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NASA NTRS2022

Rapid Model Import Tool (RMIT) User Guide

The NASA Rapid Model Import Tool (RMIT) is designed to import 3D models built in commercially available Computer Aided Design (CAD) and Digital Content Creation (DCC) development software such as; Catia, Creo, 3DS Max, Maya, etc. Upon import, RMIT processes the models to reduce file size and exports the results in a format compatible with Augmented Reality (AR) and Virtual Reality (VR) development software applications. RMIT intends to make CAD models directly accessible to engineers from local AR/VR compatible laptops and desktops.

Joseluis Chavez↗

NASA NTRS2010

Infrared Camera System for Visualization of IR-Absorbing Gas Leaks

Leak detection and location remain a common problem in NASA and industry, where gas leaks can create hazardous conditions if not quickly detected and corrected. In order to help rectify this problem, this design equips an infrared (IR) camera with the means to make gas leaks of IR-absorbing gases more visible for leak detection and location. By comparing the output of two IR cameras (or two pictures from the same camera under essentially identical conditions and very closely spaced in time) on a pixel-by-pixel basis, one can cancel out all but the desired variations that correspond to the IR absorption of the gas of interest. This can be simply done by absorbing the IR lines that correspond to the gas of interest from the radiation received by one of the cameras by the intervention of a filter that removes the particular wavelength of interest from the "reference" picture. This can be done most sensitively with a gas filter (filled with the gas of interest) placed in front of the IR detector array, or (less sensitively) by use of a suitable line filter in the same location. This arrangement would then be balanced against the unfiltered "measurement" picture, which will have variations from IR absorption from the gas of interest. By suitable processing of the signals from each pixel in the two IR pictures, the user can display only the differences in the signals. Either a difference or a ratio output of the two signals is feasible. From a gas concentration viewpoint, the ratio could be processed to show the column depth of the gas leak. If a variation in the background IR light intensity is present in the field of view, then large changes in the difference signal will occur for the same gas column concentration between the background and the camera. By ratioing the outputs, the same signal ratio is obtained for both high- and low-background signals, even though the low-signal areas may have greater noise content due to their smaller signal strength. Thus, one embodiment would use a ratioed output signal to better represent the gas column concentration. An alternative approach uses a simpler multiplication of the filtered signal to make the filtered signal equal to the unfiltered signal at most locations, followed by a subtraction to remove all but the wavelength-specific absorption in the unfiltered sample. This signal processing can also reveal the net difference signal representing the leaking gas absorption, and allow rapid leak location, but signal intensity would not relate solely to gas absorption, as raw signal intensity would also affect the displayed signal. A second design choice is whether to use one camera with two images closely spaced in time, or two cameras with essentially the same view and time. The figure shows the two-camera version. This choice involves many tradeoffs that are not apparent until some detailed testing is done. In short, the tradeoffs involve the temporal changes in the field picture versus the pixel sensitivity curves and frame alignment differences with two cameras, and which system would lead to the smaller variations from the uncontrolled variables.

Youngquist, Robert↗

NASA NTRS2014

Hardware Design and Testing of SUPERball, A Modular Tensegrity Robot

We are developing a system of modular, autonomous "tensegrity end-caps" to enable the rapid exploration of untethered tensegrity robot morphologies and functions. By adopting a self-contained modular approach, different end-caps with various capabilities (such as peak torques, or motor speeds), can be easily combined into new tensegrity robots composed of rods, cables, and actuators of different scale (such as in length, mass, peak loads, etc). As a first step in developing this concept, we are in the process of designing and testing the end-caps for SUPERball (Spherical Underactuated Planetary Exploration Robot), a project at the Dynamic Tensegrity Robotics Lab (DTRL) within NASA Ames's Intelligent Robotics Group. This work discusses the evolving design concepts and test results that have gone into the structural, mechanical, and sensing aspects of SUPERball. This representative tensegrity end-cap design supports robust and repeatable untethered mobility tests of the SUPERball, while providing high force, high displacement actuation, with a low-friction, compliant cabling system.

