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NASA NTRS2007

A Process for Producing Highly Wettable Aluminum 6061 Surfaces Compatible with Hydrazine

NASA's Global Precipitation Measurement (GPM) mission is an ongoing Goddard Space Flight Center (GSFC) project whose basic objective is to improve global precipitation measurements. The space-based portion of the mission architecture consists of a primary or core spacecraft and a constellation of NASA and contributed spacecrafts. The efforts described in this paper refer to the core spacecraft (hereafter referred to as simply GPM) which is to be fabricated at GSFC. It has been decided that the GPM spacecraft is to be a "design-for-demise-spacecraft." This requirement resulted in the need for a propellant tank that would also demise or ablate to an appropriate degree upon re-entry. Composite overwrapped aluminum lined propellant tanks with aluminum propellant management devices (PMD) were shown by analyses to demise and thus became the baseline configuration for GPM. As part of the GPM tank development effort, long term compatibility and wettability testing with hydrazine was performed on Al6061 and 2219 coupons fabricated and cleaned by conventional processes. Long term compatibility was confirmed. However, the wettability of the aluminum as measured by contact angle produced higher than desired angles (greater than 30 deg.) with excessive scatter. The availability of PMD materials exhibiting consistently low contact angles aids in the design of simple PMDs. Two efforts performed by Angeles Crest Engineering and funded by GSFC were undertaken to reduce the risk of using aluminum for the GPM PMD. The goal of the first effort was to develop a cleaning or treatment process to produce consistently low contact angles. The goal of the second effort was to prove via testing that the processed aluminum would retain compatibility with hydrazine and retain low contact angle after long term exposure to hydrazine. Both goals were achieved. This paper describes both efforts and the results achieved.

Moore, N. R.↗

NASA NTRS2006

Electrically Conductive Anodized Aluminum Surfaces

Anodized aluminum components can be treated to make them sufficiently electrically conductive to suppress discharges of static electricity. The treatment was conceived as a means of preventing static electric discharges on exterior satin-anodized aluminum (SAA) surfaces of spacecraft without adversely affecting the thermal-control/optical properties of the SAA and without need to apply electrically conductive paints, which eventually peel off in the harsh environment of outer space. The treatment can also be used to impart electrical conductivity to anodized housings of computers, medical electronic instruments, telephoneexchange equipment, and other terrestrial electronic equipment vulnerable to electrostatic discharge. The electrical resistivity of a typical anodized aluminum surface layer lies between 10(exp 11) and 10(exp 13) Omega-cm. To suppress electrostatic discharge, it is necessary to reduce the electrical resistivity significantly - preferably to < or = 10(exp 9) Omega-cm. The present treatment does this. The treatment is a direct electrodeposition process in which the outer anodized surface becomes covered and the pores in the surface filled with a transparent, electrically conductive metal oxide nanocomposite. Filling the pores with the nanocomposite reduces the transverse electrical resistivity and, in the original intended outer-space application, the exterior covering portion of the nanocomposite would afford the requisite electrical contact with the outer-space plasma. The electrical resistivity of the nanocomposite can be tailored to a value between 10(exp 7) and 10(exp 12) Omega-cm. Unlike electrically conductive paint, the nanocomposite becomes an integral part of the anodized aluminum substrate, without need for adhesive bonding material and without risk of subsequent peeling. The electrodeposition process is compatible with commercial anodizing production lines. At present, the electronics industry uses expensive, exotic, electrostaticdischarge- suppressing finishes: examples include silver impregnated anodized, black electroless nickel, black chrome, and black copper. In comparison with these competing finishes, the present nanocomposite finishes are expected to cost 50 to 20 percent less and to last longer.

Nguyen, Trung Hung↗

NASA NTRS1988

Preparation of dilute magnetic semiconductor films by metalorganic chemical vapor deposition

A method for preparation of a dilute magnetic semiconductor (DMS) film is provided, in which a Group II metal source, a Group VI metal source and a transition metal magnetic ion source are pyrolyzed in the reactor of a metalorganic chemical vapor deposition (MOCVD) system by contact with a heated substrate. As an example, the preparation of films of Cd(sub 1-x)Mn(sub x)Te, in which 0 is less than or equal to x less than or equal to 0.7, on suitable substrates (e.g., GaAs) is described. As a source of manganese, tricarbonyl (methylcyclopentadienyl) manganese (TCPMn) is employed. To prevent TCPMn condensation during its introduction into the reactor, the gas lines, valves and reactor tubes are heated. A thin-film solar cell of n-i-p structure, in which the i-type layer comprises a DMS, is also described; the i-type layer is suitably prepared by MOCVD.

