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Electron Beam Freeform Fabrication (EBF3) for Cost Effective Near-Net Shape Manufacturing

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley Research Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF3), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. EBF3 deposits of 2219 aluminium and Ti-6Al-4V have exhibited a range of grain morphologies depending upon the deposition parameters. These materials have exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF3 process is capable of bulk metal deposition at deposition rates in excess of 2500 cubic centimeters per hour (150 in3/hr) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

Taminger, Karen M.↗

Electron Beam Freeform Fabrication for Cost Effective Near-Net Shape Manufacturing

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley Research Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF3), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. EBF3 deposits of 2219 aluminium and Ti-6Al-4V have exhibited a range of grain morphologies depending upon the deposition parameters. These materials have exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF3 process is capable of bulk metal deposition at deposition rates in excess of 2500 cm3/hr (150 in3/hr) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

Taminger, Karen M.↗

Project Report: Reducing Color Rivalry in Imagery for Conjugated Multiple Bandpass Filter Based Stereo Endoscopy

A pair of conjugated multiple bandpass filters (CMBF) can be used to create spatially separated pupils in a traditional lens and imaging sensor system allowing for the passive capture of stereo video. This method is especially useful for surgical endoscopy where smaller cameras are needed to provide ample room for manipulating tools while also granting improved visualizations of scene depth. The significant issue in this process is that, due to the complimentary nature of the filters, the colors seen through each filter do not match each other, and also differ from colors as seen under a white illumination source. A color correction model was implemented that included optimized filter selection, such that the degree of necessary post-processing correction was minimized, and a chromatic adaptation transformation that attempted to fix the imaged colors tristimulus indices based on the principle of color constancy. Due to fabrication constraints, only dual bandpass filters were feasible. The theoretical average color error after correction between these filters was still above the fusion limit meaning that rivalry conditions are possible during viewing. This error can be minimized further by designing the filters for a subset of colors corresponding to specific working environments.

conjugated multiple bandpass filters (CMBF)↗

The Utility and Validity of Kinematic GPS Positioning for the Geosar Airborne Terrain Mapping Radar System

GeoSAR is an airborne, interferometric Synthetic Aperture Radar (IFSAR) system for terrain mapping, currently under development by a consortium including NASA's Jet Propulsion Laboratory (JPL), Calgis, Inc., a California mapping sciences company, and the California Department of Conservation (CaIDOC), with funding provided by the U.S. Army Corps of Engineers Topographic Engineering Center (TEC) and the U.S. Defense Advanced Research Projects Agency (DARPA). IFSAR data processing requires high-accuracy platform position and attitude knowledge. On 9 GeoSAR, these are provided by one or two Honeywell Embedded GPS Inertial Navigation Units (EGI) and an Ashtech Z12 GPS receiver. The EGIs provide real-time high-accuracy attitude and moderate-accuracy position data, while the Ashtech data, post-processed differentially with data from a nearby ground station using Ashtech PNAV software, provide high-accuracy differential GPS positions. These data are optimally combined using a Kalman filter within the GeoSAR motion measurement software, and the resultant position and orientation information are used to process the dual frequency (X-band and P-band) radar data to generate high-accuracy, high -resolution terrain imagery and digital elevation models (DEMs). GeoSAR requirements specify sub-meter level planimetric and vertical accuracies for the resultant DEMS. To achieve this, platform positioning errors well below one meter are needed. The goal of GeoSAR is to obtain 25 cm or better 3-D positions from the GPS systems on board the aircraft. By imaging a set of known point target corner-cube reflectors, the GeoSAR system can be calibrated. This calibration process yields the true position of the aircraft with an uncertainty of 20- 50 cm. This process thus allows an independent assessment of the accuracy of our GPS-based positioning systems. We will present an overview of the GeoSAR motion measurement system, focusing on the use of GPS and the blending of position data from the various systems. We will present the results of our calibration studies that relate to the accuracy the GPS positioning. We will discuss the effects these positioning, errors have on the resultant DEM products and imagery.

