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NASA NTRS1996

Experimental Investigation of the Performance of a Mach-2.7 Two-dimensional Bifurcated Duct Inlet with 30 Percent Internal Contraction

An experimental study was conducted to determine the performance of a two-dimensional, mixed-compression bifurcated duct inlet system designed for a free-stream Mach number of 2.7. Thirty percent of the supersonic area contraction occurred internally. A movable ramp was used to vary the contraction ratio for off-design operation. Boundary layer bleed regions were located on the cowl, centerbody, and sidewall surfaces. There were also provisions for vortex generators on the cowl and centerbody of the subsonic diffuser. Data were obtained over the Mach number range of 2.0 to 2.8 and at angles of yaw from 0 deg. to the maximum value prior to inlet un-start. The test at Mach 2.8 was to obtain data for an over- speed condition. The Reynolds number varied from 2.5 to 2.3 million/ft for Mach numbers above 2.5. At Mach numbers of 2.5 and lower, the Reynolds number was set at 2.5 million/ft. Bleed patterns, vortex generator patterns, and ramp position were varied, and three inlet configurations were selected for more extensive study. Two of these configurations had self-starting capability. The self-starting configuration that was developed produced 89 percent total pressure recovery at the compressor face station with 6.8 percent total bleed. The compressor face distortion was about 16 percent. Vortex generators were extremely effective in re-distributing flow but were not as effective in reducing distortion. Excellent flow symmetry was achieved between the separated halves of the inlet, and twin-duct instability was not observed. The ramp tip shock was steeper than expected. This caused the cowl lip shock to be reflected from the ramp instead of being cancelled at the shoulder. However, peak recovery at the throat was still obtained with the ramp near the design position.

Wasserbauer, J. F.↗
NASA NTRS1996

Comparison of Extravehicular Mobility Unit (EMU) suited and unsuited isolated joint strength measurements

In this study the strength of subjects suited in extravehicular mobility units (EMU's) - or Space Shuttle suits - was compared to the strength of unsuited subjects. The authors devised a systematic and complete data set that characterizes isolated joint torques for all major joints of EMU-suited subjects. Six joint motions were included in the data set. The joint conditions of six subjects were compared to increase our understanding of the strength capabilities of suited subjects. Data were gathered on suited and unsuited subjects. Suited subjects wore Class 3 or Class 1 suits, with and without thermal micrometeoroid garments (TMG's). Suited and unsuited conditions for each joint motion were compared. From this the authors found, for example, that shoulder abduction suited conditions differ from each other and from the unsuited condition. A second-order polynomial regression model was also provided. This model, which allows the prediction of suited strength when given unsuited strength information, relates the torques of unsuited conditions to the torques of all suited conditions. Data obtained will enable computer modeling of EMU strength, conversion from unsuited to suited data, and isolated joint strength comparisons between suited and unsuited conditions at any measured angle. From these data mission planners and human factors engineers may gain a better understanding of crew posture, and mobility and strength capabilities. This study also may help suit designers optimize suit strength, and provide a foundation for EMU strength modeling systems.

Maida, James C.↗
NASA NTRS1997

An Accurate and Dynamic Computer Graphics Muscle Model

A computer based musculo-skeletal model was developed at the University in the departments of Mechanical and Biomedical Engineering. This model accurately represents human shoulder kinematics. The result of this model is the graphical display of bones moving through an appropriate range of motion based on inputs of EMGs and external forces. The need existed to incorporate a geometric muscle model in the larger musculo-skeletal model. Previous muscle models did not accurately represent muscle geometries, nor did they account for the kinematics of tendons. This thesis covers the creation of a new muscle model for use in the above musculo-skeletal model. This muscle model was based on anatomical data from the Visible Human Project (VHP) cadaver study. Two-dimensional digital images from the VHP were analyzed and reconstructed to recreate the three-dimensional muscle geometries. The recreated geometries were smoothed, reduced, and sliced to form data files defining the surfaces of each muscle. The muscle modeling function opened these files during run-time and recreated the muscle surface. The modeling function applied constant volume limitations to the muscle and constant geometry limitations to the tendons.