Nouhi, Akbar↗

NASA NTRS1994

Fingered bola body, bola with same, and methods of use

The present invention discloses bola bodies, bolas, and a snaring method which makes use such devices. A bola body, according to the present invention, is nonspherical or irregular in shape rather than a smooth sphere or ovoid body. One or more fingers extends from the bola body. These fingers may be relatively straight or they may have crooked or bent portions to enhance entanglement with a bola line or lines or with each other. Two or more of such fingers may be used and may be regularly or irregularly spaced apart on a bola body. A bola with such bodies includes lines which are connected to the other bodies. In one particular embodiment of a bola body, according to the present invention, the body has an irregular shape with a bottom rectangular portion and a top pyramid portion forming a nose. A plurality of fingers is extended from the pyramidal top portion with one finger extended up and away from each of four corners of the top portion. Such a bola body tends to be initially oriented with its nose and fingers against an object being snared since the body is pulled nose first when a bola line is secured at the tip of the pyramidal portion of the bola body. With such a bola, an unwrapping bola body can slip around a target member so that two of the rod-shaped fingers catch a bola line and guide it into an area or crook between the fingers and a side of the top pyramidal portion of the bola body. Tension on the bola line maintains the line in the crook and tends to press the fingers against the unwrapped target member to stabilize the wrapping of the line about the target member. With such a bola, it is difficult for two or more lines unwrapping in different directions to move past one another without being forced together by line tension. Also, the fingers of such bola bodies may hook and hold each other. The fingers may also hook or entangle some object on or portion of the target member. A probable known target member has known dimensions and shapes so that the bola may be sized and configured to reliably snare such a known target. The bolas can be optimally sized, fashioned, and configured to contact and hold a probable target of known size, dimension, and shape.

Dzenitis, John M.↗

NASA NTRS1960

A Study of Some Factors Affecting Rolling-Contact Fatigue Life

A series of investigations using the fatigue spin rig to study the effect of several factors contributing to rolling contact fatigue life is summarized. Ball specimens of 1/2 and 9/16 inch diameter were tested at maximum theoretical Hertz compressive stresses in the range of 600,000 to 750,000 psi. Life was found to vary inversely with the tenth power of stress. In forging fiber studies, a greater concentration of failures and poorer life were observed where the greatest angle of intersection between the fiber flow lines and the surface occurred. This effect was independent of alloy composition. Higher lubricant viscosity was found to increase fatigue life, Lubricants having the same viscosity but of different base stock produced wide differences in life that correlated with the pressure viscosity coefficient of the lubricant. Higher temperature produced lower fatigue life. Dry powder lubricants produced poor fatigue life at 450 F; failure appearance indicated that the lubricant particles probably acted as minute stress raisers. In metallographic studies, nonmetallic inclusions were found to have a deleterious effect on fatigue life the inclusion size, location, composition, and condition of the matrix being contributing factors; failures were by shear cracking in the subsurface zone of maximum shear stress and eventual propagation into a shallow surface spall. Vacuum melting improved fatigue life, although a general correlation between cleanliness and fatigue life was not found. Life results for ten different bearing materials are presented.

