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Previous research has discussed the ongoing dilemma of implementing research-based findings in an applied setting. This panel will discuss lessons learned from various examples where bridges have been forged between research and operations, and examine ways to promote and achieve similar collaborations in other areas in the future.
The United States Department of Energy is planning to develop the Advanced Stirling Radioisotope Generator (ASRG) for the National Aeronautics and Space Administration (NASA) for potential use on future space missions. The ASRG provides substantial efficiency and specific power improvements over radioisotope power systems of heritage designs. The ASRG would use General Purpose Heat Source modules as energy sources and the free-piston Advanced Stirling Convertor (ASC) to convert heat into electrical energy. Lockheed Martin Corporation of Valley Forge, Pennsylvania, is integrating the ASRG systems, and Sunpower, Inc., of Athens, Ohio, is designing and building the ASC. NASA Glenn Research Center of Cleveland, Ohio, manages the Sunpower contract and provides technology development in several areas for the ASC. One area is reliability assessment for the ASC heater head, a critical pressure vessel within which heat is converted into mechanical oscillation of a displacer piston. For high system efficiency, the ASC heater head operates at very high temperature (850 C) and therefore is fabricated from an advanced heat-resistant nickel-based superalloy Microcast MarM-247. Since use of MarM-247 in a thin-walled pressure vessel is atypical, much effort is required to assure that the system will operate reliably for its design life of 17 years. One life-limiting structural response for this application is creep; creep deformation is the accumulation of time-dependent inelastic strain under sustained loading over time. If allowed to progress, the deformation eventually results in creep rupture. Since creep material properties are not available in the open literature, a detailed creep life assessment of the ASC heater head effort is underway. This paper presents an overview of that creep life assessment approach, including the reliability-based creep criteria developed from coupon testing, and the associated heater head deterministic and probabilistic analyses. The approach also includes direct benchmark experimental creep assessment. This element provides high-fidelity creep testing of prototypical heater head test articles to investigate the relevant material issues and multiaxial stress state. Benchmark testing provides required data to evaluate the complex life assessment methodology and to validate that analysis. Results from current benchmark heater head tests and newly developed experimental methods are presented. In the concluding remarks, the test results are shown to compare favorably with the creep strain predictions and are the first experimental evidence for a robust ASC heater head creep life.
Friction Stir Welding (FSW) is a welding technique that uses frictional heating combined with forging pressure to produce high strength bonds. It is attractive for aerospace applications. Although residual stresses in FSW are generally lower when compared to conventional fusion welds, recent work has shown that significant tensile residual stresses can be present in the weld after fabrication. Therefore, laser shock peening was investigated as a means of moderating the tensile residual stresses produced during welding. This slide presentation reviews the effect of Laser Peening on the weld, in tensile strength, strain, surface roughness, microhardness, surface wear/friction, and fatigue crack growth rates. The study concluded that the laser peening process can result in considerable improvement to crack initiaion, propagation and mechanical properties in FSW.
The year 2008 was an historic one for both our country and the Space Studies Board (SSB). The United States elected a new president. His first task has been to cope with an economic crisis of historic proportions. In the same year, the United States celebrated the 50th anniversary of its first spaceflight, and the SSB celebrated its 50th anniversary. As we in the space community looked back, we also looked forward. The year 2008 was truly a year of transition, for the country and for the space enterprise. Under Lennard Fisk's continued leadership, the SSB completed its year-long seminar series, Forging the Future of Space Science, which highlighted the accomplishments of space science over the past 50 years and looked ahead to the next 50 years of discoveries that await us. During the first half of the year, events were held in Tallahasse, Florida; Austin, Texas; Paris, France (in conjunction with the Committee on Space Research, which is headquartered here); Boulder, Colorado; and Fairmont, West Virginia. The series culminated in a celebration at the National Air and Space Museum in Washington, D.C., on June 26, .50 years to the day after the SSB was created. At that event, the Board presented its first James A. Van Allen Lectureship to Frank McDonald. The recent economic crisis has made it obvious that the U.S. economy does not stand alone. The global economy is becoming more and more integrated. The space enterprise cannot avoid this trend. In November, the SSB conducted a workshop in conjunction with the Aeronautics and Space Engineering Board entitled 'Future International Space Cooperation and Competition in a Globalizing World'. Its goals were to assess the current state of international cooperation and competition in space and to discuss ways in which new and emerging space powers might be better integrated into the global space community.
