents. Teamwork is a theme we explore often in Academy Sharing Knowledge (ASK), but never so directly as in this issue. You'll not only find formulas for building successful teams, you'll see examples of ones in action, strategies for how project managers can motivate their teams, and expert advice on how to choose who to work with and who not to work with. It seems like all the stories make one common point: everyone on a team counts. Few project managers can pull off a project alone, and when the whole team is performing to everyone's potential, the chances of pulling off a successful project goes up exponentially. If that doesn't seem like enough by itself, listen to this... Discerning fans of ASK will note the last two issues our Special Feature was "There are no Mistakes, Only Lessons." We have not abandoned this feature, but for now we want to broaden our repertoire. In this issue we add a new Special Feature, "My Metaphor," starting with Paul Espinosa's article "My Big Wall" about his rock climbing adventures on El Capitan in Yosemite National Park. If you think getting to Mars is work, read what it's like to scale a 3,000-foot rock face. This issue we're also welcoming two new members to our Review Board, Hugh Woodward and Jody Kusek. Hugh and Jody are our first reviewers from outside NASA, and we are delighted to have them on our team. Read their bios on the ASK Review Board page and see why we feel privileged to have them on our team.

Post, Todd↗
NASA NTRS2002

Fluid Mechanics of Capillary-Elastic Instabilities in Microgravity Environment

The aim of this project is to investigate the closure and reopening of lung airways due to surface tension forces, coupled with airway elasticity. Airways are liquid-lined, flexible tubes and closure of airways can occur by a Rayleigh instability of the liquid lining, or an instability of the elastic support for the airway as the surface tension of the air-liquid interface pulls the tube shut, or both. Regardless of the mechanism, the airway is closed because the liquid lining has created a plug that prevents axial gas exchange. In the microgravity environment, surface tension forces dominate lung mechanics and would lead to more prevalent, and more uniformly distributed air-way closure, thereby creating a potential for respiratory problems for astronauts. Once closed the primary option for reopening an airway is by deep inspiration. This maneuver will pull the flexible airways open and force the liquid plug to flow distally by the incoming air stream. Airway reopening depends to a large extent on this plug flow and how it may lead to plug rupture to regain the continuity of gas between the environment and the alveoli. In addition to mathematical modeling of plug flows in liquid-lined, flexible tubes, this work has involved benchtop studies of propagating liquid plugs down tube networks that mimic the human airway tree. We have extended the work to involve animal models of liquid plug propagation in rat lungs. The liquid is radio-opaque and x-ray video imaging is used to ascertain the movement and distribution of the liquid plugs so that comparisons to theory may be made. This research has other uses, such as the delivery of liquids or drugs into the lung that may be used for surfactant replacement therapy or for liquid ventilation.

Grotberg, James B.↗
NASA NTRS2000

Burning in Outer Space: Microgravity

A better understanding of combustion can lead to significant technological advances, such as less polluting, more fuel-efficient vehicles. Unfortunately, gravity can interfere with the study of combustion. Gravity drags down gases that are cooler- and, therefore, denser-than heated gases. This movement mixes the fuel and the oxidizer substance that promotes burning. Because of this mixing, an observer cannot necessarily distinguish what is happening as a result of the natural combustion process and what is caused, by the pull of gravity. To remove this uncertainty, scientists can conduct experiments that simulate the negation of gravity through freefall. This condition is known as a microgravity environment. A micro-gravity experiment may take place in a chamber that is dropped down a hole or from a high-speed drop tower. The experiment also be conducted in an airplane or a rocket during freefall in a parabolic flight path. This method provides less than a minute of microgravity at most. An experiment that requires the prolonged absence of gravity may necessitate the use of an orbiting spacecraft as a venue. However, access to an orbital laboratory is difficult to acquire. High-end computing centers such as the NCCS can provide a practical alternative to operating in microgravity. Scientists can model phenomena such as combustion without gravitys observational interference. The study of microgravity combustion produces important benefits beyond increased observational accuracy. Certain valuable materials that are produced through combustion can be formed with a more uniform crystal structure-and, therefore, improved structural quality-when the pull of gravity is removed. Furthermore, understanding how fires propagate in the absence of gravity can improve fire safety aboard spacecraft.