Levine, David Asher↗
NASA NTRS1997

NASA Research Announcement Phase 2 Final Report for the Development of a Power Assisted Space Suit Glove

The main goal of this program was to develop an unobtrusive power-assisted EVA glove metacarpalphalangeal (MCP) joint that could provide the crew member with as close to nude body performance as possible, and to demonstrate the technology feasibility of power assisted space suit components in general. The MCP joint was selected due to its being representative of other space suit joints, such as the shoulder, hip and carpometacarpal joint, that would also greatly benefit from this technology. In order to meet this objective, a development team of highly skilled and experienced personnel was assembled. The team consisted of two main entities. The first was comprised of ILC's experienced EVA space suit glove designers, who had the responsibility of designing and fabricating a low torque MCP joint which would be compatible with power assisted technology. The second part of the team consisted of space robotics experts from the University of Maryland's Space Systems Laboratory. This team took on the responsibility of designing and building the robotics aspects of the power-assist system. Both parties addressed final system integration responsibilities.

Lingo, Robert↗
NASA NTRS1959

Human Tolerance to Rapidly Applied Accelerations: A Summary of the Literature

The literature is surveyed to determine human tolerance to rapidly applied accelerations. Pertinent human and animal experiments applicable to space flight and to crash impact forces are analyzed and discussed. These data are compared and presented on the basis of a trapezoidal pulse. The effects of body restraint and of acceleration direction, onset rate, and plateau duration on the maximum tolerable and survivable rapidly applied accelerations are shown. Results of the survey indicate that adequate torso and extremity restraint is the primary variable in tolerance to rapidly applied accelerations. The harness, or restraint system, must be arranged to transmit the major portion of the accelerating force directly to the pelvic structure and not via the vertebral column. When the conditions of adequate restraint have been met, then the other variables, direction, magnitude, and onset rate of rapidly applied accelerations, govern maximum tolerance and injury limits. The results also indicate that adequately stressed aft-faced passenger seats offer maximum complete body support with minimum objectionable harnessing. Such a seat, whether designed for 20-, 30-, or 40-G dynamic loading, would include lap strap, chest (axillary) strap, and winged-back seat to increase headward and lateral G protection, full-height integral head rest, arm rests (load-bearing) with recessed hand-holds and provisions to prevent arms from slipping either laterally or beyond the seat back, and leg support to keep the legs from being wedged under the seat. For crew members and others whose duties require forward-facing seats, maximum complete body support requires lap, shoulder, and thigh straps, lap-belt tie-down strap, and full-height seat back with integral head support.

Eiband, A. Martin↗
NASA NTRS1997

Development of a Pamphlet Targeting Computer Workstation Ergonomics

With the increased use of computers throughout Goddard Space Flight Center, the Industrial Hygiene Office (IHO) has observed a growing trend in the number of health complaints attributed to poor computer workstation setup. A majority of the complaints has centered around musculoskeletal symptoms, including numbness, pain, and tingling in the upper extremities, shoulders, and neck. Eye strain and headaches have also been reported. In some cases, these symptoms can lead to chronic conditions such as repetitive strain injuries (RSI's). In an effort to prevent or minimize the frequency of these symptoms among the GSFC population, the IHO conducts individual ergonomic workstation evaluations and ergonomics training classes upon request. Because of the extensive number of computer workstations at GSFC, and the limited amount of manpower which the Industrial Hygiene staff could reasonably allocate to conduct workstation evaluations and employee training, a pamphlet was developed with a two-fold purpose: (1) to educate the GSFC population about the importance of ergonomically-correct computer workstation setup and the potential effects of a poorly configured workstation; and (2) to enable employees to perform a general assessment of their own workstations and make any necessary modifications for proper setup.