A family of metal/ceramic composite materials has been developed that are relatively inexpensive, lightweight alternatives to structural materials that are typified by beryllium, aluminum, and graphite/epoxy composites. These metal/ceramic composites were originally intended to replace beryllium (which is toxic and expensive) as a structural material for lightweight mirrors for aerospace applications. These materials also have potential utility in automotive and many other terrestrial applications in which there are requirements for lightweight materials that have high strengths and other tailorable properties as described below. The ceramic component of a material in this family consists of hollow ceramic spheres that have been formulated to be lightweight (0.5 g/cm3) and have high crush strength [40.80 ksi (.276.552 MPa)]. The hollow spheres are coated with a metal to enhance a specific performance . such as shielding against radiation (cosmic rays or x rays) or against electromagnetic interference at radio and lower frequencies, or a material to reduce the coefficient of thermal expansion (CTE) of the final composite material, and/or materials to mitigate any mismatch between the spheres and the matrix metal. Because of the high crush strength of the spheres, the initial composite workpiece can be forged or extruded into a high-strength part. The total time taken in processing from the raw ingredients to a finished part is typically 10 to 14 days depending on machining required.
Bulk metallic glasses (BMGs), a class of amorphous metals defined as having a thickness greater than 1 mm, are being broadly investigated by NASA for use in spacecraft hardware. Their unique properties, attained from their non-crystalline structure, motivate several game-changing aerospace applications. BMGs have low melting temperatures so they can be cheaply and repeatedly cast into complex net shapes, such as mirrors or electronic casings. They are extremely strong and wear-resistant, which motivates their use in gears and bearings. Amorphous metal coatings are hard, corrosion-resistant, and have high reflectivity. BMG composites, reinforced with soft second phases, can be fabricated into energy-absorbing cellular panels for orbital debris shielding. One limitation of BMG materials is their inability to be welded, bonded, brazed, or fastened in a convenient method to form larger structures. Cellular structures (which can be classified as trusses, foams, honeycombs, egg boxes, etc.) are useful for many NASA, commercial, and military aerospace applications, including low-density paneling and shields. Although conventional cellular structures exhibit high specific strength, their porous structures make them challenging to fabricate. In particular, metal cellular structures are extremely difficult to fabricate due to their high processing temperatures. Aluminum honeycomb sandwich panels, for example, are used widely as spacecraft shields due to their low density and ease of fabrication, but suffer from low strength. A desirable metal cellular structure is one with high strength, combined with low density and simple fabrication. The thermoplastic joining process described here allows for the fabrication of monolithic BMG truss-like structures that are 90% porous and have no heat-affected zone, weld, bond, or braze. This is accomplished by welding the nodes of stacked BMG composite panels using a localized capacitor discharge, forming a single monolithic structure. This removes many complicated and costly fabrication steps. Moreover, the cellular structures detailed in this work are among the highest- strength and most energy-absorbent materials known. This implies that a fabricated structure made from these materials would have unequaled mechanical properties compared to other metal foams or trusses. The process works by taking advantage of the electrical properties of the matrix material in the metal-matrix composite, which in this case is a metallic glass. Due to the random nanoscale arrangement of atoms (without any grain boundaries), the matrix glass exhibits a near-constant electrical resistivity as a function of temperature. By placing the composite panels between two copper electrode plates and discharging a capacitor, the entire matrix of the panel can be heated to approximately 700 C in 10 milliseconds, which is above the alloy s solidus but below the liquidus. By designing the geometry of the panels into the shape of an egg box, the electrical discharge localizes only in the tips of each pyramidal cell. By applying a forging load during discharge, the nodes of the panels can be fused together into a single piece, which then dissipates heat through radiation back into a glassy state. This means that two panels can be metallurgically fused into one panel with no heat-affected zone, creating a seamless connection between panels. During the process, the soft metal particles (dendrites) that are uniformly distributed in the glassy matrix to increase the toughness are completely unaffected by the thermoplastic joining. The novelty is that a truss (or foam-like) structure can be formed with excellent energy- absorbing capabilities without the need for machining. The technique allows for large-scale fabrication of panels, well-suited for spacecraft shields or military vehicle door panels. Crystalline metal cellular structures cannot be fabricated using the thermoplastic joining technique described here. If metal panels were te assembled into a cellular structure, they would either have to be welded, brazed, bonded, or fastened together, creating a weak spot in the structure at each connection. Welded parts require a welding material to be added to the joint and exhibit a soft and weak heat-affected zone. Brazing and bonding do not form a metallurgical joint and thus exhibit low strengths, especially when the panels are pulled apart and fasteners require high-stress-concentration holes to be drilled. No equivalent rapid heating method exists for assembling metal panels together into cellular structures, and thus, those parts must be foamed, machined, or investment cast if they are to form a monolithic structure. If the crystalline panels were to be joined using capacitive discharge, as with a spot welder, their bond would be very weak, and the panels would have to be extremely thin. In contrast, the strength of joined BMG parts has been demonstrated to have strength comparable to the parent material. This technique opens up the possibility of using large-scale BMG hardware in spacecraft, military, or commercial applications.
