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Large compound curved surfaces for collecting and concentrating radiation are fabricated by the use of several common machining and forming processes. Lightweight sectors are assembled into large reflectors. With this concept of fabrication, integrally stiffened reflective sectors up to 25 square feet in area have been produced.
The National Aeronautics and Space Administration (NASA) Exploration Systems Mission Directorate initiated an Advanced Composite Technology Project through the Exploration Technology Development Program in order to support the polymer composite needs for future heavy lift launch architectures. As an example, the large composite dry structural applications on Ares V inspired the evaluation of autoclave and out-of-autoclave (OOA) composite materials. A NASA and industry team selected the most appropriate materials based on component requirements for a heavy lift launch vehicle. Autoclaved and OOA composites were fabricated and results will highlight differences in processing conditions, laminate quality, as well as initial room temperature thermal and mechanical performance. Results from this study compare solid laminates that were both fiber-placed and hand-laid. Due to the large size of heavy-lift launch vehicle composite structures, there is significant potential that the uncured composite material or prepreg will experience significant out-life during component fabrication. Therefore, prepreg out-life was a critical factor examined in this comparison. In order to rigorously test material suppliers recommended out-life, the NASA/Industry team extended the out-time of the uncured composite prepreg to values that were approximately 50% beyond the manufacturers out-time limits. Early results indicate that the OOA prepreg composite materials suffered in both composite quality and mechanical property performance from their extended out-time. However, the OOA materials performed similarly to the autoclaved composites when processed within a few days of exposure to ambient "shop" floor handling. Follow on studies evaluating autoclave and OOA aluminum honeycomb core sandwich composites are planned.
Contaminated air and process gases, whether in a crewed spacecraft cabin atmosphere, the working volume of a microgravity science or ground-based laboratory experiment facility, or the exhaust from an automobile, are pervasive problems that ultimately effect human health, performance, and well-being. The need for highly-effective, economical decontamination processes spans a wide range of terrestrial and space flight applications. Adsorption processes are used widely for process gas decontamination. Most industrial packed bed adsorption processes use activated carbon because it is cheap and highly effective. Once saturated, however, the adsorbent is a concentrated source of contaminants. Industrial applications either dump or regenerate the activated carbon. Regeneration may be accomplished in-situ or at an off-site location. In either case, concentrated contaminated waste streams must be handled appropriately to minimize environmental impact. As economic and regulatory forces drive toward minimizing waste and environmental impact, thermal catalytic oxidation is becoming more attractive. Through novel reactor and catalyst design, more complete contaminant destruction and greater resistance to poisoning can achieved leading to less waste handling, process down-time, and maintenance. Performance of a prototype thermal catalytic reactor, based on ultra-short channel monolith (USCM) catalyst substrate design, under a variety of process flow and contaminant loading conditions is discussed. The experimental results are evaluated against present and future air quality control and process gas purification processes used on board crewed spacecraft.
The use of environmental DNA (eDNA) sampling has been proposed as a complementary method to monitor fish species in marine environments, offering a non-invasive and potentially more efficient approach to marine species observations. eDNA monitoring could be especially useful in and around sites targeted for marine energy generation as these regions need regular monitoring that would be impractical with traditional techniques. Before we can fully rely upon eDNA, we must first verify its accuracy against other proven methods, such as the use of underwater photography. In this study, I deployed a 360-degree camera in the tidal channel of Sequim Bay once a month during several hours overlapping slack tide. I investigated how having multiple people identify and count fish on underwater images could affect the overall results. Using chi square tests in R, I compared my fish identifications and counts to those made by another intern on the same images recorded in August. I found significant differences in the number of species identified and the total individual counts between the two different datasets. I also tested the statistical differences in both Shannon diversity and Pielou evenness indices between the August, September, and November camera deployments using a Hutcheson t-test. Only one significant difference was found in the Shannon index comparisons, and none were found between the Pielou evenness comparisons. These findings show that if multiple identifiers are used to process underwater images, quality control checks must be made to reduce the potential for error. This also points toward the possibility to leverage more advanced image analysis processes, such as automated image analysis software. The findings from this study also show that the dynamics of marine fish communities can vary over a few months; however, further analysis is needed to determine the extent of the seasonal changes in Sequim Bay.
High temperature (300 C) diodes for geothermal and other energy applications were developed. A comparison of reverse leakage currents of Si, GaAs, and GaP was made. Diodes made from GaP should be usable to 500 C. A Liquid Phase Epitaxy (LPE) process for producing high quality, grown junction GaP diodes is described. This process uses low vapor pressure Mg as a dopant which allows multiple boat growth in the same LPE run. These LPE wafers were cut into die and metallized to make the diodes. These diodes produce leakage currents below ten to the -9th power A/sq cm at 400 C while exhibiting good high temperature rectification characteristics. High temperature life test data is presented which shows exceptional stability of the V-I characteristics.