Faraci, Jennifer S.↗
NASA NTRS1998

Experiment 1: Orbital Processing of High-Quality Zn-Alloyed CdTe Compound Semiconductors

Zinc-alloyed cadmium telluride (Zn:CdTe) crystals were grown in unit gravity and in microgravity for comparative analysis. Two crystals were grown on USML-1/STS-50 in 1992, and two additional crystals were grown on USML-2/STS-73 in 1995. The Crystal Growth Furnace (CGF) in the seeded Bridgman-Stockbarger crystal growth geometry was utilized on both missions. Crystals grown on USML-1/STS-50 were found to have solidified with partial wall contact due to the near-absence of the hydrostatic pressure in microgravity, a residual g-vector that was not axial, and the nonwetting sample/ampoule wetting conditions. Crystals grown on USML-2/STS-73 included: a sample/ampoule identical to the USML-1/STS-73 sample/ampoule, with the addition of a restraining spring to simulate hydrostatic pressure internally, and a tapered ampoule which accomplished 2.2 cm of crystal growth without wall contact. Infrared transmission of all ground and flight samples was found to be 63-66 percent, very close to the theoretical 66 percent, suggesting good stoichiometric control. Infrared microscopy confirmed that the primary precipitates were Te and their size (1-10 microns) and density suggested that the flight- and ground-base samples experienced similar thermal histories. Longitudinal macrosegregation, calculated using scaling analysis, was predicted to be low. Nearly diffusion controlled growth was achieved even in unit gravity and macrosegregation data could be fit with a diffusion controlled model. Radial segregation was monitored and was found to vary with fraction solidified, particularly through the shoulder region, where the sample cross section was varying significantly. It was also disturbed in the flight samples in regions where asymmetric wall contact was noted. In regions where a steady state was established, the radial segregation was invariant within our experimental measurement error. Flight samples were found to be much higher in structural perfection than samples processed in unit gravity under identical growth conditions. In regions where solidification had occurred without wall contact, the free surfaces evidenced virtually no twinning, although twins appeared in the flight samples in regions of wall contact and were pervasive in the ground samples. These results were confirmed using optical microscopy and synchrotron x-ray white beam topography. Full-width half-maximum rocking curve widths (FWHM), recorded in arc-seconds, were significantly reduced from 20 a-s (1 g) to 9 a-s (micro-g) for the best regions of the crystals. The 9 a-s (FWHM) rocking curve value in the unconfined flight samples equals the best value reported terrestrially for this material. The ground samples exhibited a fully developed (111)[110] dislocation mosaic structure, whereas dislocations within the flight samples were discrete and no mosaic structure was evident. The defect density was quantitatively reduced from 75,000 (1 g) to 800 (micro-g) +/-50 percent. Dislocation etch pit density results were confirmed using transmission synchrotron white beam and monochromated beam topography. The low defect density is thought to have resulted from the near absence of hydrostatic pressure, which allowed the molten boule to solidify with little or no wall contact. This minimized the transfer of hoop stresses during solidification and post-solidification processing.

Larson, D. J., Jr.↗
NASA NTRS1999

Undercooling, Rapid Solidification, and Relations to Processing in Low Earth Orbit (A Review of the Works of Bingbo Wei)

This is a survey of the published works of Prof. Bingbo Wei of the Department of Applied Physics at Northwestern Polytechnical University, Xian P.R. China. Transformations among solid - liquid - and vapor are fundamental to the foundations of life and culture on Earth. The development and understanding of materials has lead the evolution and advancement of the human race since antiquity. Materials and fluids research is continuing today, with us standing on the shoulders of those that have gone before us. Technological and scientific breakthroughs continue due to studies of greater and greater complexity, that include for example, research done at high pressures, in high magnetic fields, at temperatures near absolute zero, and in the low gravity environment of low Earth orbit. Of particular technological importance is the liquid to solid transformation of metals and alloys. Solidification processing is generally the most important factor in the final properties of objects made of metal; and undercooling is the fundamental driving force for all solidification. The interest and resources dedicated to the study of solidification and undercooling are great and World wide. For many years B. Wei and his coworkers have been studying undercooling and rapid solidification and have amassed a significant body of published research in this important field, contributing to the leading edge of the state-of-the-art. It is the goal of this memorandum to provide a review of the research of B. Wei et al.; publications in Chinese are included in the reference list but are not discussed. The bulk of Wei's work has been in the area of undercooling and rapid solidification [1-11, 13-16, 24-36] with papers dating back to 1989, the same year he earned his Ph.D. Below, discussions of Wei's undercooling and rapid solidification research have been grouped together mostly on the basis of alloy type, such as eutectic, intermetallic, or monotectic.