Carter, Thomas L.↗

NASA NTRS2007

Critical Issues for Cu(InGa)Se2 Solar Cells on Flexible Polymer Web

Elemental in-line evaporation on glass substrates has been a viable process for the large-area manufacture of CuInSe2-based photovoltaics, with module efficiencies as high as 12.7% [1]. However, lightweight, flexible CuInSe2-based modules are attractive in a number of applications, such as space power sources. In addition, flexible substrates have an inherent advantage in manufacturability in that they can be deposited in a roll-to-roll configuration allowing continuous, high yield, and ultimately lower cost production. As a result, high-temperature polymers have been used as substrates in depositing CuInSe2 films [2]. Recently, efficiency of 14.1% has been reported for a Cu(InGa)Se2-based solar cell on a polyimide substrate [3]. Both metal foil and polymer webs have been used as substrates for Cu(InGa)Se2-based photovoltaics in a roll-to-roll configuration with reasonable success [4,5]. Both of these substrates do not allow, readily, the incorporation of Na into the Cu(InGa)Se2 film which is necessary for high efficiency devices [3]. In addition, polymer substrates, can not be used at temperatures that are optimum for Cu(InGa)Se2 deposition. However, unlike metal foils, they are electrically insulating, simplifying monolithically-integrated module fabrication and are not a source of impurities diffusing into the growing film. The Institute of Energy Conversion (IEC) has modified its in-line evaporation system [6] from deposition onto glass substrates to roll-to-roll deposition onto polyimide (PI) film in order to investigate key issues in the deposition of large-area Cu(InGa)Se2 films on flexible polymer substrates. This transition presented unexpected challenges that had to be resolved. In this paper, two major problems, spitting from the Cu source and the cracking of Mo back contact film, will be discussed and the solution to each will be presented.

Eser, Erten↗

NASA NTRS1983

Lubrication of 35-millimeter-bore ball bearings of several designs to 2.5 million DN

Parametric tests were conducted with 35mm bore, angular contact ball bearings with either a single or double outer and guided cage. The bearings were either lubricated by oil jets or employed inner ring lubrication. Outer ring cooling was added in selected tests. Lubricant flow to the bearing ranged from 300 to 1900 cc/min. All bearings were successfully run at speeds to 2.5 million DN. Increasing the lubricant flow decreased bearing ring temperatures but increased bearing power lines. The power loss and race temperatures of a jet lubricated with double outer land guided cage were always higher than those of the single land guided design at similar test conditions. The lowest bearing operating temperatures were achieved when inner ring lubrication and outer ring cooling were combined. It is found that cage slip of a double outer land guided cage is approximately twice that of a single outer land guided cage.

Schuller, F. T.↗

NASA NTRS1995

Bicycle ergometer instrumentation to determine muscle and bone forces during exercise

It is hypothesized that bone loss experienced by astronauts in zero gravity conditions may be curtailed by appropriate exercise. According to Wolf's law, bone regenerates when muscles produce stresses by pulling on the bone during daily activity and/or exercise on Earth. to use this theory to prevent or decrease bone loss, one needs to quantify musculoskeletal loads and relate them to bone density changes. In the context of the space program, it is desirable to determine musculoskeletal loads during exercise (using the bicycle ergometer in this case) so that one may make similar measurements on Earth and in space. In this manner, load measurements on Earth may be used as reference to generate similar loads during exercise in space. The work reported in this document entails a musculoskeletal load measurement system that, when complete, will provide forces at muscle insertion points and other contact points, on bone. This data will be used by Dr. Beth A. Todd, who is also a SSF working with Dr. Shackelford, as input to a finite element model of bone sections to determine stress distributions. A bicycle ergometer has been instrumented to measure parameters needed to determine musculoskeletal forces during exercise. A primary feature of the system is its compactness. It uses small/light sensors without line-of-sight requirements. The system developed includes sensors, signal processing, a data acquisition system, and software to collect the data. The sensors used include optical encoders to measure position and orientation of the pedal (foot), accelerometers to determine kinematic parameters of the shank and thigh, load cells to measure pedal forces on the sagittal plane, and EMG probes to measure muscle activity. The signals are processed using anti-aliasing filters and amplifiers. The sensors' output is digitized using 30 channels of a board mounted inside a 486 class PC. A program sets the data acquisition parameters and collects data during a time period specified by the user. The data is put directly into a file on the hard disk in binary form. The 30 channels are sampled at 200 KHz, and each 30 channel scan is done at a rate of 1000 Hz. The instrumented ergometer has been flown in the KC-135 zero-gravity (zero-g) flight to collect information needed to determine musculoskeletal forces under these conditions. Similar information has been collected in 1-g conditions for comparision with the results from the zero-g case. At this time, the sets of data from both experiments are being processed. An existing methodology will be used to determine the kinematic parameters of the shank and thigh using accelerometer and encoder data. This methodology was developed during the fellow's previous NASA/ASEE fellowship and thanks to a Director's Grant. In the future, a methodology to determine the musculoskeletal forces using Newton's Law of Motion and optimization techniques will be developed to determine forces exerted by particular muscles.