Matkowsky, Bernard↗
NASA NTRS2002

Novel Advancements in Internet-Based Real Time Data Technologies

AZ Technology has been working with MSFC Ground Systems Department to find ways to make it easier for remote experimenters (RPI's) to monitor their International Space Station (ISS) payloads in real-time from anywhere using standard/familiar devices. AZ Technology was awarded an SBIR Phase I grant to research the technologies behind and advancements of distributing live ISS data across the Internet. That research resulted in a product called "EZStream" which is in use on several ISS-related projects. Although the initial implementation is geared toward ISS, the architecture and lessons learned are applicable to other space-related programs. This paper presents the high-level architecture and components that make up EZStream. A combination of commercial-off-the-shelf (COTS) and custom components were used and their interaction will be discussed. The server is powered by Apache's Jakarta-Tomcat web server/servlet engine. User accounts are maintained in a My SQL database. Both Tomcat and MySQL are Open Source products. When used for ISS, EZStream pulls the live data directly from NASA's Telescience Resource Kit (TReK) API. TReK parses the ISS data stream into individual measurement parameters and performs on-the- fly engineering unit conversion and range checking before passing the data to EZStream for distribution. TReK is provided by NASA at no charge to ISS experimenters. By using a combination of well established Open Source, NASA-supplied. and AZ Technology-developed components, operations using EZStream are robust and economical. Security over the Internet is a major concern on most space programs. This paper describes how EZStream provides for secure connection to and transmission of space- related data over the public Internet. Display pages that show sensitive data can be placed under access control by EZStream. Users are required to login before being allowed to pull up those web pages. To enhance security, the EZStream client/server data transmissions can be encrypted to preclude interception. EZStream was developed to make use of a host of standard platforms and protocols. Each are discussed in detail in this paper. The I3ZStream server is written as Java Servlets. This allows different platforms (i.e. Windows, Unix, Linux . Mac) to host the server portion. The EZStream client component is written in two different flavors: JavaBean and ActiveX. The JavaBean component is used to develop Java Applet displays. The ActiveX component is used for developing ActiveX-based displays. Remote user devices will be covered including web browsers on PC#s and scaled-down displays for PDA's and smart cell phones. As mentioned. the interaction between EZStream (web/data server) and TReK (data source) will be covered as related to ISS. EZStream is being enhanced to receive and parse binary data stream directly. This makes EZStream beneficial to both the ISS International Partners and non-NASA applications (i.e. factory floor monitoring). The options for developing client-side display web pages will be addressed along with the development of tools to allow creation of display web pages by non-programmers.

Myers, Gerry↗
NASA NTRS1961

Flight Investigation of Effects of Selected Operating Conditions on the Bending and Torsional Moments Encountered by a Helicopter Rotor Blade

Flight tests have been conducted with a single-rotor helicopter to determine the effects of partial-power descents with forward speed, high-speed level turns, pull-outs from autorotation, and high-forward-speed high-rotor-speed autorotation on the flapwise bending and torsional moments of the rotor blade. One blade of the helicopter was equipped at 14 percent and 40 percent of the blade radius with strain gages calibrated to measure moments rather than stresses. The results indicate that the maximum moments encountered in partial-power descents with forward speed tend to be generally reduced from the maximum moments encountered during partid-power descents at zero forward speed. High-speed level turns and pull-outs from auto-rotation caused retreating-blade stall which produced torsional moments (values up to 2,400 inch-pounds). at the 14-percent-radius station that were as large as those encountered during the previous investigations of retreating-blade stall (values up t o 2,500 inch-pounds). High-forward- speed high-rotor-speed autorotation produced flapwise bending moments (values up to 7,200 inch-pounds) at the 40-percent-radius station which were as large as the flapwise bending moments (values up to 7,800 inch-pounds) a t the 14-percent-radius station encountered during partial - power vertical descents. The results of the present investigation (tip-speed ratios up to 0.325 and an unaccelerated level-flight mean lift coefficient of about 0.6), in combination with the related results of at zero forward speed produce the largest rotor-blade vibratory moments. However, inasmuch as these large moments occur only during 1 percent of the cycles and 88 percent of the cycles are at moment values less than 70 percent of these maximum values in partial-power descents, other conditions, such as high-speed flight where the large moments are combined with large percentages of time spent,must not be neglected in any rotor-blade service-life assessment.

