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High Temperature Devices for Aerospace Applications

This presentation will overview important new capabilities and benefits that next-generation higher temperature electronics promise for a variety of aerospace systems and missions. Initial aerospace infusions of higher temperature electronics to be discussed include jet engines and the prolonged robotic exploration of the Venus surface. Complete redesign of systems compared to prior conventional electronics practices would yield the most revolutionary benefits. However, the inherent higher risk and expense associated with new technology adoption will likely drive a more evolutionary technology infusion process, especially since flight qualification demands large safety margins and testing that ensures reliable operation for far longer than actual mission duration. SiC pn-junction based devices are inherently capable of the most durable operation at the highest application temperatures compared other transistor technologies, but such integrated circuits (ICs) will never achieve integration levels near today’s silicon ICs. Extreme temperature high-power devices will also be de-rated compared to room-temperature performance. While the high temperature market will always be small compared to the conventional temperature mass-market, compatibility and leveraging of existing foundry manufacturing is vital to the establishment of a sustainable high temperature electronics ecosystem sufficient to significantly improve aerospace systems.

High Temperature↗

Automated Cryocooler Monitor and Control System

A system was designed to automate cryogenically cooled low-noise amplifier systems used in the NASA Deep Space Network. It automates the entire operation of the system including cool-down, warm-up, and performance monitoring. The system is based on a single-board computer with custom software and hardware to monitor and control the cryogenic operation of the system. The system provides local display and control, and can be operated remotely via a Web interface. The system controller is based on a commercial single-board computer with onboard data acquisition capability. The commercial hardware includes a microprocessor, an LCD (liquid crystal display), seven LED (light emitting diode) displays, a seven-key keypad, an Ethernet interface, 40 digital I/O (input/output) ports, 11 A/D (analog to digital) inputs, four D/A (digital to analog) outputs, and an external relay board to control the high-current devices. The temperature sensors used are commercial silicon diode devices that provide a non-linear voltage output proportional to temperature. The devices are excited with a 10-microamp bias current. The system is capable of monitoring and displaying three temperatures. The vacuum sensors are commercial thermistor devices. The output of the sensors is a non-linear voltage proportional to vacuum pressure in the 1-Torr to 1-millitorr range. Two sensors are used. One measures the vacuum pressure in the cryocooler and the other the pressure at the input to the vacuum pump. The helium pressure sensor is a commercial device that provides a linear voltage output from 1 to 5 volts, corresponding to a gas pressure from 0 to 3.5 MPa (approx. = 500 psig). Control of the vacuum process is accomplished with a commercial electrically operated solenoid valve. A commercial motor starter is used to control the input power of the compressor. The warm-up heaters are commercial power resistors sized to provide the appropriate power for the thermal mass of the particular system, and typically provide 50 watts of heat. There are four basic operating modes. "Cool " mode commands the system to cool to normal operating temperature. "Heat " mode is used to warm the device to a set temperature near room temperature. "Pump " mode is a maintenance function that allows the vacuum system to be operated alone to remove accumulated contaminants from the vacuum area. In "Off " mode, no power is applied to the system.

Britcliffe, Michael J.↗

Correlative Analysis of Behavioral and Physiological Concomitants of Labor in Pregnant Rats

During parturition, rats exhibit characteristic behavioral expressions of labor. Lordosis contractions, consisting of an elongation of the dams body, are observed beginning several hours prior to neonate births, whereas vertical contractions, repeated rapid lifts of the abdomen, occur immediately preceding the birth of each neonate. We analyzed underlying changes in intrauterine pressure (IUP) using a telemetric sensor that we modified for use in freely-moving rats. This technique enabled us to correlate behavioral expressions of labor contractions with IUP. A small telemetric blood pressure sensor was fitted within a fluid-filled balloon, similar in size to a full term rat fetus. On Gestational day 19 of the rats' 22-day pregnancy, a unit was surgically implanted within the uterus. The dams were simultaneously videotaped, enabling us to directly correlate IUP signals with behavioral expressions of labor contractions. Earlier phases of labor, consisting predominantly of lordosis contractions were characterized by lower pressures relative to later phases during which higher pressures and vertical contractions were frequently observed.