Figueroa, Fernando↗

NASA NTRS2018

Nanoscale Fabrication of Microwave Detectors from Commercially-Available CVD-Grown Monolayer Graphene

Using commercially-available monolayer graphene, synthesized by means of chemical vapor deposition, microwave power sensing elements have been nanofabricated and integrated with microwave-grade test structures suitable for on-wafer probing. The graphene, situated on a thermal oxide, was first cleaned of stray contaminants in a forming gas environment briefly held at 250 degrees Celsius using a rapid thermal annealer. Immediately following this step, the graphene was passivated with a protective aluminum oxide layer (approximately S nm in thickness). Micrometer-scale Corbino disc test structures were then fabricated in direct contact with the graphene using a self-aligned process, which relies on the fact that tetramethylammonium hydroxide develops the photoresist while removing the aluminum oxide. Graphene nanoribbons (with widths as small 400 nm) were then fabricated across the Corbino disc gaps using electron-beam writing in conjunction with a negative tone resist. The same developer exposed the majority of the graphene while defining nanometer-scale lines of photoresist stacked upon aluminum oxide. These stacks served as etch-stops while the unprotected graphene was ion-milled in an oxygen plasma. Finally, the photoresist was removed leaving behind passivated graphene nanoribbons. Damage caused by the fabrication was evaluated by comparing the Raman spectra of the grapheme before and after processing.

detectors↗

NASA NTRS2021

A Mathematical Analysis of an Example Delay Tolerant Network using the Theory of Sheaves

NASA’s High-Data Rate Architecture (HiDRA) project is working towards a general yet practical toolkit and knowledge base to help usher in the era of new technologies for space systems communications, such as optical links. The High-Rate Delay Tolerant Networking (HDTN) implementation falls under the umbrellas of both the toolkit and the knowledge base, as its advancements illuminate more general areas of Delay Tolerant Networking (DTN) that need growth. The goal of this paper is to explore the usage of particular mathematical machineries, namely temporal flow networks and sheaves, to identify fundamental, underlying structures in DTN for space systems. Satellites, space assets, ground stations, etc. give rise to a disconnected network, and it is the goal of DTN to glue disparate links together into a cohesive system, that is, a network. Depending on a given link, the latencies might be beyond that which the Transmission Control Protocol (TCP) can handle, and contact times might have one-way light times in excess of minute (sometimes significantly longer). Some links might be periodic (say, due to orbital mechanics) or they might not be. This diversity has made it difficult to probe the underlying structure. An immediate consequence is that DTNs in practice today are controlled by globally distributed contact plans (schedules), which are the input to the contact graph routing (CGR) algorithm. While this is effective for smaller networks, it will be very difficult to scale for future networks. Deeper and more rigorous theory is needed to bring DTN to the next evolutionary step. To this end, this paper introduces and suggests a mathematical framework for DTN, and applies it to a space network that is simulated using an orbital analysis toolkit. The tag-line for the structure known as sheaves is that they are the mathematically precise way of gluing local data together into unique, global data. If we consider routing, we see that networking is a “sheafy” science. We then discuss a simplified sheaf model, known as the cellular sheaf. The sheaf-theoretic analysis is presented and discussed, as it is hoped that this and related papers will help form the primordial ooze of DTN theory. Finally there is a section of future work suggesting follow-on research.