Tensegrity↗

NASA NTRS2010

Development of an In Flight Vision Self-Assessment Questionnaire for Long Duration Space Missions

OVERVIEW A NASA Flight Medicine optometrist teamed with a human factors specialist to develop an electronic questionnaire for crewmembers to record their visual acuity test scores and perceived vision assessment. It will be implemented on the International Space Station (ISS) and administered as part of a suite of tools for early detection of potential vision changes. The goal of this effort was to rapidly develop a set of questions to help in early detection of visual (e.g. blurred vision) and/or non-visual (e.g. headaches) symptoms by allowing the ISS crewmembers to think about their own current vision during their spaceflight missions. PROCESS An iterative process began with a Space Shuttle one-page paper questionnaire generated by the optometrist that was updated by applying human factors design principles. It was used as a baseline to establish an electronic questionnaire for ISS missions. Additional questions needed for the ISS missions were included and the information was organized to take advantage of the computer-based file format available. Human factors heuristics were applied to the prototype and then they were reviewed by the optometrist and procedures specialists with rapid-turn around updates that lead to the final questionnaire. CONCLUSIONS With about only a month lead time, a usable tool to collect crewmember assessments was developed through this cross-discipline collaboration. With only a little expenditure of energy, the potential payoff is great. ISS crewmembers will complete the questionnaire at 30 days into the mission, 100 days into the mission and 30 days prior to return to Earth. The systematic layout may also facilitate physicians later data extraction for quick interpretation of the data. The data collected along with other measures (e.g. retinal and ultrasound imaging) at regular intervals could potentially lead to early detection and treatment of related vision problems than using the other measures alone.

Byrne, Vicky E.↗

NASA NTRS2015

Rapid Start-up and Loading of an Attached Growth, Simultaneous Nitrification/Denitrification Membrane Aerated Bioreactor

Membrane aerated bioreactors (MABR) are attached-growth biological systems used for simultaneous nitrification and denitrification to reclaim water from waste. This design is an innovative approach to common terrestrial wastewater treatments for nitrogen and carbon removal and implementing a biologically-based water treatment system for long-duration human exploration is an attractive, low energy alternative to physiochemical processes. Two obstacles to implementing such a system are (1) the "start-up" duration from inoculation to steady-state operations and (2) the amount of surface area needed for the biological activity to occur. The Advanced Water Recovery Systems (AWRS) team at JSC explored these two issues through two tests; a rapid inoculation study and a wastewater loading study. Results from these tests demonstrate that the duration from inoculation to steady state can be reduced to under two weeks, and that despite low ammonium removal rates, the MABRs are oversized.

Meyer, Caitlin E.↗

NASA NTRS1996

Advanced Manufacturing of Superconducting Magnets

The development of specialized materials, processes, and robotics technology allows for the rapid prototype and manufacture of superconducting and normal magnets which can be used for magnetic suspension applications. Presented are highlights of the Direct Conductor Placement System (DCPS) which enables automatic design and assembly of 3-dimensional coils and conductor patterns using LTS and HTS conductors. The system enables engineers to place conductors in complex patterns with greater efficiency and accuracy, and without the need for hard tooling. It may also allow researchers to create new types of coils and patterns which were never practical before the development of DCPS. The DCPS includes a custom designed eight-axis robot, patented end effector, CoilCAD(trademark) design software, RoboWire(trademark) control software, and automatic inspection.

Senti, Mark W.↗

NASA NTRS1997

Industrial X-Ray Imaging

In 1990, Lewis Research Center jointly sponsored a conference with the U.S. Air Force Wright Laboratory focused on high speed imaging. This conference, and early funding by Lewis Research Center, helped to spur work by Silicon Mountain Design, Inc. to break the performance barriers of imaging speed, resolution, and sensitivity through innovative technology. Later, under a Small Business Innovation Research contract with the Jet Propulsion Laboratory, the company designed a real-time image enhancing camera that yields superb, high quality images in 1/30th of a second while limiting distortion. The result is a rapidly available, enhanced image showing significantly greater detail compared to image processing executed on digital computers. Current applications include radiographic and pathology-based medicine, industrial imaging, x-ray inspection devices, and automated semiconductor inspection equipment.

