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A summary of S-2 Program problems and the solutions that were implemented is presented. The problems occurred during a period starting with the initial design concepts and continuing through the launch of the tenth S-2 flight stage information is from nine separate disciplines: design, facilities, logistics, manufacturing, material, program management, quality assurance, safety, and tests.
The problems associated with high-density digital recording (HDDR) are discussed. Five independent users of HDDR systems and their problems, solutions, and insights are provided as guidance for other users of HDDR systems. Various pulse code modulation coding techniques are reviewed. An introduction to error detection and correction head optimization theory and perpendicular recording are provided. Competitive tape recorder manufacturers apply all of the above theories and techniques and present their offerings. The methodology used by the HDDR Users Subcommittee of THIC to evaluate parallel HDDR systems is presented.
The research of this summer was a continuation of work started during the previous summer faculty fellowship period. The Friction Stir Welding process (FSW) patented by The Welding Institute (TWI), in Great Britain, has become a popular topic at the Marshall Space Flight Center over the past year. Last year it was considered a novel approach to welding but few people took it very seriously as a near term solution. However, due to continued problems with cracks in the new aluminum-lithium space shuttle external tank (ET), the friction stir process is being mobilized at full speed in an effort to mature this process for the potential manufacture of flight hardware. It is now the goal of NASA and Lockheed-Martin Corporation (LMC) to demonstrate a full-scale friction stir welding system capable of welding ET size barrel sections. The objectives this summer were: (1) Implementation and validation of the rotating dynamometer on the MSFC FSW system; (2) Collection of data for FSW process modeling efforts; (3) Specification development for FSW implementation on the vertical weld tool; (4) Controls and user interface development for the adjustable pin tool; and (5) Development of an instrumentation system for the planishing process. The projects started this summer will lead to a full scale friction stir welding system that is expected to produce a friction stir welded shuttle external tank type barrel section. The success of this could lead to the implementation of the friction stir process for manufacturing future shuttle external tanks.
Cogent Software, Inc. was formed in January 1995 by David Atkinson and Irene Woerner, both former employees of the Jet Propulsion Laboratory (JPL). Several other Cogent employees also worked at JPL. Atkinson headed JPL's Information Systems Technology section and Woerner lead the Advanced User Interfaces Group. Cogent's mission is to help companies organize and manage their online content by developing advanced software for the next generation of online directories and information catalogs. The company offers a complete range of Internet solutions, including Internet access, Web site design, local and wide-area networks, and custom software for online commerce applications. Cogent also offers DesignSphere Online, an electronic community for the communications arts industry. Customers range from small offices to manufacturers with thousands of employees, including Chemi-Con, one of the largest manufacturers of capacitors in the world.
For directly imaging exoplanets, NASA is considering space mission designs that use an external occulter as the principal starlight suppression system. These occulter designs range in diameter from 16 to 40 meters and separation distance from 8,000 to 60,000 kilometers for telescopes with primary diameters of 0.5 to 4 meters. Occulter shapes are solutions to an optimization problem which seeks to maximize suppression in the shadow subject to constraints such as size, separation, and wavelengths. These designs are based on scalar diffraction theory and must be verified experimentally to demonstrate predicted on-orbit performance. Due to the large sizes and separations involved the experiment must be scaled to lab size. We are currently expanding the existing experimental test-bed at Princeton to enable scaling of occulters operating at flight Fresnel sizes. Here we examine the effect on suppression performance of edge defects and their scaling to test-bed size.
Problems in spacecraft power system design, testing, integration, and operation are identified and solutions are defined. The specific technology development problems discussed include substorm and plasma design data, modeling of the power subsystem and components, power system monitoring and degraded system management, rotary joints for transmission of power and signals, nickel cadmium battery manufacturing and application, on-array power management, high voltage technology, and solar arrays.
