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The Mars Environmental Compatibility Assessment (MECA) Abrasion Tool

The Mars Environmental Compatibility Assessment (MECA) experiment, an instrument suite to be flown on Mars Surveyor 2001, will include a tool for doing simple mineralogical scratch and streak tests on particles from the Martian regolith. The Abrasion Tool will be applied to particles that adhere themselves to highly polished substrates of various hardnesses. Granular soil components will be subjected to a compressive force of about 3 N using a leaf spring. The spring will be applied with a paraffin actuator capable of a 0.76 mm throw to achieve a maximum displacement of about 7.5 mm at the tip of the tool. The pressure per grain will be dependent on the grain size, the number of grains that adhere to the substrate and the number of grains in compression. The pressure per particle is expected to be on the order of 100 MPa - 1 GPa. The MECA sample wheel containing the substrates will be rotated after the particles are placed in compression to produce scratches or pits. A primary goal of the Abrasion Tool is to identify quartz (Mohs' hardness = 7) using substrates of varying hardnesses. Quartz is considered hazardous to future human explorers of Mars because it can cause silicosis of the lungs if it is of respirable size. It is also hazardous to machinery, structures, and space suits because of its ability to abrade and scratch surfaces. Since large quantities of minerals harder than quartz are not expected, any scratches produced on polished quartz substrates might be reasonably attributed to quartz particles, although there may be minerals such as impact metamorphic diamond in the soils. Careful calibration of the tool will be necessary to ensure that grains are not overloaded; for example, a steel ball pressed into glass will produce a Hertzian fracture, even though it is softer than glass. Other minerals, such as magnetite (Mohs' hardness = 6.5) have been shown to scratch glass ceramics such as Zerodur (Mohs' hardness = 6.5). Thus, minerals can be differentiated: note that regardless of the mineral species, if any particle is harder than 6.5 it will certainly be an interesting discovery for both planetary geology and human exploration concerns. The scratches will be identified using the 6X optical microscope and profiled with the atomic force microscope included in the MECA instrument suite. Analysis of the scratch morphology will yield evidence concerning the shape of the particle responsible for producing each scratch. For example, angular grains should leave vertical cracks with microconchoidal lateral chipping, while rounded grains might leave chatter marks, or nested partial Hertzian cracks. Particle shape can thus be inferred from these indentation modes, as well as material hardness. In addition, particle size information may also be available if pits caused by rolling particles can be identified. Converse to scratching, the minerals may be crushed at their contact points, and be smeared onto the target substrates to leave what geologists refer to as "streaks". These are cold-welded trails of mineral material that have structure and color indicative of mineral composition. The AFM will determine the morphology of these streaks, while the microscope will ascertain the color. On the harder substrates, we might expect streaking to dominate; on the softer substrates, scratching may dominate. Progressions of material interactions across the substrate selection will be a valuable source of data for mineral discrimination. It should also be noted that many minerals have coatings (such as iron oxides), and these will have to be differentiated from the host mineral grains; laboratory tests will establish the effects of such coatings on the scratch results. Finally, we note that the microscope will provide corroborative data regarding likely mineral species by grain shapes, fracture patterns, surface textures, color, and UV fluorescence reactions. Additional information is contained in the original extended abstract.

Kuhlman, K. R.↗

Influence of Specimen Preparation and Specimen Size on Composite Transverse Tensile Strength and Scatter

The influence of specimen polishing, configuration, and size on the transverse tension strength of two glass-epoxy materials, and one carbon-epoxy material, loaded in three and four point bending was evaluated. Polishing machined edges, arid/or tension side failure surfaces, was detrimental to specimen strength characterization instead of yielding a higher, more accurate, strength as a result of removing inherent manufacture and handling flaws. Transverse tension strength was typically lower for longer span lengths due to the classical weakest link effect. However, strength was less sensitive to volume changes achieved by increasing specimen width. The Weibull scaling law typically over-predicted changes in transverse tension strengths in three point bend tests and under-predicted changes in transverse tension strengths in four point bend tests. Furthermore, the Weibull slope varied with specimen configuration, volume, and sample size. Hence, this scaling law was not adequate for predicting transverse tension strength of heterogeneous, fiber-reinforced, polymer matrix composites.