Delay Tolerant Networking↗

NASA NTRS2005

Improved Gear Shapes for Face Worm Gear Drives

Shapes different from the traditional ones have been proposed for face worm gears and for conical and cylindrical worms that mesh with them. The proposed shapes are based on the concept of generating a face worm gear surface by use of a tilted head cutter instead of by the traditional use of a hob. (As used here, head cutter is also meant to signify, alternatively, a head grinding tool.) The gear-surface-generation equipment would be similar to that used for generation of spiral bevel and hypoid gears. In comparison with the corresponding traditional hob, a tilted head cutter according to the proposal would be larger, could be fabricated with greater precision, and would enable the generation of gear surfaces with greater precision and greater productivity. A face worm gear would be generated (see figure) by use of a tilted head cutter, the blades or grinding surfaces of which would have straight-line profiles. The tilt of the head cutter would prevent interference with teeth adjacent to the groove being cut or ground. A worm to mesh with the face worm gear would be generated by use of a tilted head cutter mounted on the cradle of a generating machine. The blades or grinding surfaces of the head cutter would have a parabolic profile and would deviate from the straight-line profiles of the head cutter for the face worm gear. The shortest distance between the worm and the cradle would follow a parabolic function during the cycle of meshing in the generating process to provide a parabolic function of transmission errors to the gear drive. The small mismatch between the profiles of the face-worm-gear and worm head cutters would make it possible to localize the bearing contact in the worm gear drive. The parabolic function of transmission errors could absorb discontinuous linear functions of transmission errors caused by errors of alignment; this could afford a significant benefit, in that such errors are main sources of noise and vibration in gear drives. The main advantage of using tilted head cutters is that cutting speeds are independent of the shape-generation processes, making it possible to choose cutting speeds that are optimum with respect to requirements to minimize temperatures and deformations during fabrication and improve the quality of finished parts.

Litvin, Faydor L.↗

NASA NTRS1981

Simple geometric algorithms to aid in clearance management for robotic mechanisms

Global geometric shapes such as lines, planes, circles, spheres, cylinders, and the associated computational algorithms which provide relatively inexpensive estimates of minimum spatial clearance for safe operations were selected. The Space Shuttle, remote manipulator system, and the Power Extension Package are used as an example. Robotic mechanisms operate in quarters limited by external structures and the problem of clearance is often of considerable interest. Safe clearance management is simple and suited to real time calculation, whereas contact prediction requires more precision, sophistication, and computational overhead.

Copeland, E. L.↗

NASA NTRS2017

Growth Angle - a Microscopic View

The growth angle that is formed between the side of the growing crystal and the melt meniscus is an important parameter in the detached Bridgman crystal growth method, where it determines the extent of the crystal-crucible wall gap, and in the Czochralski and float zone methods, where it influences the size and stability of the crystals. The growth angle is a non-equilibrium parameter, defined for the crystal growth process only. For a melt-crystal interface translating towards the crystal (melting), there is no specific angle defined between the melt and the sidewall of the solid. In this case, the corner at the triple line becomes rounded, and the angle between the sidewall and the incipience of meniscus can take a number of values, depending on the position of the triple line. In this work, a microscopic model is developed in which the fluid interacts with the solid surface through long range van der Waals or Casimir dispersive forces. This growth angle model is applied to Si and Ge and compared with the macroscopic approach of Herring. In the limit of a rounded corner with a large radius of curvature, the wetting of the melt on the crystal is defined by the contact angle. The proposed microscopic approach addresses the interesting issue of the transition from a contact angle to a growth angle as the radius of curvature decreases.

Mazurak, K.↗

NASA NTRS2021

Local Ultrasonic Resonance Spectroscopy of Lithium Metal Batteries for Aerospace Applications

As next-generation aircraft and vehicles continue to develop, so do their associated energy demands. Lithium metal batteries are a leading candidate to fulfill this energy requirement, but these batteries are prone to internal dendrite defects that can lead to catastrophic thermal runaway events. Current battery management systems are capable of mitigating such risks, but are unable to detect such defects until thermal runaway has already begun. Various nondestructive evaluation (NDE) techniques, particularly ultrasonic NDE, can directly monitor internal battery parameters giving them the potential to detect critical defects prior to catastrophic failure. However, most of the current battery NDE research has focused on improved battery state-of-charge (SOC) and stateof- health (SOH) monitoring with little emphasis on critical defect detection. Thus, a measurement technique sensitive to subtle battery defects is needed. In addition, the complex mechanics of ultrasound in porous, thin, multilayered batteries prompt the use of physics-based simulation to guide inspections. In this work, an ultrasonic NDE technique has been developed utilizing frequency domain analysis of local battery resonances to detect the presence of battery defects. This technique is a practical extension of local ultrasonic resonance spectroscopy (LURS) – which previously required non-contact laser ultrasonics – to measurements with piezoelectric contact and immersion scan transducers. To extend the technique to work with piezoelectric transducers, ultrasonic battery measurements were compared to a sans-battery calibration measurement. Then, a linear systems deconvolution was used to eliminate the transfer functions of extraneous factors such as the transducer and electronics, leaving only the frequency-dependent battery reflection coefficient. The LURS technique was first validated on stainless steel and aluminum plates, producing reflection coefficients in line with analytical and numerical finite element modeling (FEM) results. Functioning Li-metal pouch cells were then seeded with lithium chip defects prior to LURS measurements. The presence of these defects is shown to cause a measurable shift in the battery’s through-thickness local resonances. 2D, frequency-domain poroelastic models of ultrasonic propagation in a single-cell lithium metal pouch battery were created and corroborated these findings. Thus, this work has both extended and proven the feasibility of the LURS technique in the detection of local battery defects.