NASA's Marshall Space Flight Center (MSFC) has recently invested much time and effort into the process development of Friction Pull Plug Welding (FPPW). FPPW, is a welding process similar to Friction Push Plug Welding in that, there is a small rotating part (plug) being spun and simultaneously pulled (forged) into a larger part. These two processes differ, in that push plug welding requires an internal reaction support, while pull plug welding reacts to the load externally. FPPW was originally conceived as a post proof repair technique for the Space Shuttle fs External Tank. FPPW was easily selected as the primary weld process used to close out the termination hole on the Constellation Program's ARES I Upper Stage circumferential Self-Reacting Friction Stir Welds (SR-FSW). The versatility of FPPW allows it to also be used as a repair technique for both SR-FSW and Conventional Friction Stir Welds. To date, all MSFC led development has been concentrated on aluminum alloys (2195, 2219, and 2014). Much work has been done to fully understand and characterize the process's limitations. A heavy emphasis has been spent on plug design, to match the various weldland thicknesses and alloy combinations. This presentation will summarize these development efforts including weld parameter development, process control, parameter sensitivity studies, plug repair techniques, material properties including tensile, fracture and failure analysis.
NASA fs Marshall Space Flight Center (MSFC) has recently invested much time and effort into the process development of Friction Pull Plug Welding (FPPW). FPPW, is a welding process similar to Friction Push Plug Welding in that, there is a small rotating part (plug) being spun and simultaneously pulled (forged) into a larger part. These two processes differ, in that push plug welding requires an internal reaction support, while pull plug welding reacts to the load externally. FPPW was originally conceived as a post proof repair technique for External Tank. FPPW was easily selected as the primary process used to close out the termination hole on the Constellation Program fs ARES I Upper Stage circumferential Self ] Reacting Friction Stir Welds (SR ]FSW). The versatility of FPPW allows it to also be used as a repair technique for both SR ]FSW and Conventional Friction Stir Welds. To date, all MSFC led development has been concentrated on aluminum alloys (2195, 2219, and 2014). Much work has been done to fully understand and characterize the process fs limitations. A heavy emphasis has been spent on plug design, to match the various weldland thicknesses and alloy combinations. This presentation will summarize these development efforts including weld parameter development, process control, parameter sensitivity studies, plug repair techniques, material properties including tensile, fracture and failure analysis.