Freedman, Adam↗

Flight Software for the LOFTID Re-Entry Vehicle

NASA’s Low-Earth Orbit Flight Test of an Inflatable Decelerator, or LOFTID, demonstrated re-entry from low-Earth orbit of a 6-meter aeroshell designed to be used as a heat shield that is larger than the rocket shroud, enabling the return of much greater mass. The LOFTID Flight Software was developed in-house and consists of three components: the Power Distribution software, the Data Recorder software, and the Camera Controller software, along with the Ground Software used for testing, operations, data integrity, and data processing. This presentation will discuss issues found in developing the Power Distribution software in cFS on a non-Linux POSIX platform, designing an efficient architecture for recording of high bandwidth data, controlling over a dozen cameras in-flight, and creating the ground support tools to verify data integrity and support the post-processing of flight data.

Paul Brewster↗

Maintaining a Local Data Integration System in Support of Weather Forecast Operations

Since 2000, both the National Weather Service in Melbourne, FL (NWS MLB) and the Spaceflight Meteorology Group (SMG) have used a local data integration system (LDIS) as part of their forecast and warning operations. Each has benefited from 3-dimensional analyses that are delivered to forecasters every 15 minutes across the peninsula of Florida. The intent is to generate products that enhance short-range weather forecasts issued in support of NWS MLB and SMG operational requirements within East Central Florida. The current LDIS uses the Advanced Regional Prediction System (ARPS) Data Analysis System (ADAS) package as its core, which integrates a wide variety of national, regional, and local observational data sets. It assimilates all available real-time data within its domain and is run at a finer spatial and temporal resolution than current national- or regional-scale analysis packages. As such, it provides local forecasters with a more comprehensive and complete understanding of evolving fine-scale weather features. Recent efforts have been undertaken to update the LDIS through the formal tasking process of NASA's Applied Meteorology Unit. The goals include upgrading LDIS with the latest version of ADAS, incorporating new sources of observational data, and making adjustments to shell scripts written to govern the system. A series of scripts run a complete modeling system consisting of the preprocessing step, the main model integration, and the post-processing step. The preprocessing step prepares the terrain, surface characteristics data sets, and the objective analysis for model initialization. Data ingested through ADAS include (but are not limited to) Level II Weather Surveillance Radar- 1988 Doppler (WSR-88D) data from six Florida radars, Geostationary Operational Environmental Satellites (GOES) visible and infrared satellite imagery, surface and upper air observations throughout Florida from NOAA's Earth System Research Laboratory/Global Systems Division/Meteorological Assimilation Data Ingest System (MADIS), as well as the Kennedy Space Center ICape Canaveral Air Force Station wind tower network. The scripts provide NWS MLB and SMG with several options for setting a desirable runtime configuration of the LDIS to account for adjustments in grid spacing, domain location, choice of observational data sources, and selection of background model fields, among others. The utility of an improved LDIS will be demonstrated through postanalysis warm and cool season case studies that compare high-resolution model output with and without the ADAS analyses. Operationally, these upgrades will result in more accurate depictions of the current local environment to help with short-range weather forecasting applications, while also offering an improved initialization for local versions of the Weather Research and Forecasting model.