Source record↗

NASA NTRS2003

Structural Anomalies Detected in Ceramic Matrix Composites Using Combined Nondestructive Evaluation and Finite Element Analysis (NDE and FEA)

Most reverse engineering approaches involve imaging or digitizing an object and then creating a computerized reconstruction that can be integrated, in three dimensions, into a particular design environment. The rapid prototyping technique builds high-quality physical prototypes directly from computer-aided design files. This fundamental technique for interpreting and interacting with large data sets is being used here via Velocity2 (an integrated image-processing software, ref. 1) using computed tomography (CT) data to produce a prototype three-dimensional test specimen model for analyses. A study at the NASA Glenn Research Center proposes to use these capabilities to conduct a combined nondestructive evaluation (NDE) and finite element analysis (FEA) to screen pretest and posttest structural anomalies in structural components. A tensile specimen made of silicon nitrite (Si3N4) ceramic matrix composite was considered to evaluate structural durability and deformity. Ceramic matrix composites are being sought as candidate materials to replace nickel-base superalloys for turbine engine applications. They have the unique characteristics of being able to withstand higher operating temperatures and harsh combustion environments. In addition, their low densities relative to metals help reduce component mass (ref. 2). Detailed three-dimensional volume rendering of the tensile test specimen was successfully carried out with Velocity2 (ref. 1) using two-dimensional images that were generated via computed tomography. Subsequent, three-dimensional finite element analyses were performed, and the results obtained were compared with those predicted by NDE-based calculations and experimental tests. It was shown that Velocity2 software can be used to render a three-dimensional object from a series of CT scan images with a minimum level of complexity. The analytical results (ref. 3) show that the high-stress regions correlated well with the damage sites identified by the CT scans and the experimental data. Furthermore, modeling of the voids collected via NDE offered an analytical advantage that resulted in more accurate assessments of the material s structural strength. The top figure shows a CT scan image of the specimen test section illustrating various hidden structural entities in the material and an optical image of the test specimen considered in this study. The bottom figure represents the stress response predicted from the finite element analyses (ref .3 ) for a selected CT slice where it clearly illustrates the correspondence of the high stress risers due to voids in the material with those predicted by the NDE. This study is continuing, and efforts are concentrated on improving the modeling capabilities to imitate the structural anomalies as detected.

Abdul-Aziz, Ali↗

NASA NTRS2016

Study of Material Consolidation at Higher Throughput Parameters in Selective Laser Melting of Inconel 718

Selective Laser Melting (SLM) is a powder bed fusion additive manufacturing process used increasingly in the aerospace industry to reduce the cost, weight, and fabrication time for complex propulsion components. SLM stands poised to revolutionize propulsion manufacturing, but there are a number of technical questions that must be addressed in order to achieve rapid, efficient fabrication and ensure adequate performance of parts manufactured using this process in safety-critical flight applications. Previous optimization studies for SLM using the Concept Laser M1 and M2 machines at NASA Marshall Space Flight Center have centered on machine default parameters. The objective of this work is to characterize the impact of higher throughput parameters (a previously unexplored region of the manufacturing operating envelope for this application) on material consolidation. In phase I of this work, density blocks were analyzed to explore the relationship between build parameters (laser power, scan speed, hatch spacing, and layer thickness) and material consolidation (assessed in terms of as-built density and porosity). Phase II additionally considers the impact of post-processing, specifically hot isostatic pressing and heat treatment, as well as deposition pattern on material consolidation in the same higher energy parameter regime considered in the phase I work. Density and microstructure represent the "first-gate" metrics for determining the adequacy of the SLM process in this parameter range and, as a critical initial indicator of material quality, will factor into a follow-on DOE that assesses the impact of these parameters on mechanical properties. This work will contribute to creating a knowledge base (understanding material behavior in all ranges of the AM equipment operating envelope) that is critical to transitioning AM from the custom low rate production sphere it currently occupies to the world of mass high rate production, where parts are fabricated at a rapid rate with confidence that they will meet or exceed all stringent functional requirements for spaceflight hardware. These studies will also provide important data on the sensitivity of material consolidation to process parameters that will inform the design and development of future flight articles using SLM.

Prater, Tracie↗

NASA NTRS2016

Study of Material Densification of In718 in the Higher Throughput Parameter Regime

Selective Laser Melting (SLM) is a powder bed fusion additive manufacturing process used increasingly in the aerospace industry to reduce the cost, weight, and fabrication time for complex propulsion components. Previous optimization studies for SLM using the Concept Laser M1 and M2 machines at NASA Marshall Space Flight Center have centered on machine default parameters. The objective of this project is to characterize how heat treatment affects density and porosity from a microscopic point of view. This is performs using higher throughput parameters (a previously unexplored region of the manufacturing operating envelope for this application) on material consolidation. Density blocks were analyzed to explore the relationship between build parameters (laser power, scan speed, and hatch spacing) and material consolidation (assessed in terms of density and porosity). The study also considers the impact of post-processing, specifically hot isostatic pressing and heat treatment, as well as deposition pattern on material consolidation in the higher energy parameter regime. Metallurgical evaluation of specimens will also be presented. This work will contribute to creating a knowledge base (understanding material behavior in all ranges of the AM equipment operating envelope) that is critical to transitioning AM from the custom low rate production sphere it currently occupies to the world of mass high rate production, where parts are fabricated at a rapid rate with confidence that they will meet or exceed all stringent functional requirements for spaceflight hardware. These studies will also provide important data on the sensitivity of material consolidation to process parameters that will inform the design and development of future flight articles using SLM.