A demonstration conducted last winter at the Tip Top Poultry Plant intended to show poultry plant managers from all over the U.S. potential solutions to the problem of plant noise. Plastic covers used over sound absorbing materials need to meet cleanability requirements, high- pressure water cleaning and other harsh maintenance procedures peculiar to the poultry processing industry. For the demonstration, Fiber Flex, Inc. manufactured and donated 750 noise panels; Owens-Corning Fiberglas Corporation donated the fiberglas cores; and the cover material was purchased from Howe and Bainbridge. The Engineering Experiment Station (EES) conducted before and after noise surveys and is evaluating the effect of noise reduction on turnover and productivity in the demonstration plant. EES plans to conduct a noise abatement workshop and update a handbook to help poultry processors with noise problems. EES study and demonstration may be applicable to other food processing plants where similar sanitary constraints exist.
The SpiderFab effort investigated the value proposition and technical feasibility of radically changing the way we build and deploy spacecraft by enabling space systems to fabricate and integrate key components on-orbit. Weeveloped an architecture for a SpiderFab system, identifying the key capabilities, and detailed two concept implementations of this architecture, one specialized for fabricating support trusses for large solar arrays, and the second a robotic system capable of fabricating spacecraft components such as antenna reflectors. We then performed analyses to evaluate the value proposition for on-orbit fabrication, and in each case found that the dramatic improvements in structural performance and packing efficiency enabled by on-orbit fabrication can provide order-of-magnitude improvements in key system metrics. For phased-‐array radars, SpiderFab enables order-of-magnitude increases in gain-per-stowed-volume. For the New Worlds Observer mission, SpiderFab construction of a starshade can provide a ten-fold increase in the number of Earth-like planets discovered per dollar. For communications systems, SpiderFab can change the cost equation for large antenna reflectors, enabling affordable deployment of much larger apertures than feasible with current deployable technologies. To establish the technical feasibility, we identified methods for combining several additive manufacturing technologies with robotic assembly technologies, metrology sensors, and thermal control techniques to provide the capabilities required to implement a SpiderFab system. We performed proof-of-concept level testing of these approaches, in each case demonstrating that the proposed solutions are feasible, and establishing the SpiderFab architecture at TRL-3. Further maturation of SpiderFab to mission-readiness is well-suited to an incremental development program. Affordable smallsat demonstrations will prepare the technology for full-scale demonstration that will unlock the full potential of the SpiderFab architecture by flight qualifying and validating an on-orbit fabrication and integration process that can be re-used to reduce the life-cycle cost and increase power, bandwidth, resolution, and sensitivity for a wide range of NASA Science and Exploration missions.
A research team of U.S. Government agencies and engine manufacturers conducted an experiment to test volcanic-ash ingestion by a NASA owned engine in the same family as the PW 2000 that was donated by the U.S. Air Force. The experiment, called Vehicle Integrated Propulsions Research (VIPR) test, was conducted under the auspices of NASAs Convergent Aeronautics Solutions (CAS) Program and took place in summer of 2015 at Edwards AFB in California as an on-ground, on-wing test. The primary objectives of the volcanic ash test were to determine the effect on the engine of several hours of exposure to low to moderate ash concentrations and to evaluate the capability of engine health management technologies for detecting these effects. The target concentrations of volcanic ash tested were at 1 and 10 mgm3. A natural volcanic ash was used that is representative of distal ash clouds many 100s to 1000 km from a volcanic source. The glassy ash particles were expected to soften and become less viscous when exposed to the high temperatures of the combustion chamber, then stick to the nozzle guide vanes of the high-pressure turbine and this was observed. Numerous observations and measurements of the engines performance and degradation were made during the course of the experiment, including borescope inspections after each test run. The engine has been disassembled so that detailed inspections of the engine effects have been made. A summary of the test methodology and execution will be made along with results from the test. While not intended to be sufficient for rigorous certification of engine performance when ash is ingested, the experiment should provide useful information to aircraft manufacturers, airline operators, and military and civil regulators in their efforts to evaluate the range of risks that ash hazards pose to aviation.