OBrien, T. Kevin↗

Paint Analysis

Lewis Research Center (LEW) has assisted The Cleveland Museum of Art (CMA) in analyzing the museum's paintings. Because of the many layers of paint that are often involved, this is a complex process. The cross-section of a paint chip must be scanned with a microscope to determine whether a paint layer is original or a restoration. The paint samples, however, are rarely flat enough for high magnification viewing and are frequently scratched. LEW devised an automated method that produces intact, flat, polished paint cross-sections. A sophisticated microprocessor-controlled grinding and polishing machine was manually employed in preparation of exotic samples for aerospace research was a readily adaptable technique. It produced perfectly flat samples with clearly defined layers. The process has been used successfully on a number of paintings, and LEW and CMA are considering additional applications.

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Production of Near-Mirror Surface Quality by Precision Grinding

Mechanical components such as gears and bearings operate with the working surfaces in intimate contact with a mating part. The performance of such components will be influenced by the quality of the working surface. In general, a smoother surface will perform better than a rougher surface since the lubrication conditions are improved. For example, surfaces with a special near-mirror quality finish of low roughness performed better than ground surfaces when tested using a block-on-ring arrangement. Bearings with near-mirror quality have been tested and analyzed; lower running torques were measured and improved fatigue life was anticipated. Experiments have been done to evaluate the performance of gears with improved, low roughness surface finishing. The measured performance improvements include an increased scuffing (scoring) load capacity by a factor of 1.6, a 30-percent reduction of gear tooth running friction, and longer fatigue lives by a factor of about four. One can also anticipate that near-mirror quality surface finishing could improve the performance of other mechanical components such as mechanical seals and heavily loaded journal bearings. Given these demonstrated benefits, capable and economical methods for the production of mechanical components with near-mirror quality surfaces are desired. One could propose the production of near-mirror quality surfaces by several methods such as abrasive polishing, chemical assisted polishing, or grinding. Production of the surfaces by grinding offers the possibility to control the macro-geometry (form), waviness, and surface texture with one process. The present study was carried out to investigate the possibility of producing near-mirror quality surfaces by grinding. The present study makes use of a specially designed grinding machine spindle to improve the surface quality relative to the quality produced when using a spindle of conventional design.

Dimofte, Florin↗

Influence of Specimen Preparation and Specimen Size on the Transverse Tensile Strength and Scatter of Glass Epoxy Laminates

The influence of specimen polishing, specimen configuration, and specimen size on the transverse tension strength of two glass epoxy materials loaded in three and four point bending was evaluated. Polishing machined edges, and/or tension side failure surfaces, was detrimental to specimen strength characterization instead of yielding a higher, more accurate, strength as a result of removing inherent manufacture and handling flaws. Transverse tension strength was sensitive to span length due to the classical weakest link effect. However, strength was less sensitive to volume changes achieved by increasing specimen width. The Weibull scaling law over-predicted changes in transverse tension strengths in three point bend tests and under-predicted changes in transverse tension strengths in four point bend tests. Furthermore, the Weibull slope varied with specimen configuration, volume, and sample size. Hence, the utility of this scaling law for predicting transverse tension strength is unclear.

OBrien, T. Kevin↗

Final Results of the Ball AMSD Beryllium Mirror

The 1.4-meter semi-rigid, beryllium Advanced Mirror System Demonstrator (AMSD) mirror completed initial cryogenic testing at Marshall's X-ray Calibration Facility (XRCF) in August of 2003. Results of this testing show the mirror to have very low cryogenic surface deformation and possess exceptional figure stability. Subsequent to this cryogenic testing beryllium was selected as the material of choice for the James Webb Space Telescope (JWST) multi-segment primary mirror. Therefore, the AMSD mirror was sent back to SSG-Tinsley for additional ambient polishing to JWST requirements. The mirror was successfully polished to less than 22nm rms of low frequency error. Those additional results are presented with comparisons to the JWST requirements.

Chaney, David M.↗

Poco Graphite Inc. SuperSiC 0.25m Mirror Cryogenic Test Result

SuperSiC, a low areal density material, developed by POCO Graphite, have been used as mirror substrate for high energy lasers, laser radar systems, surveillance, telescopes, scan mirrors and satellites. SuperSiC has excellent thermal properties and cryogenic stability. It exhibits exceptional polishability for reflective optics with high strength, stiffness, and excellent thermal conductivity. A lightweighted 0.2-diameter polished SuperSic mirror was tested at cryogenic temperature at NASMSFC. Optical test results showed 6nm cry0 deformation from ambient to 30 degrees Kelvin and little to no change in its surface figure due to cry0 cycling.