One of the legacies of the samples collected by the Apollo and Luna missions is the link forged between radiometric ages of rocks and relative ages according to stratigraphic relationships and impact crater size-frequency distributions. Our current understanding of the history of the inner solar system is based on the relative chronology of individual planets, tied to the absolute geochronology of the Moon via these important samples. Sample ages have enabled us to infer that impact-melt breccias from Apollo 14 and 15 record the formation of the Imbrium Basin, those from the highland massifs at Apollo 17 record the age of Serenitatis, those from the KREEP-poor Apollo 16 site record the age of Nectaris, and materials from Luna 24 record the age of Crisium. Ejecta from smaller and younger craters Copernicus and Tycho were sampled at Apollo 12 and 17, respectively, and local craters such as Cone at Apollo 14, and North Ray and South Ray at Apollo 16 were also sampled and ages determined for those events. Much of what we understand about the lunar impact flux is based on these ages. Samples from these nearside locations reveal a preponderance of impact-disturbed or recrystallized ages between 3.75 and 3.95 billion years. Argon and lead loss (and correlated disturbances in the Rb-Sr system) have been attributed to metamorphism of the lunar crust by an enormous number of impacts in a brief pulse of time, called the Lunar Cataclysm or Late Heavy Bombardment. Subsequent high-precision geochronometric analyses of Apollo samples and lunar highlands meteorites show a wider range of ages, but very few older than 4 Ga. The paucity of ancient impact melt rocks has been interpreted to mean that either that most impact basins formed at this time, or that ejecta from the large, near-side, young basins dominates the Apollo samples.
One of the legacies of the samples collected by the Apollo and Luna missions is the link forged between radiometric ages of rocks and relative ages according to stratigraphic relationships and impact crater size-frequency distributions. Our current understanding of the history of the inner solar system is based on the relative chronology of individual planets, tied to the absolute geochronology of the Moon via these important samples. Samples from these nearside locations reveal a preponderance of impact-disturbed or recrystallized ages between 3.75 and 3.95 billion years. Argon and lead loss (and correlated disturbances in the Rb-Sr system) have been attributed to metamorphism of the lunar crust by an enormous number of impacts in a brief pulse of time, called the Lunar Cataclysm or Late Heavy Bombardment. Subsequent high-precision geochronometric analyses of Apollo samples and lunar highlands meteorites show a wider range of ages, but very few older than 4 Ga. The paucity of ancient impact melt rocks has been interpreted to mean that either that most impact basins formed at this time, or that ejecta from the large, near-side, young basins dominates the Apollo samples. Selenochronology is getting more complicated: new results question meaning of sample ages, crater counts, crater production functions, and the solar system itself. Improved geological mapping of lunar geologic units and boundaries using multiple remote sensing datasets. High-resolution image-based crater counting of discrete geologic units and relating them to location. Improved understanding of the regolith thickness and its global variation (GRAIL). Tying the sampling of impact-melt rocks to the lunar impact flux. Using improved techniques (magnetic fields, diffusion studies, isotopic analysis) on existing samples. New sample return from benchmark craters, particularly SPA, which appears in 2013 Decadal Survey.
A new method was developed for creating a less expensive shield for ADRs using 1018 carbon steel. This shield has been designed to have similar performance to the expensive vanadium permendur shields, but the cost is 30 to 50% less. Also, these shields can be stocked in a variety of sizes, eliminating the need for special forgings, which also greatly reduces cost.
One of the legacies of the samples collected by the Apollo and Luna missions is the link forged between radiometric ages of rocks and relative ages according to stratigraphic relationships and impact crater size-frequency distributions. Our current understanding of the history of the inner solar system is based on the relative chronology of individual planets, tied to the absolute geochronology of the Moon via these important samples. Sample ages have enabled us to infer that impact-melt breccias from Apollo 14 and 15 record the formation of the Imbrium Basin, those from the highland massifs at Apollo 17 record the age of Serenitatis, those from the KREEP-poor Apollo 16 site record the age of Nectaris, and materials from Luna 24 record the age of Crisium. Ejecta from smaller and younger craters Copernicus and Tycho were sampled at Apollo 12 and 17, respectively, and local craters such as Cone at Apollo 14, and North Ray and South Ray at Apollo 16 were also sampled and ages determined for those events. Much of what we understand about the lunar impact flux is based on these ages. Samples from these nearside locations reveal a preponderance of impact-disturbed or recrystallized ages between 3.75 and 3.95 billion years. Argon and lead loss (and correlated disturbances in the Rb-Sr system) have been attributed to metamorphism of the lunar crust by an enormous number of impacts in a brief pulse of time, called the Lunar Cataclysm or Late Heavy Bombardment. Subsequent high-precision geochronometric analyses of Apollo samples and lunar highlands meteorites show a wider range of ages, but very few older than 4 Ga. The paucity of ancient impact melt rocks has been interpreted to mean that either that most impact basins formed at this time, or that ejecta from the large, near-side, young basins dominates the Apollo samples.