Baer, L. A.↗

Research pressure instrumentation for NASA Space Shuttle main engine, modification no. 5

The purpose of Modification No. 5 of this contract is to expand the scope of work (Task C) of this research study effort to develop pressure instrumentation for the SSME. The objective of this contract (Task C) is to direct Honeywell's Solid State Electronics Division's (SSED) extensive experience and expertise in solid state sensor technology to develop prototype pressure transducers which are targeted to meet the SSME performance design goals and to fabricate, test and deliver a total of 10 prototype units. SSED's basic approach is to effectively utilize the many advantages of silicon piezoresistive strain sensing technology to achieve the objectives of advanced state-of-the-art pressure sensors in terms of reliability, accuracy and ease of manufacture. More specifically, integration of multiple functions on a single chip is the key attribute of this technology which will be exploited during this research study.

Anderson, P. J.↗

A Diamond Electron Tunneling Micro-Electromechanical Sensor

A new pressure sensing device using field emission from diamond coated silicon tips has been developed. A high electric field applied between a nano-tip array and a diaphragm configured as electrodes produces electron emission governed by the Fowler Nordheim equation. The electron emission is very sensitive to the separation between the diaphragm and the tips, which is fixed at an initial spacing and bonded such that a cavity is created between them. Pressure applied to the diaphragm decreases the spacing between the electrodes, thereby increasing the number of electrons emitted. Silicon has been used as a substrate on which arrays of diamond coated sharp tips have been fabricated for electron emission. Also, a diaphragm has been made using wet orientation dependent etching. These two structures were bonded together using epoxy and tested. Current - voltage measurements were made at varying pressures for 1-5 V biasing conditions. The sensitivity was found to be 2.13 mV/V/psi for a 20 x 20 array, which is comparable to that of silicon piezoresistive transducers. Thinner diaphragms as well as alternative methods of bonding are expected to improve the electrical characteristics of the device. This transducer will find applications in many engineering fields for pressure measurement.

Albin, Sacharia↗

Monitoring Composite Material Pressure Vessels with a Fiber-Optic/Microelectronic Sensor System

We discuss the concept of an integrated, fiber-optic/microelectronic distributed sensor system that can monitor composite material pressure vessels for Air Force space systems to provide assessments of the overall health and integrity of the vessel throughout its entire operating history from birth to end of life. The fiber optic component would include either a semiconductor light emitting diode or diode laser and a multiplexed fiber optic sensing network incorporating Bragg grating sensors capable of detecting internal temperature and strain. The microelectronic components include a power source, a pulsed laser driver, time domain data acquisition hardware, a microprocessor, a data storage device, and a communication interface. The sensing system would be incorporated within the composite during its manufacture. The microelectronic data acquisition and logging system would record the environmental conditions to which the vessel has been subjected to during its storage and transit, e.g., the history of thermal excursions, pressure loading data, the occurrence of mechanical impacts, the presence of changing internal strain due to aging, delamination, material decomposition, etc. Data would be maintained din non-volatile memory for subsequent readout through a microcomputer interface.

Klimcak, C.↗

Responses of a hot film and a pressure probe to acoustic excitation in mean flow

The responses of a hot film sensor and a pressure probe to acoustic excitation in steady flow up to a Mach number of 0.5 were measured and compared with the responses of a microphone, flush mounted in the wall of the flow duct. When compared in terms of fluctuating pressure, the response of the pressure probe was less than that of the wall microphone by about 2.1 dB or less at the 0.5 Mach number, while the response of the ho film probe was as much as 6.0 dB above that of the wall sensor, at the Mach numbers 0.3 and 0.5. In terms of fluctuating Reynolds number, the response of the hot film probe was greater than that of the wall-mounted sensor by at most 5.0 dB at the same Mach numbers. Removing the response contribution from fluctuating temperature in the hot film mathematical model improved the agreement between the two transducer responses for both comparisons.