Eng, Ron↗

Improved Edge Performance in MRF

The fabrication of large segmented optics requires a polishing process that can correct the figure of a surface to within a short distance from its edges-typically, a few millimeters. The work here is to develop QED's Magnetorheological Finishing (MRF) precision polishing process to minimize residual edge effects.

Shorey, Aric↗

The Surface Structure of Ground Metal Crystals

The changes produced on metallic surfaces as a result of grinding and polishing are not as yet fully understood. Undoubtedly there is some more or less marked change in the crystal structure, at least, in the top layer. Hereby a diffusion of separated crystal particles may be involved, or, on plastic material, the formation of a layer in greatly deformed state, with possible recrystallization in certain conditions. Czochralski verified the existence of such a layer on tin micro-sections by successive observations of the texture after repeated etching; while Thomassen established, roentgenographically by means of the Debye-Scherrer method, the existence of diffused crystal fractions on the surface of ground and polished tin bars, which he had already observed after turning (on the lathe). (Thickness of this layer - 0.07 mm). Whether this layer borders direct on the undamaged base material or whether deformed intermediate layers form the transition, nothing is known. One observation ty Sachs and Shoji simply states that after the turning of an alpha-brass crystal the disturbance starting from the surface, penetrates fairly deep (approx. 1 mm) into the crystal (proof by recrystallization at 750 C).

Boas, W.↗

B-Roll of AMSD Mirror

This video shows the Advanced Mirror System Demonstrator (AMSD) mirror being inspected and handled at Tinsley. The mirror is a beryllium mirror technology demonstrator that is a critical item demonstrating that the James Webb Space Telescope mirrors can be fabricated and will meet the performance requirements. Because Tinsley is very concerned about sharing proprietary information, the video, shot by them, does not show any key aspects of the polishing process (such as the polishing heads). The video includes workers at Tinsley rotating and inspecting the mirror. Excerpts of this video will be provided as part of a press release on JWST technology.

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Angular Distribution of Elastically Scattered Electrons Determined and Its Effect on Collector Performance Computed

It has been demonstrated that the suppression of secondary electron emission significantly improves the performance of electron beam collectors (ref. 1). However, a complete analysis of the effects of secondary electron emission with respect to collector performance has not been possible because of the lack of quantitative data on angular distributions of secondary electrons. Secondary electrons are emitted with energies ranging from near zero to the energy of the incident primary. For our purposes, we define elastically scattered electrons as secondary electrons within 20 percent of the incident energy. Elastically scattered electrons are of great concern because their energy allows them to follow trajectories that can carry them almost anywhere within the vacuum envelope. If these secondaries leave the collector and reenter the slow wave circuit, they can produce undesired signal distortion and oscillation.This apparatus, which was built by Krainsky (ref. 2), was used at the NASA Lewis Research Center to obtain detailed measurements of the angular distributions of elastically scattered secondaries. Data were obtained for three surfaces of significant interest to collector applications: highly polished copper, copper roughened by ion sputtering, and isotropic graphite. Lewis researchers discovered that elastically scattered electrons have a complex angular distribution that is strongly dependent on the atomic number and surface morphology of the target material, as well as the energy and angle of incidence of the primary beam. At low energies, secondary emission from polished copper in the chosen energy range is primarily directed back to the source of primary electrons (backscattering). Forward scattering increases with primary energy until, at high energies, forward scattering dominates the angular distribution. Although back-scattered secondaries dominate the distributions of the textured copper surface, the yield is substantially lower. From the standpoint of secondary emission, isotropic graphite is the most attractive material because it exhibits low yield and little back scattering.