Long-duration human capabilities beyond low Earth orbit (LEO), either in support of or as an alternative to lunar surface operations, have been assessed at least since the late 1960s. Over the next few months, we will present short histories of concepts for long-duration, free-space human habitation beyond LEO from the end of the Apollo program to the Decadal Planning Team (DPT)/NASA Exploration Team (NExT), which was active in 1999 2000 (see Forging a vision: NASA s Decadal Planning Team and the origins of the Vision for Space Exploration , The Space Review, December 19, 2005). Here we summarize the brief existence of the Future In-Space Operations (FISO) working group in 2005 2006 and its successor, a telecon-based colloquium series, which we co-moderate.
Extraterrestrial water-bearing minerals are of great importance both for understanding the formation and evolution of the solar system and for supporting future human activities in space. Asteroids are the primary source of meteorites, many of which show evidence of an early heating episode and varying degrees of aqueous alteration. The origin and characterization of hydrated minerals (minerals containing H2O or OH) among both the main-belt and near-earth asteroids is important for understanding a wide range of solar system formation and evolutionary processes, as well as for planning for human exploration. Current hypotheses postulate asteroids began as mixtures of water ice and anhydrous silicates. A heating event early in solar system history was then responsible for melting the ice and driving aqueous alteration. The link between asteroids and meteorites is forged by reflectance spectra, which show 3-μm bands indicative of bound OH or H2O on the C-class asteroids, which are believed to be the parent bodies of the carbonaceous chondrites in our collections. The conditions at which aqueous alteration occurred in the parent bodies of carbonaceous chondrites are thought to be well-constrained: at 0-25 C for less than 15 Myr after asteroid formation. In previous models, many scenarios exhibit peak temperatures of the rock and co-existing liquid water in more than 75 percent of the asteroid's volume rising to 150 C and higher, due to the exothermic hydration reactions triggering a thermal runaway effect. However, even in a high porosity, water-saturated asteroid very limited liquid water flow is predicted (distances of 100's nm at most). This contradiction has yet to be resolved. Still, it may be possible for water to become liquid even in the near-surface environment, for a long enough time to drive aqueous alteration before vaporizing or freezing then subliming. Thus, we are using physics- and chemistry-based models that include thermal and fluid transport as well as the effects of relevant chemical reactions, to investigate whether formation of hydrated minerals can occur in the surface and near-surface environments of carbonaceous type asteroids. These models will elucidate how the conditions within the parent body that cause internal aqueous alteration play themselves out at the asteroid's surface. We are using our models to determine whether the heat budget of 20-100-km bodies is sufficient to bring liquid water to the near-surface and cause mineral alteration, or whether additional heat input at the surface (i.e, by impacts) is needed to provide a transient liquid water source for mineral hydration without large- scale liquid water transport.
The Technology Watch (Tech Watch) project is directed by the NASA Human Research Programs (HRP) Exploration Medical Capability (ExMC) element, and primarily focuses on ExMC technology gaps. The project coordinates the efforts of multiple NASA centers, including the Johnson Space Center (JSC), Glenn Research Center (GRC), Ames Research Center (ARC), and the Langley Research Center (LaRC). The objective of Tech Watch is to identify emerging, high-impact technologies that augment current NASA HRP technology development efforts. Identifying such technologies accelerates the development of medical care and research capabilities for the mitigation of potential health issues encountered during human space exploration missions. The aim of this process is to leverage technologies developed by academia, industry and other government agencies and to identify the effective utilization of NASA resources to maximize the HRP return on investment. The establishment of collaborations with these entities is beneficial to technology development, assessment and/or insertion, and advance NASAs goal to provide a safe and healthy environment for human exploration. In fiscal year 2013, the Tech Watch project maintained student project activity aimed at specific ExMC gaps, completed the gap report review cycle for all gaps through a maturated gap report review process, and revised the ExMC Tech Watch Sharepoint site for enhanced data content and organization. Through site visits, internships and promotions via aerospace journals, several student projects were initiated and completed this past year. Upon project completion, the students presented their results via telecom or WebEx to the ExMC Element as a whole. The upcoming year will continue to forge strategic alliances and student projects in the interest of technology and knowledge gap closure. Through the population of Sharepoint with technologies assessed by the gap owners, the database expansion will develop a more comprehensive technology set for each gap. By placing such data in Sharepoint, the gap report updates in fiscal year 2014 are anticipated to be streamlined since the evaluated technologies will be readily available to the gap owners in a sortable archive, and may be simply exported into the final gap report presentation.