Cordner, Samuel↗

NASA NTRS2004

SIS Mixer Design for a Broadband Millimeter Spectrometer Suitable for Rapid Line Surveys and Redshift Determinations

We present some detail of the waveguide probe and SIS mixer chip designs for a low-noise 180-300 GHz double- sideband receiver with an instantaneous RF bandwidth of 24 GHz. The receiver's single SIS junction is excited by a broadband, fixed-tuned waveguide probe on a silicon substrate. The IF output is coupled to a 6-18 GHz MMIC low- noise preamplifier. Following further amplification, the output is processed by an array of 4 GHz, 128-channel analog autocorrelation spectrometers (WASP 11). The single-sideband receiver noise temperature goal of 70 Kelvin will provide a prototype instrument capable of rapid line surveys and of relatively efficient carbon monoxide (CO) emission line searches of distant, dusty galaxies. The latter application's goal is to determine redshifts by measuring the frequencies of CO line emissions from the star-forming regions dominating the submillimeter brightness of these galaxies. Construction of the receiver has begun; lab testing should begin in the fall. Demonstration of the receiver on the Caltech Submillimeter Observatory (CSO) telescope should begin in spring 2003.

Rice, F.↗

NASA NTRSDate not supplied

Effects of Defects Analysis and Sizing Framework for Efficient Design of Composite Structures

Design of large composite structures requires striking a balance between permitted flaw size,strength margins, weight, and production rate. Stringent requirements manufacturing flaws can result in a lightweight structure because the strength properties are assumed to be closer to pristine. However, these stringent requirements can lead to production delays due to increased inspection and rework needed during the layup and rejection of parts after cure. Conversely, permitting larger flaws can reduce production delays, but will likely result in a heavier structure due to increased conservatism needed to maintain acceptable structural margins. The tradeoff between these criteria can vary between different structures and material systems, so the balance between manufacturing and design requirements is always a moving target. Assessment of this tradeoff requires having the ability to quickly evaluate the impact of flaw size on strength margin across an entire structure for a large number of load cases. The approach taken in this work is to implement an effects of defects analysis and sizing framework within HyperX. HyperX performs optimization of composite structures; this capability has been enhanced to include structural flaw data in the margin of safety calculations performed during optimization. Both the flaw import process and analysis of flaws have been generalized such that any flaw type from any source can be considered. The resulting tool enables rapid assessment of the impact of defects both at a vehicle and part level.

Effects of defects↗

NASA NTRSDate not supplied

Effects of Defects Analysis and Sizing Framework for Efficient Design of Composite Structures

Effects of defects↗

NASA NTRS1982

A new solution to parameter adaptive estimation of random processes

This paper is concerned with the development of an adaptive state estimator that is capable of tracking switched linear plants that undergo rapid configuration changes. The particular adaptive estimator developed here is called the Sliding Window Detector/Estimator (SWDE) algorithm. Unlike previous algorithms, the SWDE algorithm is designed specifically for the switched-linear plant problem. It uses a joint detection/estimation approach to give a very close approximation to the unrealizable optimum switched-linear estimator. An extremely reliable and accurate estimator can be constructed by combining a modified Parameter Adaptive Estimation (PAE) algorithm with SWDE. The algorithm has been fully verified by extensive computer simulation, and the implementation advantages afforded by this method make it suitable for use in a wide variety of applications.