Ludi, LeRoy H.↗
NASA NTRS2002

Factors Affecting the Latitudinal Location of the Intertropical Convergence Zone in a GCM

The dominant role of the latitudinal peak of the sea surface temperature (SST) in determining the latitudinal location of the intertropical convergence zone (ITCZ) is well-known. However, the roles of the other factors are less well-known and are the topic of this study. These other factors include the inertial stability, the interaction between convection and surface fluxes and the interaction between convection and radiation. Since these interactions involve convection, in a model they involve the cumulus parameterization scheme. These factors are studied with a general circulation model with uniform SST and solar angle. Under the aforementioned model settings, the latitudinal location of the ITCZ is the latitude where the balance of two types of attraction on the ITCZ, both due to earth's rotation, exists. Directly related to the Coriolis parameter, the first type pulls the ITCZ toward the equator and is not sensitive to model design changes. Related to the convective circulation, the second type pulls the ITCZ poleward and is sensitive to model design changes. Due to the shape and the magnitude of the attractors, the balance of the two types of attractions is reached either at the equator or more than 10 degrees away from the equator. The former case results in a single ITCZ over the equator and the latter case a double ITCZ straddling the equator.

Chao, Winston C.↗
NASA NTRS1946

Airscrew Gyroscopic Moments

When flying in a turn or pulling out of a dive, the airscrew exerts a gyroscopic moment on the aircraft, In the case of airscrews with three or more blades, arranged symmetrically, the value of the gyroscopic moment is J(sub x) omega(sub x) omega(sub y), where J(sub x) denotes the axial moment of inertia about the axis of rotation of the airscrew, omega(sub x) the angular upeed of the airscrew about its axis, and omega (sub Y) the rotary speed of the whole aircraft about an axis parallel to the plane of the airscrew (e.g., when pulling up, the transverse axis of the aircraft). The gyroscopic moment then tends to rotate the aircraft about an axis perpendicular to those of the two angular speeds and, in the came of airscrews with three or more blades, is constant during a revolution of the airscrew. With two-bladed airscrews, on the contrary, although the calculate gyroscopic moment represents the mean value in time, it fluctuates about this value with a frequency equal to twice the revolutions per minute. In addition, pulsating moments likewise occur about the other two axes. This fact is known from the theory of the asymmetrical gyro; the calculations that have been carried out for the determination of the various gyroscopic moments, however, mostly require an exact knowledge of the gyro theory. The problem will therefore be approached in another manner based on quite elementary considerations. The considerations are of importance, not only in connection with the gyroscopic moments exerted by the two-bladed airscrew on the aircraft, but also with the stressing of the blades of airscrews with an arbitrary number of blades.

Bock, G.↗
NASA NTRS2005

Beyond Einstein: From the Big Bang to Black Holes

How did the Universe begin? Does time have a beginning and an end? Does space have edges? The questions are clear and simple. They are as old as human curiosity. But the answers have always seemed beyond the reach of science. Until now. In their attempts to understand how space, time, and matter are connected, Einstein and his successors made three predictions. First, space is expanding from a Big Bang; second, space and time can tie themselves into contorted knots called black holes where time actually comes to a halt; third, space itself contains some kind of energy that is pull- ing the Universe apart. Each of these three predictions seemed so fantastic when it was made that everyone, including Einstein himself, regarded them as unlikely. Incredibly, all three have turned out to be true. Yet Einstein's legacy is one of deep mystery, because his theories are silent on three questions raised by his fantastic predictions: (1) What powered the Big Bang? (2) What happens to space, time, and matter at the edge of a black hole? (3) What is the mysterious dark energy pulling the Universe apart? The answers to these questions-which lie at the crux of where our current theories fail us-will lead to a profound, new understanding of the nature of time and space. To find answers, however, we must venture beyond Einstein. The answers require new theories, such as the inflationary Universe and new insights in high-energy particle theory. Like Einstein s theories, these make fantastic predictions that seem hard to believe: unseen dimensions and entire universes beyond our own. We must find facts to confront and guide these new theories. Powerful new technologies now make this possible. And NASA and its partners are developing an armada of space-based observatories to chart the path to discovery. Here is where the Beyond Einstein story begins. By exploring the three questions that are Einstein s legacy, we begin the next revolution in understanding our Universe. We plot our way forward using clues from observations and from new ideas connecting the worlds of the very small and the very large, from the atom out through the deepest reaches of the cosmos.