Watson, Leela R.↗

Embossed Teflon AF Laminate Membrane Microfluidic Diaphragm Valves

A microfluidic system has been designed to survive spaceflight and to function autonomously on the Martian surface. It manipulates microscopic quantities of liquid water and performs chemical analyses on these samples to assay for the presence of molecules associated with past or present living processes. This technology lies at the core of the Urey Instrument, which is scheduled for inclusion on the Pasteur Payload of the ESA ExoMars rover mission in 2013. Fabrication processes have been developed to make the microfabricated Teflon-AF microfluidic diaphragm pumps capable of surviving extreme temperature excursions before and after exposure to liquid water. Two glass wafers are etched with features and a continuous Teflon membrane is sandwiched between them (see figure). Single valves are constructed using this geometry. The microfabricated devices are then post processed by heating the assembled device while applying pneumatic pressure to force the Teflon diaphragm against the valve seat while it is softened. After cooling the device, the embossed membrane retains this new shape. This solves previous problems with bubble introduction into the fluid flow where deformations of the membrane at the valve seat occurred during device bonding at elevated temperatures (100-150 C). The use of laminated membranes containing commercial Teflon AF 2400 sheet sandwiched between spun Teflon AF 1600 layers performed best, and were less gas permeable than Teflon AF 1600 membranes on their own. Spinning Teflon AF 1600 solution (6 percent in FLOURINERT(Registered TradeMark) FC40 solvent, 3M Company) at 500 rpm for 1.5 seconds, followed by 1,000 rpm for 3 seconds onto Borofloat glass wafers, results in a 10-micron-thick film of extremely smooth Teflon AF. This spinning process is repeated several times on flat, blank, glass wafers in order to gradually build a thick, smooth membrane. After running this process at least five times, the wafer and Teflon coating are heated under vacuum at 220 C for one hour in order to drive off any residual solvent present in the composite film. After this, a second blank, glass wafer is brought down from above and the stack is held under vacuum at 3 atm mechanical pressure for ten 10 hours.

Willis, Peter↗

Experiments on Nucleation in Different Flow Regimes

The vast majority of metallic engineering materials are solidified from the liquid phase. Understanding the solidification process is essential to control microstructure, which in turn, determines the properties of materials. The genesis of solidification is nucleation, where the first stable solid forms from the liquid phase. Nucleation kinetics determine the degree of undercooling and phase selection. As such, it is important to understand nucleation phenomena in order to control solidification or glass formation in metals and alloys. Early experiments in nucleation kinetics were accomplished by droplet dispersion methods. Dilatometry was used by Turnbull and others, and more recently differential thermal analysis and differential scanning calorimetry have been used for kinetic studies. These techniques have enjoyed success; however, there are difficulties with these experiments. Since materials are dispersed in a medium, the character of the emulsion/metal interface affects the nucleation behavior. Statistics are derived from the large number of particles observed in a single experiment, but dispersions have a finite size distribution which adds to the uncertainty of the kinetic determinations. Even though temperature can be controlled quite well before the onset of nucleation, the release of the latent heat of fusion during nucleation of particles complicates the assumption of isothermality during these experiments. Containerless processing has enabled another approach to the study of nucleation kinetics. With levitation techniques it is possible to undercool one sample to nucleation repeatedly in a controlled manner, such that the statistics of the nucleation process can be derived from multiple experiments on a single sample. The authors have fully developed the analysis of nucleation experiments on single samples following the suggestions of Skripov. The advantage of these experiments is that the samples are directly observable. The nucleation temperature can be measured by noncontact optical pyrometry, the mass of the sample is known, and post processing analysis can be conducted on the sample. The disadvantages are that temperature measurement must have exceptionally high precision, and it is not possible to isolate specific heterogeneous sites as in droplet dispersions.

Bayuzick, R. J.↗

In-Flight Edge Response Measurements for High Spatial Resolution Remote Sensing Systems

In-flight measurement of spatial resolution were conducted as part of the ASA Scientific Data Purchase (SDP) Validation and Verification (V&V) process. Characterization included remote sensing systems with ground sample distance (GSD) of 1 meter or less, such as the panchromatic imager on-board the ICONOS satellite and the airborne ADAR System 5500 multispectral instrument. Final image products were used to evaluate the effect of both the image acquisition system (e.g., optics, electronics, motion, jitter, atmosphere) and image post-processing (e.g., resampling, modulation trasfer function (MTF) compensator). Spatial resolution was characterized by full width at half maximum (FWHM) of an edge response-derived line spread function. This was found to be a more robust measure of spatial resolution than the value of NTF at Nyquist frequency The edge responses were analysed using the tilted-edge technique that ovecomes the spatial sampling limitations of the digital imaging systems. As an enhancement to existing algorithms, the slope of the edge response and the orientation of the edge target were determined by a single computational process. Adjacent black and white square panels, either painted on a flat surface or deployed as traps, formed the ground-based edge targets used in the tests. Orientation of the deployable tarps was optimized beforehand, based on simulations of the imaging system. Numerous edge target images were analyzed for each of the tested sensors. The effect of such factors as acquisition geometry, temporal variability, MTF compensation, and GSD on spatial resolution were investigated.