Jones, M. G.↗

Liquid level sensor

Potentiometer-type pressure transducer improves liquid level sensing by using the pressure-induced motion of a diaphragm to alter the resistance of the sensor

Matica, S. W.↗

Very low velocity flow sensor uses fluidic techniques

Parallel-flow wind sensor provides differential pressure output which is nearly linear and relatively insensitive to supply pressure over a wide range of wind velocities. Cross-flow wind sensor outputs are input to a fluidic amplifier to obtain high pressure output for low wind velocities without changing output characteristics.

Turek, R. F.↗

Elastomeric Sensing of Pressure with Liquid Metal and Wireless Inductive Coupling

This project describes resistance-based soft sensors filled with liquid metal, which permit measurements of large strains (0 percent to 110 percent), associated with small forces of less than 30 Newtons. This work also demonstrates a methodology for wireless transfer of these strain measurements without connected electrodes. These sensors allow intermittent detection of pressure on soft membranes with low force. Adapting these sensors for passive wireless pressure sensing will eliminate the need for embedded batteries, and will allow the sensors to transmit pressure data through non-conductive materials including glass and acrylic. The absence of batteries allows us to embed these sensors into materials for long-term use because the sensors only use passive analog circuit elements. We found the oxidation of the liquid metal (eutectic gallium indium) plays a role in the repeatability of the soft sensors. We investigated how the oxidation layer affected the behavior of the sensor by encapsulating materials (silicone, fluorosilicone, and PVC) with varied permeabilities to oxygen. We measured the effects of mechanical loading on the oxidation layer and the effects of wireless inductive coupling on the oxidation layer. We concluded our research by investigating the effects of embedding self-resonant circuits into polydimethylsiloxane (PDMS). Efforts to design engineered systems with soft materials are a growing field with progress in soft robotics, epidermal electronics, and wearable electronics. In the field of soft robotics, PDMS-based grippers are capable of picking up delicate objects because their form-fitting properties allow them to conform to the shape of objects more easily than conventional robotic grippers. Epidermal devices also use PDMS as a substrate to hold electronic components such as radios, sensors, and power supply circuits. Additionally, PDMS-based soft sensors can monitor human motion with liquid metal embedded within micro-channels. Passive wireless sensors have applications in structural health monitoring and medical health monitoring. Doctors can take wireless blood pressure measurements inside arteries to monitor the progression of heart disease. Glaucoma patients can use this technology to monitor the pressure in their eyes to track the progression of the disease.

Dick, Jacob↗

Spanwise measurements of vertical components of atmospheric turbulence

Correlation and spectrum magnitude estimates are computed for vertical gust velocity measurements at the nose and wing tips of a NASA B-57B aircraft for six level flight, low speed and low altitude runs and are compared with those of the von Karman atmospheric turbulence model extended for spanwise relationships. The distance between the wing tips was 62.6 ft. Airspeeds ranged from about 330 to 400 ft/sec, heights above the ground ranged from near ground level to about 5250 ft. and gust velocity standard deviations ranged from 4.10 to 8.86 ft/sec. Integral scale lengths, determined by matching measured autocorrelation estimates with those of the model, ranged from 410 to 2050 ft. Digital signals derived from piezoelectric sensors provided continuous pressure and airspeed measurements. Some directional acceleration sensitivity of the sensors was eliminated by sensor orientation, and their performance was spectrally verified for the higher frequencies with supplemental onboard piezoresistive sensors. The model appeared to satisfactorily predict the trends of the measured cross-correlations and cross-spectrum magnitudes, particularly between the nose and wing tips. However, the measured magnitude estimates of the cross-spectra between the wing tips exceeded the predicted levels at the higher frequencies. Causes for the additional power across the wing tips were investigated. Vertical gust velocity components evaluated along and lateral to the flight path implied that the frozen-turbulence-field assumption is a suitable approximation.

