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The objective of this work is to perfect and extend the acoustic position technique that was developed at JPL for use in the future Space Processing Laboratory in Space. The main effort is centered on design of a position device for processing of molten materials. Namely, a resonator has the capability of positioning in an extreme temperature gradient and a frequency servo loop to maintain it there as the temperature varies.
This presentation will discuss the multiple projects performed in United Space Alliance's Human Engineering Modeling and Performance (HEMAP) Lab, improvements that resulted from analysis, and the future applications of the HEMAP Lab for risk assessment by evaluating human/machine interaction and ergonomic designs.
As NASA s Dawn spacecraft explores the surface of Vesta, it has become abundantly clear that Vesta is like no other planetary body visited to date. Dawn is collecting global data at increasingly higher spatial resolution during its one-year orbital mission. The bulk properties of Vesta have previously been linked to the HED meteorites through remote mineral characterization of its surface from Earth-based spectroscopy. A principal puzzle has been why Vesta exhibits relatively unweathered diagnostic optical features compared to other large asteroids. Is this due to the composition of this proto-planet or the space environment at Vesta? Alteration or weathering of materials in space normally develops as the products of several processes accumulate on the surface or in an evolving particulate regolith, transforming the bedrock into fragmental material with properties that may be measurably different from the original. Data from Dawn reveal that the regolith of Vesta is exceptionally diverse. Regional surface units are observed that have not been erased by weathering with time. Several morphologically-fresh craters have excavated bright, mafic-rich materials and exhibit bright ray systems. Some of the larger craters have surrounding subdued regions (often asymmetric) that are lower in albedo and relatively red-sloped in the visible while exhibiting weaker mafic signatures. Several other prominent craters have rim exposures containing very dark material and/or display a system of prominent dark rays. Most, but not all, dark areas associated with craters exhibit significantly lower spectral contrast, suggesting that either a Vesta lithology with an opaque component has been exposed locally or that the surface has been contaminated by a relatively dark impactor. Similarly, most, but not all, bright areas associated with craters exhibit enhanced mafic signatures compared to surroundings. On a regional scale, the large south polar structure and surrounding terrain exhibit relatively strong mafic absorption features, suggesting either a concentration of mafic materials or that materials exposed have been less affected by space weathering products. These combined initial observations indicate some space weathering processes are active in this part of the main asteroid belt, but are highly variable across the surface of Vesta. Such processes include: impacts from wandering asteroidal debris and local mixing at both micro- and macro-scales, irradiation by solar wind and galactic particles, production and distribution of impact breccias or melt products, and local movement of materials to gravity lows (gradual as well as sudden).
A study program was conducted to clarify the role of gravity in the fluid mechanics of certain molten metal processes of potential significance to manufacturing in space. In particular, analyses were conducted of the M551 Metals Melting Experiment and the M553 Sphere Forming Experiment to be conducted in the M512 Facility onboard Skylab. The M551 experiment consisted of a study of electron beam welding of various metals, and the M553 experiment studied the formation of molten metal spheres by free-floating in a near zero-gravity environment. The analyses of these experiments and a comparison with ground-based and KC135 experimental results are presented.
A study program was conducted to clarify the role of gravity in the fluid mechanics of certain molten metal processes of potential significance to manufacturing in space. In particular, analyses were conducted of the M551 Metals Melting Experiment and the M553 Sphere Forming Experiment to be conducted in the M512 Facility onboard Skylab. The M551 experiment consisted of a study of electron beam welding of various metals, and the M553 experiment studied the formation of molten metal spheres by free-floating in a near zero-gravity environment. The analyses of these experiments and a comparison with ground-based and KC135 experimental results are presented.
Range and azimuth correlation in the time domain using current state-of-the-art CCD LSI technology provides a potentially practical means of achieving real-time pipeline processing of SAR images for future space missions. The proposed range correlator approach, using already demonstrated CCD transversal filtering techniques, will require very little power: less than 10 watts per Seasat-type 20-km processing module. The azimuth correlator architecture is considerably more demanding since it requires a large number of parallel chips (1020 for a Seasat-type 20-km module) to achieve a real-time processing capability.
Crystal growth; solidification of metals, alloys, and composites; fluids, transports, and chemical processes; and ultrahigh vacuum and containerless technologies are discussed.
The design, construction and calibration of a computer-linked multicolor pyrometer is described. The device was constructed for ready adaptation to a spacecraft and for use in the control of thermal processes for manufacturing materials in space. The pyrometer actually uses only one color at a time, and is relatively insensitive to uncertainties in the heated object's emissivity because the product of the color and the temperature has been selected to be within a regime where the radiant energy emitted from the body increases very rapidly with temperature. The instrument was calibrated and shown to exceed its design goal of temperature measurements between 300 and 2000 C, and its accuracy in the face of imprecise knowledge of the hot object's emissivity was demonstrated.