Krainsky, Isay L.↗

Gear Durability Shown To Be Improved by Superfinishing

Gears, bearings, and similar mechanical elements transmit loads through contacting surfaces. At the NASA Glenn Research Center at Lewis Field, we postulated that the fatigue lives of gears could be improved by providing smoother tooth surfaces. A superfinishing process was applied to a set of conventionally ground, aerospace-quality gears. This process produced a highly polished, mirrorlike surface as shown in the preceding photograph. The surface fatigue lives of both superfinished and conventionally ground gears were measured by experiments. The superfinished gears survived about four times longer than the conventionally ground gears. These superfinished gears were produced from conventionally ground, aerospace-quality gears whose geometry had been inspected. The gears were superfinished by placing them in a vibrating bath consisting of water, detergent, abrasive powder, and small pieces of zinc. Upon removal from the bath, the surfaces were highly polished, as depicted in the preceding photograph. The gears were again inspected, and dimensional measurements made before and after the superfinishing operation were compared. Superfinishing removed the peaks of the grinding marks and left a much smoother surface. Profile and spacing checks proved that the overall gear tooth shape was not affected in any harmful way. Superfinishing uniformly removed approximately 2.5 microns from each surface.

Krautz, Timothy L.↗

Abernathy's Lap

A lap in this instance is not a midriff but a tool for presision.polishing and grinding. During the Saturn V moonbooster program, Marshall Space Flight Center found a need for a better lap. The need arose from the exquisitely precise tolerances required for parts of the launch vehicle's guidance,and control system. So William J. Abernathy, a former Marshall employee, built a better lap; he invented a method for charging aluminum lap plates with diamond powder, then hard-anodizing them. The resulting lap produces a high polish on materials ranging from the softest aluminum to the hardest ceramics. It operates faster, wears longer and requires less reworking. Abernathy got NASA's permission to obtain a personal patent and he formed the one-man Abernathy Laps Co. in Huntsville, which produces a variety of laps. One of Abernathy's customers is Bell Aerospace Textron, Buffalo, which uses the laps to finish polish delicate instrument parts produced for NASA's Viking and other space programs. Says a Bell official: "Time needed (with the Abernathy lap) is a fraction of that required by conventional methods. The result is extremely accurate flatness and surface finish." Abernathy is providing laps for other manufacturing applications and for preparation of metallurgical specimens. The business is small but steady, and Abernathy plans expansion into other markets.

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Lightweight optical mirrors formed in single crystal substrate

This invention is directed to a process for manufacturing a lightweight mirror from a single crystal material, such as single crystal silicon. As a near perfect single crystal material, single crystal silicon has much lower internal stress than a conventional material. This means much less distortion of the optical surface during the light weighting process. After being ground and polished, a single crystal silicon mirror is light weighted by removing material from the back side using ultrasonic machining. After the light weighting process, the single crystal silicon mirror may be used as-is or further figured by conventional polishing or ion milling, depending on the application and the operating wavelength.

Bly, Vincent T.↗

Genesis of Augite-Bearing Ureilites: Evidence From LA-ICP-MS Analyses of Pyroxenes and Olivine

Ureilites are ultramafic achondrites composed primarily of coarse-grained low-Ca pyroxene and olivine with interstitial carbonaceous material, but a number of them contain augite [1]. Ureilites are considered to be restites after partial melting of a chondritic precursor, although at least some augite-bearing ureilites may be partially cumulate [1, 2]. In this scenario, the augite is a cumulus phase derived from a melt that infiltrated a restite composed of typical ureilite material (olivine+low-Ca pyroxene) [2]. To test this hypothesis, we examined the major and trace element compositions of silicate minerals in select augite-bearing ureilites with differing mg#. Polished thick sections of the augite-bearing ureilites ALH 84136 , EET 87511, EET 96293, LEW 88201, and META78008 and augite-free typical ureilite EET 90019 were examined by EPMA for major and minor elements and laser ablation ICP-MS (LA-ICP-MS) for trace elements, REE in particular. Although EET 87511 is reported to contain augite, the polished section that we obtained did not.