Blonski, Slawomir↗

Ring element dynamic stresses

The stresses in the CTRAPRG and CTRIARG ring elements are not calculated for any of the dynamic solutions in the current COSMIC version of NASTRAN. A DMAP alter sequence for Solution 8 and post-processing program, NASTPOST, are presented to calculate these stresses. Test cases are used which describe the method. The stiffness and the consistent versus concentrated mass problems ascribed to this element are reviewed. The DMAP alter sequence introduces Solution 8 displacements to a Solution 1 module to calculate real and imaginary stress components during the execution of Solution 8. The post-processor, NASTPOST, calculates the magnitude/phase stress results. The DMAP sequence was written specifically for level 52 MSC/NASTRAN, but can certainly be used for any COSMIC version with slight modification.

Lambert, N.↗

Supersonic flow computations over aerospace configurations using an Euler marching solver

For fully supersonic flows, an efficient strategy for obtaining numerical solutions is to employ space marching techniques. A full potential marching technique, known as the SIMP code and capable of handling such embedded subsonic regions, has achieved some success analyzing low supersonic Mach number flows. The extension of the full potential approach to the Euler equation which model the exact nonlinear inviscid gas dynamic flow processes is presented. Within the assumption of an inviscid flow, such an Euler marching solver can be applied to a wide class of shocked flows including the hypersonic range. The intent is to maintain some of the basic features of the full potential SIMP code within the Euler solver in dealing with geometry input, gridding techniques, and input/output routines including post processing of results. An Euler marching code known as EMTAC was developed. Results obtained for a variety of configurations involving canard, wing, horizontal tail, flow-through inlet, and fuselage using both the EMTAC and SIMP codes are reported. For shocked cases satisfying the isentropic assumption, the EMTAC and SIMP codes produced practically the same results. In terms of execution time, the EMTAC code is slower.

Szema, Kuo-Yen↗

Experiments on Nucleation in Different Flow Regimes

The vast majority of metallic engineering materials are solidified from the liquid phase. Understanding the solidification process is essential to control microstructure, which in turn, determines the properties of materials. The genesis of solidification is nucleation, where the first stable solid forms from the liquid phase. Nucleation kinetics determine the degree of undercooling and phase selection. As such, it is important to understand nucleation phenomena in order to control solidification or glass formation in metals and alloys. Early experiments in nucleation kinetics were accomplished by droplet dispersion methods [1-6]. Dilitometry was used by Turnbull and others, and more recently differential thermal analysis and differential scanning calorimetry have been used for kinetic studies. These techniques have enjoyed success; however, there are difficulties with these experiments. Since materials are dispersed in a medium, the character of the emulsion/metal interface affects the nucleation behavior. Statistics are derived from the large number of particles observed in a single experiment, but dispersions have a finite size distribution which adds to the uncertainty of the kinetic determinations. Even though temperature can be controlled quite well before the onset of nucleation, the release of the latent heat of fusion during nucleation of particles complicates the assumption of isothermality during these experiments. Containerless processing has enabled another approach to the study of nucleation kinetics [7]. With levitation techniques it is possible to undercool one sample to nucleation repeatedly in a controlled manner, such that the statistics of the nucleation process can be derived from multiple experiments on a single sample. The authors have fully developed the analysis of nucleation experiments on single samples following the suggestions of Skripov [8]. The advantage of these experiments is that the samples are directly observable. The nucleation temperature can be measured by noncontact optical pyrometry, the mass of the sample is known, and post processing analysis can be conducted on the sample. The disadvantages are that temperature measurement must have exceptionally high precision, and it is not possible to isolate specific heterogeneous sites as in droplet dispersions.