Source record↗
NASA NTRS2006

Metal-Ferroelectric-Semiconductor Field-Effect Transistor NAND Gate Switching Time Analysis

Previous research investigated the modeling of a N Wga te constructed of Metal-Ferroelectric- Semiconductor Field-Effect Transistors (MFSFETs) to obtain voltage transfer curves. The NAND gate was modeled using n-channel MFSFETs with positive polarization for the standard CMOS n-channel transistors and n-channel MFSFETs with negative polarization for the standard CMOS p-channel transistors. This paper investigates the MFSFET NAND gate switching time propagation delay, which is one of the other important parameters required to characterize the performance of a logic gate. Initially, the switching time of an inverter circuit was analyzed. The low-to-high and high-to-low propagation time delays were calculated. During the low-to-high transition, the negatively polarized transistor pulls up the output voltage, and during the high-to-low transition, the positively polarized transistor pulls down the output voltage. The MFSFETs were simulated by using a previously developed model which utilized a partitioned ferroelectric layer. Then the switching time of a 2-input NAND gate was analyzed similarly to the inverter gate. Extension of this technique to more complicated logic gates using MFSFETs will be studied.

Phillips, Thomas A.↗
NASA NTRS2007

Wire Crimp Termination Verification Using Ultrasonic Inspection

The development of a new ultrasonic measurement technique to quantitatively assess wire crimp terminations is discussed. The amplitude change of a compressional ultrasonic wave propagating through the junction of a crimp termination and wire is shown to correlate with the results of a destructive pull test, which is a standard for assessing crimp wire junction quality. Various crimp junction pathologies such as undercrimping, missing wire strands, incomplete wire insertion, partial insulation removal, and incorrect wire gauge are ultrasonically tested, and their results are correlated with pull tests. Results show that the nondestructive ultrasonic measurement technique consistently (as evidenced with destructive testing) predicts good crimps when ultrasonic transmission is above a certain threshold amplitude level. A physics-based model, solved by finite element analysis, describes the compressional ultrasonic wave propagation through the junction during the crimping process. This model is in agreement within 6% of the ultrasonic measurements. A prototype instrument for applying this technique while wire crimps are installed is also presented. The instrument is based on a two-jaw type crimp tool suitable for butt-splice type connections. Finally, an approach for application to multipin indenter type crimps will be discussed.

Perey, Daniel F.↗
NASA NTRS1998

Micromachined peristaltic pump

A micromachined pump including a channel formed in a semiconductor substrate by conventional processes such as chemical etching. A number of insulating barriers are established in the substrate parallel to one another and transverse to the channel. The barriers separate a series of electrically conductive strips. An overlying flexible conductive membrane is applied over the channel and conductive strips with an insulating layer separating the conductive strips from the conductive membrane. Application of a sequential voltage to the series of strips pulls the membrane into the channel portion of each successive strip to achieve a pumping action. A particularly desirable arrangement employs a micromachined push-pull dual channel cavity employing two substrates with a single membrane sandwiched between them.

Hartley, Frank T.↗
NASA NTRS1994

Particle sensor array

A particle sensor array which in a preferred embodiment comprises a static random access memory having a plurality of ion-sensitive memory cells, each such cell comprising at least one pull-down field effect transistor having a sensitive drain surface area (such as by bloating) and at least one pull-up field effect transistor having a source connected to an offset voltage. The sensitive drain surface area and the offset voltage are selected for memory cell upset by incident ions such as alpha-particles. The static random access memory of the present invention provides a means for selectively biasing the memory cells into the same state in which each of the sensitive drain surface areas is reverse biased and then selectively reducing the reversed bias on these sensitive drain surface areas for increasing the upset sensitivity of the cells to ions. The resulting selectively sensitive memory cells can be used in a number of applications. By way of example, the present invention can be used for measuring the linear energy transfer of ion particles, as well as a device for assessing the resistance of CMOS latches to Cosmic Ray induced single event upsets. The sensor of the present invention can also be used to determine the uniformity of an ion beam.

Buehler, Martin G.↗
NASA NTRS2008

Effect of Orion Post-Touchdown Parachute Release Time on Vehicle Rollover

The effects that the Orion parachutes have on the vehicle response once the vehicle lands on the ground are examined in this report. A concern with the Orion landing is that structural accelerations will cause vehicle and/or crew injuries or that the vehicle may roll over. The parachute effects are thought to have the potential of pulling the vehicle over during conditions such as higher winds or in some cases stabilizing the vehicle by preventing its motions after touchdown. A collection of representative landing conditions is used to assess the post-touchdown parachute release effect, and it was determined that, in general, there is no significant advantage or disadvantage to releasing the parachutes past the time when the vehicle touches ground. For landing conditions when there is a high horizontal wind, retaining the parachutes has a detrimental effect on vehicle rollover because the drag force on the parachutes pulls the vehicle over. Under this condition, some form of automated parachute release should be a requirement given that an attached parachute may cause the vehicle to roll over. An automated system would ensure that the release occur within 0.50 sec of touchdown (time when parachute regains tension), which is not enough time for a crew-operated manual release.