Herrin, J. S.↗

Simplified Generation of High-Angular-Momentum Light Beams

A simplified method of generating a beam of light having a relatively high value of angular momentum (see figure) involves the use of a compact apparatus consisting mainly of a laser, a whispering- gallery-mode (WGM) resonator, and optical fibers. The method also can be used to generate a Bessel beam. ( Bessel beam denotes a member of a class of non-diffracting beams, so named because their amplitudes are proportional to Bessel functions of the radii from their central axes. High-order Bessel beams can have high values of angular momentum.) High-angular-momentum light beams are used in some applications in biology and nanotechnology, wherein they are known for their ability to apply torque to make microscopic objects rotate. High-angular-momentum light beams could also be used to increase bandwidths of fiber-optic communication systems. The present simplified method of generating a high-angular-momentum light beam was conceived as an alternative to prior such methods, which are complicated and require optical setups that include, variously, holograms, modulating Fabry-Perot cavities, or special microstructures. The present simplified method exploits a combination of the complex structure of the electromagnetic field inside a WGM resonator, total internal reflection in the WGM resonator, and the electromagnetic modes supported by an optical fiber. The optical fiber used to extract light from the WGM resonator is made of fused quartz. The output end of this fiber is polished flat and perpendicular to the fiber axis. The input end of this fiber is cut on a slant and placed very close to the WGM resonator at an appropriate position and orientation. To excite the resonant whispering- gallery modes, light is introduced into the WGM resonator via another optical fiber that is part of a pigtailed fiber-optic coupler. Light extracted from the WGM resonator is transformed into a high-angular- momentum beam inside the extraction optical fiber and this beam is emitted from the polished flat output end. By adjusting the geometry of this apparatus, it is possible to generate a variety of optical beams characterized by a wide range of parameters. These beams generally have high angular momenta and can be of either Bessel or Bessel-related types.

Savchenkov, Anatoliy↗

Diamond Smoothing Tools

Diamond smoothing tools have been proposed for use in conjunction with diamond cutting tools that are used in many finish-machining operations. Diamond machining (including finishing) is often used, for example, in fabrication of precise metal mirrors. A diamond smoothing tool according to the proposal would have a smooth spherical surface. For a given finish machining operation, the smoothing tool would be mounted next to the cutting tool. The smoothing tool would slide on the machined surface left behind by the cutting tool, plastically deforming the surface material and thereby reducing the roughness of the surface, closing microcracks and otherwise generally reducing or eliminating microscopic surface and subsurface defects, and increasing the microhardness of the surface layer. It has been estimated that if smoothing tools of this type were used in conjunction with cutting tools on sufficiently precise lathes, it would be possible to reduce the roughness of machined surfaces to as little as 3 nm. A tool according to the proposal would consist of a smoothing insert in a metal holder. The smoothing insert would be made from a diamond/metal functionally graded composite rod preform, which, in turn, would be made by sintering together a bulk single-crystal or polycrystalline diamond, a diamond powder, and a metallic alloy at high pressure. To form the spherical smoothing tip, the diamond end of the preform would be subjected to flat grinding, conical grinding, spherical grinding using diamond wheels, and finally spherical polishing and/or buffing using diamond powders. If the diamond were a single crystal, then it would be crystallographically oriented, relative to the machining motion, to minimize its wear and maximize its hardness. Spherically polished diamonds could also be useful for purposes other than smoothing in finish machining: They would likely also be suitable for use as heat-resistant, wear-resistant, unlubricated sliding-fit bearing inserts.

Voronov, Oleg↗

The Effect of Composition on the Surface Finish of PS400: A New High Temperature Solid Lubricant Coating

A new composite, multi-constituent, solid lubricant coating, NASA PS400, developed for high temperature tribological applications, exhibits a smoother surface finish after grinding and polishing than its predecessors PS200 and PS300. In this paper, the baseline composition of PS400 is modified to investigate each individual constituent s role on the achievable surface finish through a series of coating deposition, grinding, and polishing experiments. Furthermore, to explore the limits of compositional tailoring for improved tribological performance, several PS400 coatings were doped with additional solid lubricants (graphite, MoS2 and BN) and tribologically tested. The test results clearly showed that, compared to PS300 coatings, PS400 achieves a smoother surface finish via a reduced lubricant content. Coatings prepared with higher than the baseline level (10 wt%) of lubricants exhibited higher final surface roughness than the earlier generation PS300 coatings. Reducing or eliminating the one or both lubricants (fluorides or silver) did not further improve the surface finish suggesting that the current composition of PS400 is near optimal with respect to surface finish. Lastly, attempts to improve the poor initial room temperature tribological behavior of PS400 via the addition of traditional solid lubricants were unsuccessful. Based upon this work and earlier results it is expected that future research will concentrate on developing methods to produce a lubricious glaze on the rubbing surface during break in to ensure that low friction and wear are rapidly achieved.

DellaCorte, Christopher↗