Bayuzick, Robert J.↗

Experiments on Nucleation in Different Flow Regimes

The vast majority of metallic engineering materials are solidified from the liquid phase. Understanding the solidification process is essential to control microstructure, which in turn, determines the properties of materials. The genesis of solidification is nucleation, where the first stable solid forms from the liquid phase. Nucleation kinetics determine the degree of undercooling and phase selection. As such, it is important to understand nucleation phenomena in order to control solidification or glass formation in metals and alloys. Early experiments in nucleation kinetics were accomplished by droplet dispersion methods. Dilitometry was used by Turnbull and others, and more recently differential thermal analysis and differential scanning calorimetry have been used for kinetic studies. These techniques have enjoyed success; however, there are difficulties with these experiments. Since materials are dispersed in a medium, the character of the emulsion/metal interface affects the nucleation behavior. Statistics are derived from the large number of particles observed in a single experiment, but dispersions have a finite size distribution which adds to the uncertainty of the kinetic determinations. Even though temperature can be controlled quite well before the onset of nucleation, the release of the latent heat of fusion during nucleation of particles complicates the assumption of isothermality during these experiments. Containerless processing has enabled another approach to the study of nucleation kinetics. With levitation techniques it is possible to undercool one sample to nucleation repeatedly in a controlled manner, such that the statistics of the nucleation process can be derived from multiple experiments on a single sample. The authors have fully developed the analysis of nucleation experiments on single samples following the suggestions of Skripov. The advantage of these experiments is that the samples are directly observable. The nucleation temperature can be measured by noncontact optical pyrometry, the mass of the sample is known, and post-processing analysis can be conducted on the sample. The disadvantages are that temperature measurement must have exceptionally high precision, and it is not possible to isolate specific heterogeneous sites as in droplet dispersions. Levitation processing of refractory materials in ultra high vacuum provides an avenue to conduct these kinetic studies on single samples. Two experimental methods have been identified where ultra high vacuum experiments are possible; electrostatic levitation in ground-based experiments and electromagnetic processing in low earth orbit on TEMPUS. Such experiments, reported here, were conducted on zirconium. Liquid zirconium is an excellent solvent and has a high solubility for contaminants contained in the bulk material as well as those contaminants found in the vacuum environment. Oxides, nitrides, and carbides do not exist in the melt, and do not form on the surface of molten zirconium, for the materials and vacuum levels used in this study. Ground-based experiments with electrostatic levitation have shown that the statistical nucleation kinetic experiments are viable and yield results which are consistent with classical nucleation theory. The advantage of low earth orbit experiments is the ability to vary the flow conditions in the liquid prior to nucleation. The put-pose of nucleation experiments in TEMPUS was to examine.

Bayuzick, R. J.↗

Wavelet Filter Banks for Super-Resolution SAR Imaging

This paper discusses Innovative wavelet-based filter banks designed to enhance the analysis of super resolution Synthetic Aperture Radar (SAR) images using parametric spectral methods and signal classification algorithms, SAR finds applications In many of NASA's earth science fields such as deformation, ecosystem structure, and dynamics of Ice, snow and cold land processes, and surface water and ocean topography. Traditionally, standard methods such as Fast-Fourier Transform (FFT) and Inverse Fast-Fourier Transform (IFFT) have been used to extract Images from SAR radar data, Due to non-parametric features of these methods and their resolution limitations and observation time dependence, use of spectral estimation and signal pre- and post-processing techniques based on wavelets to process SAR radar data has been proposed. Multi-resolution wavelet transforms and advanced spectral estimation techniques have proven to offer efficient solutions to this problem.