The development and demonstration of manufacturing technologies for the structural application of Celion graphite/LARC-160 polyimide composite material is discussed. Process development and fabrication of demonstration components are discussed. Process development included establishing quality assurance of the basic composite material and processing, nondestructive inspection of fabricated components, developing processes for specific structural forms, and qualification of processes through mechanical testing. Demonstration components were fabricated. The demonstration components consisted of flat laminates, skin/stringer panels, honeycomb panels, chopped fiber compression moldings, and a technology demonstrator segment (TDS) representative of the space shuttle aft body flap.
This document outlines the structural verification approach for the Space Shuttle External Tank Forward Bipod Foam Closeout. Due to the Space Shuttle Columbia accident, debris has become a major concern. The intent of the structural verification is to ensure that any debris shed from the bipod is within acceptable limits. Since cohesive failure due to internal defects was identified as the most likely cause of the STS-107 bipod ramp foam failure, verification for this failure mode receives particular emphasis. However, all failure modes for TPS are considered and appropriate verification rationale is developed for each failure mode. Figure 1 depicts the structural verification of a production design where analysis and test are the primary methods of verification. It can be seen that the successful completion of structural verification is dependent on three main areas: 1. Production process control and quality assurance must ensure that test articles and/or analytical models are representative of (or conservatively envelope) production hardware in terms of geometry, materials and processing. Variability and defects must be considered. 2. Flight environments must be sufficiently characterized to bound driving environments for all failure modes. Applied environments, either test or analytical, must be representative of flight environments and have a load factor that satisfies design requirements. 3. Structural verification must include all failure modes. A comprehensive list of failure modes and the underlying failure mechanisms has been generated based on flight and test experience. Verification tests and / or analyses must address each failure mode. ET TPS Verification is accomplished by a combination of analysis, test, and similarity.
This slide presentation reviews the developments at Marshall Space Flight Center in fabricating Electroformed Nickel X-ray Optical devices. Missions that are using the mandrels created using the described process are reviewed, and improvements in the process of creating better quality mandrels are also reviewed. One of the processes, Electrochemically-Enhanced Mechanical Polishing (EEMP), is described. The Alignment and mounting system for full-shell replicated X-Ray Optics is shown, and the selective deposition process is also shown.
The Plankton, Aerosol, Cloud, and ocean Ecosystem (PACE) mission is NASA’s next investment in ocean biology, clouds, and aerosol data records. A key feature of PACE is the inclusion of an advanced satellite radiometer, Ocean Color Instrument (OCI), a global mapping radiometer that combines multispectral and hyperspectral remote sensing. The geolocation processing is performed for OCI using spacecraft navigation data and an instrument geometry model. To evaluate the geolocation accuracy for OCI and develop refinements to the processing methods, control point matching using Landsat data has been implemented as a step in the operational processing of OCI data at the Science Data Segment. This processing provides between 200 and 300 high-quality matchups per day with good global and geometric distribution, allowing rapid evaluation of the OCI geolocation accuracy. The results provided an early indication of the overall quality of the geolocation processing and of specific aspects needing improvement. A standard set of granules was identified to support rapid implementation and testing of geolocation refinements, and this approach has been highly successful in improving the geolocation processing accuracy to meet the science requirements. The evaluation will continue throughout the mission to ensure the ongoing accuracy of geolocation. This paper describes the control point matching methodology, the approach to development of the geolocation processing refinements, and the recent results.
The Plankton, Aerosol, Cloud, and ocean Ecosystem (PACE) mission is NASA’s next investment in ocean biology, clouds, and aerosol data records. A key feature of PACE is the inclusion of an advanced satellite radiometer, Ocean Color Instrument (OCI), a global mapping radiometer that combines multispectral and hyperspectral remote sensing. The geolocation processing is performed for OCI using spacecraft navigation data and an instrument geometry model. To evaluate the geolocation accuracy for OCI and develop refinements to the processing methods, control point matching using Landsat data has been implemented as a step in the operational processing of OCI data at the Science Data Segment. This processing provides between 200 and 300 high-quality matchups per day with good global and geometric distribution, allowing rapid evaluation of the OCI geolocation accuracy. The results provided an early indication of the overall quality of the geolocation processing and of specific aspects needing improvement. A standard set of granules was identified to support rapid implementation and testing of geolocation refinements, and this approach has been highly successful in improving the geolocation processing accuracy to meet the science requirements. The evaluation will continue throughout the mission to ensure the ongoing accuracy of geolocation. This paper describes the control point matching methodology, the approach to development of the geolocation processing refinements, and the recent results.