Lawrence, Charles↗
NASA NTRS2009

Silicon Microleaks for Inlets of Mass Spectrometers

Microleaks for inlets of mass spectrometers used to analyze atmospheric gases can be fabricated in silicon wafers by means of photolithography, etching, and other techniques that are commonly used in the manufacture of integrated circuits and microelectromechanical systems. The microleaks serve to limit the flows of the gases into the mass-spectrometer vacuums to specified very small flow rates consistent with the capacities of the spectrometer vacuum pumps. There is a need to be able to precisely tailor the dimensions of each microleak so as to tailor its conductance to a precise low value. (As used here, "conductance" signifies the ratio between the rate of flow in the leak and the pressure drop from the upstream to the downstream end of the leak.) To date, microleaks have been made, variously, of crimped metal tubes, pulled glass tubes, or frits. Crimped-metal and pulled-glass-tube microleaks cannot readily be fabricated repeatably to precise dimensions and are susceptible to clogging with droplets or particles. Frits tend to be differentially chemically reactive with various gas constituents and, hence, to distort the gas mixtures to be analyzed. The present approach involving microfabrication in silicon largely overcomes the disadvantages of the prior approaches.

Harpold, Dan↗
NASA NTRS2008

Compact, Highly Stable Ion Atomic Clock

A mercury-ion clock now at the breadboard stage of development (see figure) has a stability comparable to that of a hydrogen-maser clock: In tests, the clock exhibited an Allan deviation of between 2 x 10(exp -13) and 3 x 10(exp -13) at a measurement time of 1 second, averaging to about 10(exp -15) at 1 day. However, the clock occupies a volume of only about 2 liters . about a hundredth of the volume of a hydrogen-maser clock. The ion-handling parts of the apparatus are housed in a sealed vacuum tube, wherein only a getter pump is used to maintain the vacuum. Hence, this apparatus is a prototype of a generation of small, potentially portable high-precision clocks for diverse ground- and space-based navigation and radio science applications. Furthermore, this new ion-clock technology is about 100 times more stable and precise than the rubidium atomic clocks currently in use in the NAV STAR GPS Earth-orbiting satellites. In this clock, mercury ions are shuttled between a quadrupole and a 16-pole linear radio-frequency trap. In the quadrupole trap, the ions are tightly confined and optical state selection from a Hg-202 radio-frequency-discharge ultraviolet lamp is carried out. In the 16-pole trap, the ions are more loosely confined and atomic transitions resonant at frequency of about 40.507 GHz are interrogated by use of a microwave beam at that frequency. The trapping of ions effectively eliminates the frequency pulling caused by wall collisions inherent to gas-cell clocks. The shuttling of the ions between the two traps enables separation of the state-selection process from the clock microwave- resonance process, so that each of these processes can be optimized independently of the other. The basic ion-shuttling, two-trap scheme as described thus far is not new: it has been the basis of designs of prior larger clocks. The novelty of the present development lies in major redesigns of its physics package (the ion traps and the vacuum and optical subsystems) to effect the desired reduction of size to a volume of no more than a couple of liters. The redesign effort has included selection of materials for the vacuum tube, ion trap, and ultraviolet windows that withstand bakeout at a temperature of approx.450 C in preparation for sealing the tube to contain the vacuum. This part of the redesign effort follows the approach taken in the development of such other vacuum-tube electronic components as flight traveling- wave-tube amplifiers having operational and shelf lives as long as 15 years. The redesign effort has also included a thorough study of residual-gas-induced shifts of the ion-clock frequency and a study of alternative gases as candidates for use as a buffer gas within the sealed tube. It has been found that neon is more suitable than is helium, which has been traditionally used for this purpose, in that the pressure-induced frequency pulling by neon is between a third and a half of that of helium. In addition, because neon diffuses through solids much more slowly than does helium, the loss of neon by diffusion over the operational lifetime is expected to be negligible.