Sheybani, Ehsan O.↗

EOS MLS Level 2 Data Processing Software Version 3

This software accepts the EOS MLS calibrated measurements of microwave radiances products and operational meteorological data, and produces a set of estimates of atmospheric temperature and composition. This version has been designed to be as flexible as possible. The software is controlled by a Level 2 Configuration File that controls all aspects of the software: defining the contents of state and measurement vectors, defining the configurations of the various forward models available, reading appropriate a priori spectroscopic and calibration data, performing retrievals, post-processing results, computing diagnostics, and outputting results in appropriate files. In production mode, the software operates in a parallel form, with one instance of the program acting as a master, coordinating the work of multiple slave instances on a cluster of computers, each computing the results for individual chunks of data. In addition, to do conventional retrieval calculations and producing geophysical products, the Level 2 Configuration File can instruct the software to produce files of simulated radiances based on a state vector formed from a set of geophysical product files taken as input. Combining both the retrieval and simulation tasks in a single piece of software makes it far easier to ensure that identical forward model algorithms and parameters are used in both tasks. This also dramatically reduces the complexity of the code maintenance effort.

Livesey, Nathaniel J.↗

Application of Low Dimensional Manifolds in NO(x) Prediction

A new post-processing technique has been developed, based on the Intrinsic Low Dimensional Manifold (ILDM) method of Maas and Pope. The ILDM method is a dynamical systems approach to the simplification of large chemical kinetic mechanisms. By identifying low-dimensional attracting manifolds, the method allows complex full mechanisms to be parameterized by just a few variables: In effect, generating reduced chemical mechanisms by an automatic procedure. These resulting mechanisms however, still retain all the species used in the full mechanism. The NO(x) post-processor takes an ILDM reduced mechanism and attempts to map this mechanism to the results of a CFD calculation. This mapping allows the NO(x) concentrations at each grid node to be obtained from the ILDM reduced mechanism, as well as other trace species of interest. Because a mapping procedure is used, this method is very fast, being able to process one million node calculations in just a few minutes.

Norris, A. T.↗

A fully ro-vibrationally resolved corona model for the molecular hydrogen Fulcher-𝛼 system

A ro-vibrationally resolved corona model for the molecular hydrogen Fulcher-𝛼 transition based on the Yacora solver is introduced. The model couples 1365 ro-vibrational levels of the 𝑋 1 ⁢𝛴$^+_𝑔$, 𝑑 3⁢ 𝛱 𝑢 and 𝑎 3 ⁢𝛴$^+_𝑔$ states via electron impact excitation from the ground state into the 𝑑 3⁢ 𝛱 𝑢 state and subsequent spontaneous emission into the 𝑎 3 ⁢𝛴$+_𝑔$ state. For the process of electron impact excitation a set of 45260 fully ro-vibrationally resolved cross sections calculated with the molecular convergent close-coupling (MCCC) method in the adiabatic-nuclei formulation is applied. The MCCC cross sections are compared with results of a scaling method used in other works, demonstrating the need for dedicated ro-vibrationally resolved cross sections. By post-processing the model output, entire Fulcher spectra can be simulated. These spectra are benchmarked with measurements from an inductively coupled plasma discharge at a pressure between 1.1–10 Pa and a RF power of 700 W. The model results agree very well with the experiment both in relative shape and in absolute value. A non-ro-vibrationally resolved, purely electronically resolved collisional radiative model for molecular hydrogen (including further states and reaction channels) is applied to investigate the validity of the corona approximation for the benchmark plasmas and the relevance of possible process extensions of the corona model. Furthermore, the influence of collisional quenching, autoionization and predissociation is discussed.

74 ATOMIC AND MOLECULAR PHYSICS↗

Using spatial logic in classification of Landsat TM data

A strategy for spatial/spectral classification of Landsat TM data is presented. The strategy is founded upon 'spatial logic', a logic that seeks to emulate important aspects of visual image interpretation. The carefully structured classification process begins with spectral stratification of the data into water, vegetated and non-vegetated pixels. A region growing algorithm is then used to define 'fields' of similar land cover composition. Fields are characterized by cover composition, size and neighborhood characteristics. A supervised iterative contextual classification algorithm is developed to assign final land use/land cover labels. Maps are generalized using a spatial post-processing technique. Positive, though preliminary, results are presented.

Merchant, J. W.↗