Sleeper, Robert K.↗

Work on Planetary Atmospheres and Planetary Atmosphere Probes

A summary final report of work accomplished is presented. Work was performed in the following areas: (1) Galileo Probe science analysis, (2) Galileo probe Atmosphere Structure Instrument, (3) Mars Pathfinder Atmosphere Structure/Meteorology instrument, (4) Mars Pathfinder data analysis, (5) Science Definition for future Mars missions, (6) Viking Lander data analysis, (7) winds in Mars atmosphere Venus atmospheric dynamics, (8) Pioneer Venus Probe data analysis, (9) Pioneer Venus anomaly analysis, (10) Discovery Venus Probe Titan probe instrument design, and (11) laboratory studies of Titan probe impact phenomena. The work has resulted in more than 10 articles published in archive journals, 2 encyclopedia articles, and many working papers. This final report is organized around the four planets on which there was activity, Jupiter, Mars, Venus, and Titan, with a closing section on Miscellaneous Activities. A major objective was to complete the fabrication, test, and evaluation of the atmosphere structure experiment on the Galileo probe, and to receive, analyze and interpret data received from the spacecraft. The instrument was launched on April 14, 1989. Calibration data were taken for all experiment sensors. The data were analyzed, fitted with algorithms, and summarized in a calibration report for use in analyzing and interpreting data returned from Jupiter's atmosphere. The sensors included were the primary science pressure, temperature and acceleration sensors, and the supporting engineering temperature sensors. Computer programs were written to decode the Experiment Data Record and convert the digital numbers to physical quantities, i.e., temperatures, pressures, and accelerations. The project office agreed to obtain telemetry of checkout data from the probe. Work to extend programs written for use on the Pioneer Venus project included: (1) massive heat shield ablation leading to important mass loss during entry; and (2) rapid planet rotation, which introduced terms of motion not needed on Venus. When the Galileo Probe encountered Jupiter, analysis and interpretation of data commenced. The early contributions of the experiment were to define (1) the basic structure of the deep atmosphere, (2) the stability of the atmosphere, (3) the upper atmospheric profiles of density, pressure, and temperature. The next major task in the Galileo Probe project was to refine, verify and extend the analysis of the data. It was the verified, and corrected data, which indicated a dry abiabatic atmosphere within measurement accuracy. Temperature in the thermosphere was measured at 900 K. Participation in the Mars atmospheric research included: (1) work as a team member of the Mars Atmosphere Working Group, (2) contribution to the Mars Exobiology Instrument workshop, (3) asssistance in planning the Mars global network and (4) assitance in planning the Soviet-French Mars mission in 1994. This included a return to the Viking Lander parachute data to refine and improve the definition of winds between 1.5 and 4 kilometer altitude at the two entry sites. The variability of the structure of Mars atmosphere was addressed, which is known to vary with season, latitude, hemisphere and dust loading of the atmosphere. This led to work on the Pathfinder project. The probe had a deployable meteorology mast that had three temperature sensors, and a wind sensor at the tip of the mast. Work on the Titan atmospheric probe was also accomplished. This included developing an experiment proposal to the European Space Agency (ESA), which was not selected. However, as an advisor in the design and preparation of the selected experiment the researcher interacted with scientist on the Huygens Probe Atmosphere Structure Experiment. The researcher also participated in the planning for the Venus Chemical Probe. The science objectives of the probe were to resolve unanswered questions concerning the minor species chemistry of Venus' atmosphere that control cloud formation, greenhouse effectiveness, and the thermal structure. The researcher also reviewed problems with the Pioneer Venus Probe, that caused anomalies which occurred on the Probes at and below 12.5 km level of the Venus' atmosphere. He convened and participated in a workshop that concluded the most likely hardware cause was insulation failure in the electrical harness outside the Probes' pressure vessels. It was discovered that the shrink tubing material failed at 600K. This failure could explain the anomalies experienced by the probes. The descent data of the Pioneer probes, and the Soviet Vega Lander was analyzed to evaluate the presence of small scale gravity waves in and below the Venus cloud layer.