The Technology Watch (Tech Watch) project is directed by the NASA Human Research Program's (HRP) Exploration Medical Capability (ExMC) element, and primarily focuses on ExMC technology gaps. The project coordinates the efforts of multiple NASA centers, including the Johnson Space Center (JSC), Glenn Research Center (GRC), Ames Research Center (ARC), and the Langley Research Center (LaRC). The objective of Tech Watch is to identify emerging, high-impact technologies that augment current NASA HRP technology development efforts. Identifying such technologies accelerates the development of medical care and research capabilities for the mitigation of potential health issues encountered during human space exploration missions. The aim of this process is to leverage technologies developed by academia, industry and other government agencies and to identify the effective utilization of NASA resources to maximize the HRP return on investment. The establishment of collaborations with these entities is beneficial to technology development, assessment and/or insertion, and advance NASA's goal to provide a safe and healthy environment for human exploration. In fiscal year 2013, the Tech Watch project maintained student project activity aimed at specific ExMC gaps, completed the gap report review cycle for all gaps through a maturated gap report review process, and revised the ExMC Tech Watch Sharepoint site for enhanced data content and organization. Through site visits, internships and promotions via aerospace journals, several student projects were initiated and completed this past year. Upon project completion, the students presented their results via telecom or WebEx to the ExMC Element as a whole. The upcoming year will continue to forge strategic alliances and student projects in the interest of technology and knowledge gap closure. Through the population of Sharepoint with technologies assessed by the gap owners, the database expansion will develop a more comprehensive technology set for each gap. By placing such data in Sharepoint, the gap report updates in fiscal year 2014 are anticipated to be streamlined since the evaluated technologies will be readily available to the gap owners in a sortable archive, and may be simply exported into the final gap report presentation
Precipitation-strengthened, nickel-based superalloys are widely used in the aerospace and energy industries due to their excellent environmental resistance and outstanding mechanical properties under extreme conditions. Powder-bed additive manufacturing (AM) technologies offer the potential to revolutionize the processing of superalloy turbine components by eliminating the need for extensive inventory or expensive legacy tooling. Like selective laser melting (SLM), electron beam melting (EBM) constructs three-dimensional dense components layer-by-layer by melting and solidification of atomized, pre-alloyed powder feedstock within 50-200 micron layers. While SLM has been more widely used for AM of nickel alloys like 718, EBM offers several distinct advantages, such as less retained residual stress, lower risk of contamination, and faster build rates with multiple-electron-beam configurations. These advantages are particularly attractive for turbine disks, for which excessive residual stress and contamination can shorten disk life during high-temperature operation. In this presentation, we will discuss the feasibility of fabricating disk superalloy components using EBM AM. Originally developed using powder metallurgy forging processing, disk superalloys contain a higher refractory content and precipitate volume fraction than alloy 718, thus making them more prone to thermal cracking during AM. This and other challenges to produce homogeneous builds with desired properties will be presented. In particular, the quality of lab-scale samples fabricated via a design of experiments, in which the beam current, build temperature, and beam velocity were varied, will be summarized. The relationship between processing parameters, microstructure, grain orientation, and mechanical response will be discussed.
NASA Marshall Space Flight Center (MSFC) developed Ultrasonic Stir Welding (USW) to join large pieces of very high-strength metals such as titanium and Inconel. USW, a solid-state weld process, improves current thermal stir welding processes by adding high-power ultrasonic (HPU) energy at 20 kHz frequency. The addition of ultrasonic energy significantly reduces axial, frictional, and shear forces; increases travel rates; and reduces wear on the stir rod, which results in extended stir rod life. The USW process decouples the heating, stirring, and forging elements found in the friction stir welding process allowing for independent control of each process element and, ultimately, greater process control and repeatability. Because of the independent control of USW process elements, closed-loop temperature control can be integrated into the system so that a constant weld nugget temperature can be maintained during welding.