Ultrasound↗

NASA NTRS1994

Fourth order difference methods for hyperbolic IBVP's

Fourth order difference approximations of initial-boundary value problems for hyperbolic partial differential equations are considered. We use the method of lines approach with both explicit and compact implicit difference operators in space. The explicit operator satisfies an energy estimate leading to strict stability. For the implicit operator we develop boundary conditions and give a complete proof of strong stability using the Laplace transform technique. We also present numerical experiments for the linear advection equation and Burgers' equation with discontinuities in the solution or in its derivative. The first equation is used for modeling contact discontinuities in fluid dynamics, the second one for modeling shocks and rarefaction waves. The time discretization is done with a third order Runge-Kutta TVD method. For solutions with discontinuities in the solution itself we add a filter based on second order viscosity. In case of the non-linear Burger's equation we use a flux splitting technique that results in an energy estimate for certain different approximations, in which case also an entropy condition is fulfilled. In particular we shall demonstrate that the unsplit conservative form produces a non-physical shock instead of the physically correct rarefaction wave. In the numerical experiments we compare our fourth order methods with a standard second order one and with a third order TVD-method. The results show that the fourth order methods are the only ones that give good results for all the considered test problems.

Gustafsson, Bertil↗

NASA NTRS1978

Pilot line report: Development of a high efficiency thin silicon solar cell

Experimental technology advances were implemented to increase the conversion efficiency of ultrathin 2cm x 2cm cells, to demonstrate a capability for fabricating such cells at a rate of 10,000 per month, and to fabricate 200 large-area ultrathin cells to determine their feasibility of manufacture. A production rate of 10,000 50 micron m cells per month with lot average AM0 efficiencies of 11.5% was demonstrated, with peak efficiencies of 13.5% obtained. Losses in most stages of the processing were minimized, the remaining exceptions being in the photolithography and metallization steps for front contact generation and breakage handling. The 5cm x 5cm cells were fabricated with a peak yield in excess of 40% for over 10% AM0 efficiency. Greater fabrication volume is needed to fully evaluate the expected yield and efficiency levels for large cells.

Source record↗

NASA NTRS1993

Check valve with poppet dashpot/frictional damping mechanism

An inline check valve for a flow line where the valve element is guided for inline travel forward and rearward of a valve sealing member and is spring biased to a closed sealing condition is presented. One of the guides for the valve element includes a dashpot housing with a bore and plunger member to control the rate of travel of the valve element in either direction, providing a guiding function. The plunger member is arranged with a dashpot ring to frictionally contact the dashpot bore and has an interior tortuous flow path from one side to the other side of the dashpot ring. The dashpot housing is not anchored to the valve body so that the valve can be functional even if the dashpot ring becomes jammed in the dashpot housing.

Morris, Brian G.↗

NASA NTRS1982

Vacuum tight quartz ampoule for Bridgman growth of crystals with interface demarcation

A growth ampoule for protecting the furnace lining and to prevent a change in the composition of the melt during growth of Pb-T-Te or Ge semiconductors doped with Ga is described. Mo foil is inserted into a quartz tube and sealed at the ends. A vacuum pumping system collapses the tube onto the foil. Spotwelded Mo wires lead in two directions from the collapsed section through quartz capillaries, one of which is also collapsed, on the wire, which provides a contact point for seeded growth of the semiconductor. The ampoule has been used for Bridgeman growth of crystals using a hot zone of 1150 C, with a temperature gradient of 240 C/m, and with current pulses up to 40 A/sq cm.

Crouch, R. K.↗