As space missions become longer in duration and reach out to more distant locations such as Mars, solids waste processing progresses from storage technologies to reclamation technologies. Current low Earth orbit technologies consist of store-and dispose to space or return to Earth. Fully regenerative technologies recycle wastes. The materials reclaimed from waste can be used to provide the basic materials to support plant growth for food including carbon dioxide, water, and nutrients. Other products can also be reclaimed from waste such as hydrocarbons and activated carbon. This poster describes development at Ames Research Center of a process to make activated carbon from space mission wastes and to make an incineration system that produces clean flue gas. Inedible biomass and feces contain hydrocarbons in a form that can be pyrolyzed and converted to activated carbon. The activated carbon can then be used to clean up contaminants from various other life support systems; in particular, the activated carbon can be used regeneratively to remove NOx from incinerator flue gas. Incinerator flue gas can also be cleaned up by the use of reductive and oxidative catalysts. A catalytic incinerator flue gas cleanup system has been developed at ARC that produces flue gas clean enough (with the exception of carbon dioxide) to meet the Space Minimum Allowable Concentration limits for human exposure.
Flight experiments utilizing a low gravity environment to elucidate and control various processes, or ground based activities that provide supporting research are compiled. Six major categories: crystal growth; solidification of metals, alloys, and composites; fluids, transports, and chemical processes; glasses and ceramics; ultrahigh vacuum and containerless processing technologies; and combustion are included. A list of patents and appendices providing a compilation of anonymously authored collections and reports and a cross reference index are included.
Literature dealing with flight experiments utilizing a low gravity environment to elucidate and control various processes or with ground based activities that provide supporting research is listed. Included are Government reports, contractor reports, conference proceedings, and journal articles. Subdivisions of the bibliography include the five categories: crystal growth; metals, alloys, and composites, fluids and transport; glasses and ceramics; and Ultrahigh Vacuum and Containerless Processing Technologies, in addition to a list of patents and a compilation of anonymously authored collections and reports and a cross reference index.
A new method is described, including results, to measure, control, and follow containerless processing in ground based levitators. This technique enables instantaneous optical property measurements from a transient solid or liquid surface concurrent with true temperature measurement. This was used successfully as a diagnostic tool to follow processing of Al, Si, and Ti during electromagnetic levitation. Experiments on Al show the disappearance of the oxide (emittance 0.33) at ca. 1300 C leaving a liquid surface with an emittance of 0.06. Electromagnetic levitation of silicon shows a liquid with a constant emittance (0.2) but with a solid whose emittance decreases very rapidly with increasing temperature. Consequently, the processing of materials at high temperatures can be controlled quite well through the control of surface optical properties.
Data collection and processing from space science satellites
This work is motivated by NASA plans to conduct welding experiments on the ISS. It is expected that deployment of welding and additive manufacturing technologies in the space environment has the potential to revolutionise how orbiting platforms are designed, manufactured, and assembled. However, the structure, composition and quality of a weld is extremely dependent on the environment and can be difficult to control in space. Shielding gases would also be tough to manage as gases behave differently in zero gravity and airless environments. Additional points of concern are related to the spatter and sparks dynamics in space. Therefore, there is a need for a more basic understanding of welding processes by computational modelling. To provide such an insight we developed state of art models of the ARC torch, droplet detachment and transfer, and the melt pool build up using magnetohydrodynamics approximation and level set method for two-phase liquid metal/-gas flow modelling. Two finite element models were built using 2D axisymmetric geometry in COMSOL Multiphysics®: (i) stationary model of the ARC torch and (ii) dynamical model of droplet detachment and transfer. Both models demonstrate reasonable agreement with earlier experimental observations and high sensitivity to the temperature dependence of the thermophysical parameters on the system materials. The models were used to provide physical insight into ARC welding in various environments and geometries. It was shown, in particular, that there is a significant probability of gas bubbles trapping in the meltpool and a possibility of unbounded wondering of sparks in the welding chamber in zero gravity. In addition, we estimated metal evaporation rate that may be hazardous in the confined environment of the ISS. These issues raise concern of quality of the weld and safety for ISS applications.
The metallographic characterization, analysis, and property measurement of ground samples for comparison with those processed on Skylab are described. Experiments on metals melting and exothermic brazing are summarized, and results are presented.
A number of visualization techniques are discussed in a laboratory experiment designed to study phenomena that occur in space. Visualization tools are used to design the apparatus, collect data, and make one-, two-, and three-dimensional plots of the results. These tools are an indispensable part of the experiment because the data sets are hundreds of megabytes in size and rapid turnaround is required.
Nickel-tin (12 wt percent tin) samples were processed in the sphere forming experiment on Skylab 2. The results were characterized for sphericity, density, microhardness, porosity, surface morphology, segregation, chemical composition, Curie point, and crystallography. These results are discussed along with conclusions and recommendations.
Dimensionless conservation equations are presented and the theoretical bases of fluid behavior aboard orbiting satellites with application to the processes of manufacturing crystals in weightlessness. The small amount of gravitational acceleration is shown to increase the separation of bands of varying concentration. Natural convection is shown to have no practical effect on crystallization from a liquid melt. Barodiffusion is also negligibly small in realistic conditions of weightlessness. The effects of surface tension become increasingly large, and suggestions are made for further research.