deGroh, Henry C., III↗
NASA NTRS1999

Mechanical Property Analysis in the Retracted Pin-Tool (RPT) Region of Friction Stir Welded (FSW) Aluminum Lithium 2195

The "Auto-Adjustable Pin Tool for Friction Stir Welding", was developed at The Marshall Space Flight Center to address process deficiencies unique to the FSW process. The auto-adjustable pin tool, also called the retractable pin-tool (R.PT) automatically withdraws the welding probe of the pin-tool into the pin-tool's shoulder. The primary function of the auto-adjustable pin-tool is to allow for keyhole closeout, necessary for circumferential welding and localized weld repair, and, automated pin-length adjustment for the welding of tapered material thickness. An overview of the RPT hardware is presented. The paper follows with studies conducted using the RPT. The RPT was used to simulate two capabilities; welding tapered material thickness and closing out the keyhole in a circumferential weld. The retracted pin-tool regions in aluminum- lithium 2195 friction stir weldments were studied through mechanical property testing and metallurgical sectioning. Correlation's can be =de between retractable pin-tool programmed parameters, process parameters, microstructure, and resulting weld quality.

Ding, R. Jeffrey↗
NASA NTRS1996

3C 279 Multiwavelength Monitoring: The Ground-Based Campaign - 2

The optically violently variable quasar 3C 279 was monitored simultaneously from radio to gamma-ray frequencies in 1992 December - 1993 January. We report a detailed study of the ground-based results from radio to optical wavelengths. These data show that 3C 279 has a typical blazar spectrum, slightly rising at radio frequency and then progressively steeper above a first turnover frequency between 37 and 90 GHz. In the millimeter wavelength region, a simple power law is not an adequate description of the spectrum. We suggest that the millimeter "shoulder" corresponds to an additional emission component, self-absorbed between 150 and 375 GHz, possibly associated with the detachment of a new Very Long Base Interferometry (VLBI) knot and with the start of radio flare. A flux increase of 20% over 20 days was observed at 37 and 90 GHz, while contemporaneously the R-band flux doubled in about two weeks. The lack of strong variability in contemporaneous X-ray light curves (possible X-ray variations are less than 30%) implies no direct (i.e., zero lag) correlation between the optical and X-ray fluxes. If X-rays are produced by inverse-Compton scattering of relativistic electrons on some seed photons, the above results exclude that the observed optical photons are the seeds and/or that the relativistic electrons radiating via synchrotron in the optical band are responsible for the scattering to X-ray energies. We suggest that the X-rays are instead produced through the inverse-Compton process by electrons of lower energy, which radiate via synchrotron in the radio to millimeter wave bands and which scatter either on the synchrotron photons themselves or on external photons.

Grandi, P.↗
NASA NTRS1999

A Methodology for Investigating Adaptive Postural Control

Our research on postural control and human-environment interactions provides an appropriate scientific foundation for understanding the skill of mass handling by astronauts in weightless conditions (e.g., extravehicular activity or EVA). We conducted an investigation of such skills in NASA's principal mass-handling simulator, the Precision Air-Bearing Floor, at the Johnson Space Center. We have studied skilled movement-body within a multidisciplinary context that draws on concepts and methods from biological and behavioral sciences (e.g., psychology, kinesiology and neurophysiology) as well as bioengineering. Our multidisciplinary research has led to the development of measures, for manual interactions between individuals and the substantial environment, that plausibly are observable by human sensory systems. We consider these methods to be the most important general contribution of our EVA investigation. We describe our perspective as control theoretic because it draws more on fundamental concepts about control systems in engineering than it does on working constructs from the subdisciplines of biomechanics and motor control in the bio-behavioral sciences. At the same time, we have attempted to identify the theoretical underpinnings of control-systems engineering that are most relevant to control by human beings. We believe that these underpinnings are implicit in the assumptions that cut across diverse methods in control-systems engineering, especially the various methods associated with "nonlinear control", "fuzzy control," and "adaptive control" in engineering. Our methods are based on these theoretical foundations rather than on the mathematical formalisms that are associated with particular methods in control-systems engineering. The most important aspects of the human-environment interaction in our investigation of mass handling are the functional consequences that body configuration and stability have for the pick up of information or the achievement of overt goals. It follows that an essential characteristic of postural behavior is the effective maintenance of the orientation and stability of the sensory and motor "platforms" (e.g., head or shoulders) over variations in the human, the environment and the task. This general skill suggests that individuals should be sensitive to the functional consequences of body configuration and stability. In other words, individuals should perceive the relation between configuration, stability, and performance so that they can adaptively control their interaction with the surroundings. Human-environment interactions constitute robust systems in that individuals can maintain the stability of such interactions over uncertainty about and variations in the dynamics of the interaction. Robust interactions allow individuals to adopt orientations and configurations that are not optimal with respect to purely energetic criteria. Individuals can tolerate variation in postural states, and such variation can serve an important function in adaptive systems. Postural variability generates stimulation which is "textured" by the dynamics of the human-environment system. The texture or structure in stimulation provides information about variation in dynamics, and such information can be sufficient to guide adaption in control strategies. Our method were designed to measure informative patterns of movement variability.