Lester, Peter↗

Remote query measurement of pressure, fluid-flow velocity, and humidity using magnetoelastic thick-film sensors

Free-standing magnetoelastic thick-film sensors have a characteristic resonant frequency that can be determined by monitoring the magnetic flux emitted from the sensor in response to a time varying magnetic field. This property allows the sensors to be monitored remotely without the use of direct physical connections, such as wires, enabling measurement of environmental parameters from within sealed, opaque containers. In this work, we report on application of magnetoelastic sensors to measurement of atmospheric pressure, fluid-flow velocity, temperature, and mass load. Mass loading effects are demonstrated by fabrication of a remote query humidity sensor, made by coating the magnetoelastic thick film with a thin layer of solgel deposited Al2O3 that reversibly changes mass in response to humidity. c2000 Elsevier Science S.A. All rights reserved.

NASA Discipline Life Sciences Technologies↗

Characterization of Flap Edge Noise Radiation from a High-Fidelity Airframe Model

The results of an experimental study of the noise generated by a baseline high-fidelity airframe model are presented. The test campaign was conducted in the open-jet test section of the NASA Langley 14- by 22-foot Subsonic Tunnel on an 18%-scale, semi-span Gulfstream airframe model incorporating a trailing edge flap and main landing gear. Unsteady surface pressure measurements were obtained from a series of sensors positioned along the two flap edges, and far field acoustic measurements were obtained using a 97-microphone phased array that viewed the pressure side of the airframe. The DAMAS array deconvolution method was employed to determine the locations and strengths of relevant noise sources in the vicinity of the flap edges and the landing gear. A Coherent Output Power (COP) spectral method was used to couple the unsteady surface pressures measured along the flap edges with the phased array output. The results indicate that outboard flap edge noise is dominated by the flap bulb seal cavity with very strong COP coherence over an approximate model-scale frequency range of 1 to 5 kHz observed between the array output and those unsteady pressure sensors nearest the aft end of the cavity. An examination of experimental COP spectra for the inboard flap proved inconclusive, most likely due to a combination of coherence loss caused by decorrelation of acoustic waves propagating through the thick wind tunnel shear layer and contamination of the spectra by tunnel background noise at lower frequencies. Directivity measurements obtained from integration of DAMAS pressure-squared values over defined geometric zones around the model show that the baseline flap and landing gear are only moderately directional as a function of polar emission angle.

Humphreys, William M., Jr.↗

Accuracy of quantum sensors measuring yield photon flux and photosynthetic photon flux

Photosynthesis is fundamentally driven by photon flux rather than energy flux, but not all absorbed photons yield equal amounts of photosynthesis. Thus, two measures of photosynthetically active radiation have emerged: photosynthetic photon flux (PPF), which values all photons from 400 to 700 nm equally, and yield photon flux (YPF), which weights photons in the range from 360 to 760 nm according to plant photosynthetic response. We selected seven common radiation sources and measured YPF and PPF from each source with a spectroradiometer. We then compared these measurements with measurements from three quantum sensors designed to measure YPF, and from six quantum sensors designed to measure PPF. There were few differences among sensors within a group (usually <5%), but YPF values from sensors were consistently lower (3% to 20%) than YPF values calculated from spectroradiometric measurements. Quantum sensor measurements of PPF also were consistently lower than PPF values calculated from spectroradiometric measurements, but the differences were <7% for all sources, except red-light-emitting diodes. The sensors were most accurate for broad-band sources and least accurate for narrow-band sources. According to spectroradiometric measurements, YPF sensors were significantly less accurate (>9% difference) than PPF sensors under metal halide, high-pressure sodium, and low-pressure sodium lamps. Both sensor types were inaccurate (>18% error) under red-light-emitting diodes. Because both YPF and PPF sensors are imperfect integrators, and because spectroradiometers can measure photosynthetically active radiation much more accurately, researchers should consider developing calibration factors from spectroradiometric data for some specific radiation sources to improve the accuracy of integrating sensors.

NASA Center KSC↗