A compression tool used to make 1-in. (2.5-cm) diameter disks of high-temperature polymers was designed to be shorter and of larger diameter than conventional tools to reduce heat loss to the surrounding air, thus making more efficient use of applied heat. This system is less sensitive to the amount and quality of insulation than previous tools, provides more repeatable processing, and improves the quality of the samples produced. These improvements come without increasing the weight of the punch portion of the tool over that of a conventional version, an important quality when handling lower-viscosity resins. In use, the base and body of the tool are assembled, and the polymer to be processed is placed into the body of the tool. The punch is inserted, and the assembled tool is placed into the press. A temperature/ pressure profile appropriate to the nature of the polymer is applied. A series of computational and experimental runs were made using a conventional tool to validate the computational model. The new tool design was then modeled, and when the performance showed a marked improvement, the new tool was manufactured. A new series of experimental runs showed that the thermal performance of the new tool agreed well with model predictions.
Wet etching, CF4 and SF6 reactive ion etching (RIE), RIE/wet hybrid etching, Cl-based RIE, ion milling, and liftoff techniques have been investigated for use in superconductive Nb/Al-Al2O3/Nb fabrication processes. High-quality superconductor-insulator-superconductor (SIS) junctions have been fabricated using a variety of these etching methods; however, each technique offers distinct tradeoffs for a given process an wafer design. In particular, it was shown that SF6 provides an excellent RIE chemistry for low-voltage anisotropic etching of Nb with high selectivity to Al. The SF6 tool has greatly improved the trilevel resist junction insulation process. Excellent repeatability, selectivity with respect to quartz, and submicron resolution make Cl2 + BCl3 + CHCl3 RIE a very attractive process for trilayer patterning.
The contouring of 8-13.5 micrometer thermal data collected over a forestry site in Virginia is described. The data were collected at an altitude of 1000 ft above terrain on November 4, 1970. The site was covered on three approximately parallel lines. The purpose of the contouring was to attempt to delineate pine trees attacked by southern pine bark beetle, and to map other important terrain categories. Special processing steps were required to achieve the correct aspect ratio of the thermal data. The reference for the correction procedure was color infrared photography. Data form and quality are given, processing steps are outlined, a brief interpretation of results is given, and conclusion are presented.
The Paton Welding Institute, Kiev, Ukraine, has developed the Universal Hand Tool for processing Metals in the space environment. The Universal is a hand held, 1 kilowatt electron beam welding tool designed to accept attachments to enable welding with and without filler wire, cutting, and coating by vapor deposition. The Marshall Space Flight Center, together with the Paton Institute, designed and developed the International Space Welding Experiment (ISWE) to demonstrate the Universal Welding System during an extravehicular activity on STS-87. ISWE was subsequently demanifested and has not been remanifested at this time. This paper describes the science objectives of ISWE, the safety hazards associated with manual welding in space and the associated resolutions, and the results of ground based development efforts. The Universal was adequate for processing the samples planned for ISWE and was successfully modified to meet shuttle payload constraints. Sample cleanliness and operator training proved to be the primary drivers for the quality of the processed samples.
The ways are described by which propellant processing is affected by choices made in designing rocket engines. Tradeoff studies, design proof or scaleup studies, and special design features are presented that are required to obtain high product quality, and optimum processing costs. Processing is considered to include the operational steps involved with the lining and preparation of the motor case for the grain; the procurement of propellant raw materials; and propellant mixing, casting or extrusion, curing, machining, and finishing. The design criteria, recommended practices, and propellant formulations are included.
Software application or development in optical image digital data processing requires a fast, good quality, yet inexpensive hard copy of processed images. To achieve this, a Cambo camera with an f 2.8/150-mm Xenotar lens in a Copal shutter having a Graflok back for 4 x 5 Polaroid type 57 pack-film has been interfaced to an existing Adage, AGT-30/Electro-Mechanical Research, EMR 6050 graphic computer system. Time-lapse photography in conjunction with a log to linear voltage transformation has resulted in an interactive system capable of producing a hard copy in 54 sec. The interactive aspect of the system lies in a Tektronix 4002 graphic computer terminal and its associated hard copy unit.
The Software Engineering Guidebook describes SEPG (Software Engineering Process Group) supported processes and techniques for engineering quality software in NASA environments. Three process models are supported: structured, object-oriented, and evolutionary rapid-prototyping. The guidebook covers software life-cycles, engineering, assurance, and configuration management. The guidebook is written for managers and engineers who manage, develop, enhance, and/or maintain software under the Computer Software Services Contract.
With the ever increases in the capabilities of computers for numerical computations, we are on the verge of using these tools to model manufacturing processes for improving the efficiency of these processes as well as the quality of the products. One such process is casting for the production of metals. However, in order to model metal casting processes in a meaningful way it is essential to have the basic properties of these materials in their molten state, solid state as well as in the mixed state of solid and liquid. Some of the properties needed may be considered as intrinsic such as the density, heat capacity or enthalpy of freezing of a pure metal, while others are not. For instance, the enthalpy of solidification of an alloy is not a defined thermodynamic quantity. Its value depends on the micro-segregation of the phases during the course of solidification. The objective of the present study is to present a thermodynamic approach to obtain some of the intrinsic properties and combining thermodynamics with kinetic models to estimate such quantities as the enthalpy of solidification of an alloy.