McDonald, P. V.↗
NASA NTRS1999

Principal Investigator-in-a-Box

Human performance in orbit is currently limited by several factors beyond the intrinsic awkwardness of motor control in weightlessness. Cognitive functioning can be affected by such factors as cumulative sleep loss, stress and the psychological effects of long-duration small-group isolation. When an astronaut operates a scientific experiment, the performance decrement associated with such factors can lead to lost or poor quality data and even the total loss of a scientific objective, at great cost to the sponsors and to the dismay of the Principal Investigator. In long-duration flights, as anticipated on the International Space Station and on any planetary exploration, the experimental model is further complicated by long delays between training and experiment, and the large number of experiments each crew member must perform. Although no documented studies have been published on the subject, astronauts report that an unusually large number of simple errors are made in space. Whether a result of the effects of microgravity, accumulated fatigue, stress or other factors, this pattern of increased error supports the need for a computerized decision-making aid for astronauts performing experiments. Artificial intelligence and expert systems might serve as powerful tools for assisting experiments in space. Those conducting space experiments typically need assistance exactly when the planned checklist does not apply. Expert systems, which use bits of human knowledge and human methods to respond appropriately to unusual situations, have a flexibility that is highly desirable in circumstances where an invariably predictable course of action/response does not exist. Frequently the human expert on the ground is unavailable, lacking the latest information, or not consulted by the astronaut conducting the experiment. In response to these issues, we have developed "Principal Investigator-in-a-Box," or [PI], to capture the reasoning process of the real expert, the Principal Investigator, and combine that with real-time data available in space in order to advise the astronaut about how to proceed in real time. [PI] advises the astronaut during the progress of an experiment in much the same way a real Principal Investigator might do while looking over the astronaut's shoulder. In its original application, [PI] mimicked several of the tasks of the Principal Investigator, including data quality monitoring, troubleshooting, prescheduling, protocol management and "interesting data" detection. The proposed research focuses on the efficacy of this technique as applied to the data quality monitoring and troubleshooting aspects of [PI].

Young, Laurence R.↗
NASA NTRS1997

A Biomechanical Comparison of 1-G and Fully-Loaded Simulated Zero-Gravity Locomotion

Exercise will almost certainly play an integral part in minimizing the bone mineral loss and muscular atrophy that occur during spaceflight. It has been hypothesized that an effective exercise regimen can be developed to elicit loads on the lower extremities and require muscle actions which resemble those encountered on Earth. The Penn State Zero-Gravity Simulator (PSZS) is a device which suspends subjects horizontally from multiple latex cords, with each cord negating the weight of a limb segment. A treadmill mounted on the wall under the PSZS enables subjects to run in simulated 0G. Subjects wear a harness to which a number of springs, which provide a gravity replacement load, are connected. The opposite end of each spring is connected to the side of the treadmill. During exercise, astronauts currently wear a similar harness in which the spring tethering load pulls at both the waist and shoulders. Ground reaction forces, muscular activations, and joint angles of the left leg during overground, treadmill, and fully-loaded zero-gravity simulated (ZLS) locomotion were assessed in order to gain insight into the effectiveness of the exercise regimen used by NASA to prevent the muscular atrophy and bone demineralization which occur in weightlessness. There were three hypotheses to this research. It was hypothesized that there will be no differences in peak ground reaction forces and peak loading rates between overground gait and gait in the full body weight loaded conditions in the ZLS. A second hypothesis was that that there will be no differences in hip, knee, and ankle joint positions between walking or running overground, on a standard treadmill, and in full bodyweight loaded conditions in the ZLS. The third hypothesis was that the muscular activations, as a percentage of maximal voluntary contraction, will be similar between walking or running overground, on a standard treadmill, and in full body-weight loaded conditions in the ZLS.