Zwicke, P. E.↗

NASA NTRS1998

The Applicability of Jet-Shear-Layer Mixing and Effervescent Atomization for Low-NO(x) Combustors

An investigation has been conducted to develop appropriate technologies for a low-NO(x), liquid-fueled combustor. The combustor incorporates an effervescent atomizer used to inject fuel into a premixing duct. Only a fraction of the combustion air is used in the premixing process. This fuel-rich mixture is introduced into the remaining combustion air by a rapid jet-shear-layer mixing process involving radial fuel-air jets impinging on axial air jets in the primary combustion zone. Computational modeling was used as a tool to facilitate a parametric analysis appropriate to the design of an optimum low-NO(x) combustor. A number of combustor configurations were studied to assess the key combustor technologies and to validate the three-dimensional modeling code. The results from the experimental testing and computational analysis indicate a low-NO(x) potential for the jet-shear-layer combustor. Key features found to affect NOx emissions are the primary combustion zone fuel-air ratio, the number of axial and radial jets, the aspect ratio and radial location of the axial air jets, and the radial jet inlet hole diameter. Each of these key parameters exhibits a low-NO(x) point from which an optimized combustor was developed Also demonstrated was the feasibility of utilizing an effervescent atomizer for combustor application. Further developments in the jet-shear-layer mixing scheme and effervescent atomizer design promise even lower NO(x) with high combustion efficiency.

Colantonio, R. O.↗

NASA NTRS2004

Infrared Spectroscopy of Star Formation in Galactic and Extragalactic Regions

Last year we submitted and had accepted a paper entitled "The Far-Infrared Emission Line and Continuum Spectrum of the Seyfert Galaxy NGC 1068," by Spinoglio, L., Malkan, M., Smith. HA, Gonzalez-Alfonso, E., and Fischer, J. This analysis was based on the SWAS Monte Carlo code modeling of the OH lines in galaxies observed by ISO. Since that meeting last spring considerable effort has been put into improving the Monte Carlo code. A group of European astronomers, including Prof. Eduardo Gonzalez-Alfonso, had been performing Monte Carlo modeling of other molecules seen in ISO galaxies. We used portions of this grant to bring Prof. Gonzalez-Alfonso to Cambridge for an intensive working visit. A second major paper on the ISO IR spectroscopy of galaxies, "The Far Infrared Spectrum of Arp 220," Gonzalez-Alfonso, E., Smith. H., Fischer, J., and Cernicharo, J., is in press. Spitzer science development was the major component of this past year;s research. This program supported the development of five Early Release Objects for Spitzer observations on which Dr. Smith was Principal Investigator or Co-Investigator, and another five proposals for GO time. The early release program is designed to rapidly present to the public and the scientific community some exciting results from Spitzer in the first months of its operation. The Spitzer instrument and science teams submitted proposals for ERO objects, and a competitive selection process narrowed these down to a small group with exciting science and realistic observational parameters. This grant supported Dr. Smith's participation in the ERO process, including developing science goals, identifying key objects for observation, and developing the detailed AOR (observing formulae) to be use by the instruments for mapping, integrating, etc.). During this year Dr. Smith worked on writing up and publishing these early results. The attached bibliography includes six of Dr. Smith's articles. During this past year Dr. Smith also led or helped to develop proposals for ten Spitzer GO Programs, and three others. Appendix B lists the programs involved.

Smith, Howard A.↗

NASA NTRS2011

Science of Opportunity: Heliophysics on the FASTSAT Mission and STP-S26

The FASTSAT spacecraft, which was launched on November 19, 2010 on the DoD STP-S26 mission, carries three instruments developed in joint collaboration by NASA GSFC and the US Naval Academy: PISA, TTl, and MINI_ME.I,1 As part of a rapid-development, low-cost instrument design and fabrication program, these instruments were a perfect match for FASTSAT, which was designed and built in less than one year. These instruments, while independently developed, provide a collaborative view of important processes in the upper atmosphere relating to solar and energetic particle input, atmospheric response, and ion outflow. PISA measures in-situ irregularities in electron number density, TIl provides limb measurements of the atomic oxygen temperature profile with altitude, and MINI-ME provides a unique look at ion populations by a remote sen sing technique involving neutral atom imaging. Together with other instruments and payloads on STP-S26 such as the NSF RAX mission, FalconSat-5, and NanoSail-D (launched as a tertiary payload from FASTSAT), these instruments provide a valuable "constellation of opportunity" for following the now of energy and charged and neutral particles through the upper atmosphere. Together, and for a small fraction of the price of a major mission, these spacecraft will measure the energetic electrons impacting the upper atmosphere, the ions leaving it, and the large-scale plasma and neutral response to these energy inputs. The result will be a new model for maximizing scientific return from multiple small, distributed payloads as secondary payloads on a larger launch vehicle.

Rowland, Douglas E.↗

NASA NTRS1988

Multi-color pyrometer for materials processing in space

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.

Frish, Michael B.↗