Prestage, John↗
NASA NTRS2009

NASA Bioreactors Advance Disease Treatments

The International Space Station (ISS) is falling. This is no threat to the astronauts onboard, however, because falling is part of the ISS staying in orbit. The absence of gravity beyond the Earth s atmosphere is actually an illusion; at the ISS s orbital altitude of approximately 250 miles above the surface, the planet s gravitational pull is only 12-percent weaker than on the ground. Gravity is constantly pulling the ISS back to Earth, but the space station is also constantly traveling at nearly 18,000 miles per hour. This means that, even though the ISS is falling toward Earth, it is moving sideways fast enough to continually miss impacting the planet. The balance between the force of gravity and the ISS s motion creates a stable orbit, and the fact that the ISS and everything in it including the astronauts are falling at an equal rate creates the condition of weightlessness called microgravity. The constant falling of objects in orbit is not only an important principle in space, but it is also a key element of a revolutionary NASA technology here on Earth that may soon help cure medical ailments from heart disease to diabetes. In the mid-1980s, NASA researchers at Johnson Space Center were investigating the effects of long-term microgravity on human tissues. At the time, the Agency s shuttle fleet was grounded following the 1986 Space Shuttle Challenger disaster, and researchers had no access to the microgravity conditions of space. To provide a method for recreating such conditions on Earth, Johnson s David Wolf, Tinh Trinh, and Ray Schwarz developed that same year a horizontal, rotating device called a rotating wall bioreactor that allowed the growth of human cells in simulated weightlessness. Previously, cell cultures on Earth could only be grown two-dimensionally in Petri dishes, because gravity would cause the multiplying cells to sink within their growth medium. These cells do not look or function like real human cells, which grow three-dimensionally in the body. Experiments conducted by Johnson scientist Dr. Thomas Goodwin proved that the NASA bioreactor could successfully cultivate cells using simulated microgravity, resulting in three-dimensional tissues that more closely approximate those in the body. Further experiments conducted on space shuttle missions and by Wolf as an astronaut on the Mir space station demonstrated that the bioreactor s effects were even further expanded in space, resulting in remarkable levels of tissue formation. While the bioreactor may one day culture red blood cells for injured astronauts or single-celled organisms like algae as food or oxygen producers for a Mars colony, the technology s cell growth capability offers significant opportunities for terrestrial medical research right now. A small Texas company is taking advantage of the NASA technology to advance promising treatment applications for diseases both common and obscure.

Source record↗
NASA NTRS2007

Improved Quick-Release Pin Mechanism

An improved quick-release pin mechanism supplants a prior such mechanism in which the pin bears a shear load to hold two objects together. The prior mechanism, of a ball-locking design, can fail when vibrations cause balls to fall out. The load-bearing pin is an outer tube with a handle at one end (hereafter denoted the near end). Within the outer tube is a spring-loaded inner tube that includes a handle at its near end and a pivoting tab at its far end. The pin is inserted through holes in the objects to be retained and the inner tube is pushed against an offset pivot inside the outer tube to make the tab rotate outward so that it protrudes past the outer diameter of the outer tube, and the spring load maintains this configuration so that the pin cannot be withdrawn through the holes. Pushing the handles together against the spring load moves the locking tab out far enough that the tab becomes free to rotate inward. Then releasing the inner-tube handle causes the tab to be pulled into a resting position inside the outer tube. The pin can then be pulled out through the holes.

Wright, Jay M.↗
NASA NTRS2010

A Method For The Verification Of Wire Crimp Compression Using Ultrasonic Inspection

The development of a new ultrasonic measurement technique to assess quantitatively wire crimp terminations is discussed. The amplitude change of a compressional ultrasonic wave propagating at right angles to the wire axis and through the junction of a crimp termination is shown to correlate with the results of a destructive pull test, which is a standard for assessing crimp wire junction quality. To demonstrate the technique, the case of incomplete compression of crimped connections is ultrasonically tested, and the results are correlated with pull tests. Results show that the nondestructive ultrasonic measurement technique consistently predicts good crimps when the ultrasonic transmission is above a certain threshold amplitude level. A quantitative measure of the quality of the crimped connection based on the ultrasonic energy transmitted is shown to respond accurately to crimp quality. A wave propagation model, solved by finite element analysis, describes the compressional ultrasonic wave propagation through the junction during the crimping process. This model is in agreement within 6% of the ultrasonic measurements. A prototype instrument for applying this technique while wire crimps are installed is also presented. The instrument is based on a two-jaw type crimp tool suitable for butt-splice type connections. A comparison of the results of two different instruments is presented and shows reproducibility between instruments within a 95% confidence bound.

Cramer, K. E.↗