Welcome to the HELIOS Technology Challenge Guide. This document is intended to serve as a general road map for participants of the HELIOS Technology Challenge [HTC] Program and the associated inaugural challenge: HTC-01: Cost-Effective Additive Manufacturing in Space. Please note that this guide is not a rule book and is not meant to hinder the development of innovative ideas. Its primary goal is to highlight the objectives of the HTC-01 Challenge and to describe possible solution routes and pitfalls that such technology may encounter in space. Please also note that participants wishing to demonstrate any hardware developed under this program during any future HELIOS Technology Challenge showcase event(s) may be subject to event regulations to be published separately at a later date.
Ferroelectric random access semiconductor memories (FeRAMs) are an ideal nonvolatile solution for space applications. These memories have low power performance, high endurance and fast write times. By combining commercial ferroelectric memory technology with radiation hardened CMOS technology, nonvolatile semiconductor memories for space applications can be attained. Of the few radiation hardened semiconductor manufacturers, none have embraced the development of radiation hardened FeRAMs, due a limited commercial space market and funding limitations. Government funding may be necessary to assure the development of radiation hardened ferroelectric memories for space applications.
Disclosed herein is a shape memory alloy comprising 48 to 50 atomic percent nickel, 15 to 30 atomic percent hathium, 1 to 5 atomic percent aluminum; with the remainder being titanium. Disclosed herein too is a method of manufacturing a shape memory alloy comprising mixing together to form an alloy nickel, hafnium, aluminum and titanium in amounts of 48 to 50 atomic percent nickel, 15 to 30 atomic percent hafnium, 1 to 5 atomic percent aluminum; with the remainder being titanium; solution treating the alloy at a temperature of 700 to 1300.degree. C. for 50 to 200 hours; and aging the alloy at a temperature of 400 to 800.degree. C. for a time period of 50 to 200 hours to form a shape memory alloy.
An article in NASA Tech Briefs describing a vacuum bagging process for forming composite parts helped a small Oklahoma Company to improve its manufacturing process. President of Performance Extremes, Larry Ortega, and his partners make motorcycle parts from carbon/epoxy to reduce weight. Using vacuum bags, parts have a better surface and fewer voids inside. When heat used in the vacuum bag process caused deformation upon cooling, a solution found in another tech brief solved the problem. A metal plate inside the vacuum bag made for more even heat transfer. A third article described a simple procedure for repairing loose connector pins, which the company has also utilized.
Dust is a major concern for lunar exploration. To combat the effects of dust, NASA, academia, and industry are developingsolutions to the dust problem. One potential technology solution for this problem is the Electrodynamic DustShield (EDS). Many years of research and development have gone into this technology. The Materials on InternationalSpace Station Experiment - 11 (MISSE-11) provides a long term space exposure platform for this technology to verifycompatibility of materials and manufacturing processes to the space environment. The MISSE-11 EDS experimentconsists of 12 EDS panels. These panels are made of glass, polyimide, or prototype spacesuit fabric. Some panels arecovered with a lotus leaf coating while others are covered with thermal paint. They are flown in the wake position ofthe ISS to simulate the lunar environment. Two panels are in an active configuration and are energized with a highvoltage power supply, which generates high-voltage pulses to activate the dust shields. Current and voltage data arerecovered from each of these trials to compare to baseline data. Also, each of the EDS panels are imaged on a monthlybasis to track any changes with time that may occur with the EDS variants. In this paper, we report preliminary dataand analysis from this spaceflight experiment.