McCrory, Jean L.↗
NASA NTRS2001

Transonic Investigation of Two-Dimensional Nozzles Designed for Supersonic Cruise

An experimental and computational investigation has been conducted to determine the off-design uninstalled drag characteristics a of a two-dimensional convergent-divergent nozzle designed for a supersonic cruise civil transport. The main objective of this investigation was to determine the effects of varying nozzle external flap curvature and sidewall boattail angle and curvature on nozzle drag The experimental investigation was conducted in the Langley 16-Foot Transonic Tunnel at Mach numbers from 0.80 to 1.20 at nozzle pressure ratios up to nine. Three-dimensional simulations of nozzle performance were obtained with the computational fluid dynamics code PAB using turbulence closure and nonlinear Reynolds stress modeling. The results of this investigation indicate that excellent correlation between experimental and predicted results was obtained for the nozzle with a moderate amount of boattail curvature. The nozzle with an external flap having a sharp shoulder (no curvature) had the lowest nozzle pressure drag. At a Mach number of 1.2, sidewall pressure drag doubled as sidewall boattail angle was increased from 4 to 8 deg. Reducing the height of the sidewall caused large decreases in both the sidewall and flap pressure drags.

Capone, Francis J.↗
NASA NTRS2001

Closed-Loop Control System for Friction Stir Welding Retractable Pin Tool

NASA invention disclosure, NASA Case No. MFS-31413, entitled "System for Controlling the Stirring Pin of a Friction Stir Welding Apparatus", (Patent Pending) authored by Jeff Ding, Dr Peter Romine and Pete Oelgoetz, addresses the precision control of the friction stir welding process. The closed-loop control system automatically adjusts the spinning welding pin, real-time, to maintain a precise penetration ligament (i.e., distance between pin-tip and weld panel backside surface). A specific pin length can be maintained while welding constant thickness or tapered material thickness weld panels. The closed-loop control system provides operator data and information relative to the exact position of the welding pin inside the weld joint. This paper presents the closed-loop RPT control system that operates using the auto-feedback of force signals sensed by the tip and shoulder of the welding pin. Significance: The FSW process can be successfully used in a production environment only if there is a method or technique that informs the FSW operator the precise location of the welding pin inside the weld joint. This is essential for applications in aerospace, automotive, pressure vessel, commercial aircraft and other industries.

Ding, R. Jeffrey↗
NASA NTRS2002

Case Descriptions and Observations About Cutis Marmorata From Hypobaric Decompressions

There is disagreement about the pathophysiology, classification, and treatment of cutis marmorata (CM), so there is disagreement about the disposition and medical status of a person that had CM. CM is rare, associated with stressful decompressions, and may be associated with serious signs and symptoms of decompression sickness (DCS). CM presents as purple or bluish-red skin mottling, often in the pectoral region, shoulders, chest, or upper abdomen. It is unethical to induce CM in humans so all information comes from retrospective analysis of case reports, or from animal models. A literature search, seven recent case reports from the Johnson Space Center and Brooks Air Force Base Hypobaric DCS Databases, interviews with DCS treatment experts, and responses to surveys provided the factual information used to arrive at our conclusions and recommendations. The "weight of evidence" indicates that CM is a local, not centrally mediated or systemic response to bubbles. It is unclear whether obstruction of arterial or venous blood flow is the primary insult since the lesion is reported under either condition. Any neurological or cardiovascular involvements are coincidental, developing along the same time course. The skin could be the source of the bubbles due to its mass, the associated layer of fat, and the variable nature of skin blood flow. CM should not be categorized as Type II DCS, should be included with other skin manifestations in a category called cutaneous DCS, and hyperbaric treatment is only needed if ground level oxygen is ineffective in the case of altitude-induced CM.