The NASA Centennial Challenges: 3D-Printed Habitat Challenge seeks to develop the fundamental technologies necessary to manufacture an off-world habitat using mission recycled materials and/or local indigenous materials. The vision is that autonomous habitat manufacturing machines will someday be deployed to the Moon or Mars to construct shelters for human habitation. NASA and Bradley University, are holding a new US$ 2.5 million competition to design and build a 3-D printed habitat for deep space exploration, including the agency's journey to Mars. The multi-phase 3-D Printed Habitat Challenge, part of NASA's Centennial Challenges program, is designed to advance the additive construction technology needed to create sustainable housing solutions for Earth and beyond. The first phase of the competition ran through Sept. 27, 2015. This phase, a design competition, called on participants to develop state-of-the-art architectural concepts that take advantage of the unique capabilities 3-D printing offers. The top 3 prizes with a prize purse of $40,000 were awarded at the 2015 World Maker Faire in New York. The second phase of the competition is called the Structural Member Competition and it is divided into three levels happening in the spring and summer of 2017. The Compression Test Competition (Level 1) focuses on the fabrication technologies needed to manufacture structural components from a combination of indigenous materials and recyclables, or indigenous materials alone. For Level 1, teams will develop 3D printable materials, build a 3D printing machine, and print two specimens: a truncated cone and a cylinder. The Level 2 Beam Member Competition is the second of three sub-competitions within the overall Structural Member Competition. For Level 2, teams will print a beam that will be tested. The Level 3 Head to Head Competition is the third of three sub-competitions within the overall Structural Member Competition. For Level 3, teams will develop 3D printable materials, use a 3D printing machine, and print three compression specimens of the elected material, three flexural specimens of the elected material, and one dome structure. Tests conducted on the specimens and the dome structure will determine Level 3 scores and awards. On Earth these same habitat manufacturing capabilities could be used to produce housing wherever affordable housing is needed and access to conventional building materials and skills is limited. Terrestrially, it is envisioned that local indigenous materials (dirt, clay, sand, etc.) could be combined with readily available recyclable materials and used to construct semi-permanent shelters against environmental elements for human habitation. The goal of the 3D-Printed Habitat Challenge is to foster the development of new technologies necessary to additively manufacture a habitat using local indigenous materials with, or without, recyclable materials. This paper will summarize the Level 2 results of this NASA Centennial Challenge competition and it will discuss related technology advancement.
The introduction of liquid hydrogen as a fuel for large, long haul air transports requires an integrated approach involving the air terminal authorities and the liquid hydrogen suppliers, as well as the airline operators and the air transport manufacturers. To illustrate the scope of the requirements necessary to support large air transports at the air terminals, perspectives are drawn to surface some concerns each of the principals may have to face, and to identify those that will require cooperative efforts to obtain integrated solutions.
A method of manufacturing nickel electrodes distinctive for its use of a composite material for the electrode made up of nickel compound, electrode material, cobalt in metal form or cobalt in compound form is investigated. The composite is over-discharged (same as reverse charging) in an alkaline solution. After dealkalization, synthetic resin adhesive is added and the electrode is formed. Selection of the cobalt compound is made from a group consisting of cobalt oxide, cobalt hydroxide, cobalt carbonate and cobalt sulfate. The method upgrades plate characteristics by using an active material in a non-sintered type nickel electrode, which is activated by electro-chemical effect.
Metal additive manufacturing (AM) processes are being used to enable economical manufacturing of legacy alloys as well as advancing new alloys. Laser powder bed fusion (L-PBF) is a metal AM process that has high maturity and being used to produce a variety of parts for space applications including complex propulsion components. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique space applications such as high-pressure hydrogen environments. NASA HR-1 is a high strength Fe-Ni based superalloy designed to resist high pressure hydrogen environment embrittlement (HEE), oxidation, and corrosion that has been successfully adapted to laser powder directed energy deposition (LP-DED). Insights gained from the NASA HR-1 development for LP-DED have guided the development process for L-PBF. However, adapting NASA HR-1 to L-PBF posed new challenges due to the distinct differences between the additive manufacturing processes. During parameter development, sensitivities were observed in post-processing that necessitated additional optimization of heat treatments. Additionally, the variations in thickness and how it influenced the microstructural response during heat treatment was characterized. Understanding these sensitivities is important to qualification of the material in a L-PBF machine. This ensures that the microstructures and properties of the material maintain consistency in production. This presentation will cover parameter development along with post-processing challenges and solutions will be discussed in addition to key material properties as it pertains to application performance and qualification per NASA-STD-6030. Improvements made by developing a derivative alloy, NASA HR-2, will be highlighted through preliminary small scale parameter development, material characterization, and initial property testing.