Conkin, Johnny↗
NASA NTRS1999

Flow Trajectories in Friction Stir Welding

In the Friction Stir Welding (FSW) process, a rotating, shouldered tool with a threaded pin is inserted under pressure along the seam of two pieces of metal which are tightly clamped together, and secured against a rigid anvil underneath. The rotating pin travels along the seam and through a combination of pressure and friction heating produces a zone of plastic deformation around the pin within the workpiece on either side of the seam. As the pin is moved in the direction of welding, the plasticised material moves around the tool and bonds together behind it. The elements of the material flow behavior are a combination of three elements. There is a rotational transport of material being carried around the tool, extrusion of material being forced around the pin on both sides into the cavity created behind it, and a lifting and dropping of material as it is stirred and mixed by the rotating action of the pin. It was assumed that rotational motion of the plastic zone is the primary mechanism for transport of material around the welding tool. A kinematic mathematical model was used to compute trajectories of material movement for various distributions of rotational slip within the plastic zone. These trajectories were then compared with the results of an experiment that produced radiographs of markers embedded in a workpiece that was welded with the FSW process. It was assumed that the copper wire markers retained their original length as the aluminum material flowed around them. The kinematic model included a constraint so that the displacements were such that the total length of the wire markers did not increase after deformation. There was good agreement between the calculated trajectories for the case of localized slip at the outer surface of the plastic deformation zone and the radiographs of the copper wire markers. The trajectories differed markedly from the radiograph traces when a distributed slip zone was assumed. It was concluded that the flow field could be described generally by a rotating plug model with slip occurring on the surface at the outer boundary of the plastic zone.

Bernstein, Edward L.↗
NASA NTRS1998

Aerothermal Effects of Cavities and Protuberances for High-Speed Sample Return Capsules

Extraterrestrial sample return is a growing component of solar system exploration. Currently, four missions, Stardust, 1 Muses-C, 2 Genesis, and Mars Sample Return, are under development that employ sample return as a prime component of the mission architecture. Respectively, these missions will return samples from the tail of a comet, an asteroid, the solar wind, and, Mars. An important component of these missions and the focus of this paper is the design of the sample return capsule (SRC). The purpose of the SRC is to safely return to Earth any gathered samples for terrestrial analysis. The two major design constraints for any SRC are as follows: 1) it must be able to survive a high-speed Earth entry (11 km/s to as a high as 15 km/s), 2) the mass of the SRC must be as small as possible. Because the SRC mass is carried from Earth to the sample sight and back, the SRC mass is a strong driver in the mission mass budget. Further, for the Mars Sample Return Capsule, planetary protection is another constraint. For this capsule, the probability of planetary contamination at Earth due to an SRC failure at entry must be minimal. For an SRC, a possible failure mechanism is severe local heating as a result of cavities and or protuberances in the SRC forebody heatshield. For example, the Apollo Command Module had a number of cavities and protuberances as part of the baseline designs Wind-tunnel tests of models containing small cavities and protuberances showed severe local heating augmentations in the vicinity of these surface discontinuities.4-5 As another example, the Genesis SRC forebody heat-shield contains penetrations (cavities) to mount the vehicle to the carrier bus. It is expected that these penetrations will also experience a severe local heating environment. A concern is that the large thermal gradients may produce sufficient thermal stress to cause local mechanical failure of the heatshield. Penetrations to the forebody heat-shield can also result from damage at vehicle integration, during launch, or during transportation of the sample return capsule from earth to the sample site and back. For example, the Starting SRC was damaged near the shoulder during the heatshield integration process producing a local surface discontinuity. Also, the Starting SRC traverses through the tail of a comet and is in space for 7 years. Thus, damage to the heatshield as a result of micrometeroid impact is a concern. Finally, it is difficult to characterize the effects of these potential heatshield singularities with ground-test facilities. Either detailed simulation or a dedicated flight test is required.

Olynick, David↗