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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS1993

STS-51 pad abort. OV103-engine 2033 (ME-2) fuel flowmeter sensor open circuit

The STS-51 initial launch attempt of Discovery (OV-103) was terminated on KSC launch pad 39B on 12 Aug. 1993 at 9:12 AM E.S.T. due to a sensor redundancy failure in the liquid hydrogen system of ME-2 (Engine 2033). The event description and time line are summarized. Propellant loading was initiated on 12 Aug. 1993 at 12:00 AM EST. All space shuttle main engine (SSME) chill parameters and Launch Commit Criteria (LCC) were nominal. At engine start plus 1.34 seconds a Failure Identification (FID) was posted against Engine 2033 for exceeding the 1800 spin intra-channel (A1-A2) Fuel Flowrate sensor channel qualification limit. The engine was shut down at 1.50 seconds followed by Engines 2032 and 2030. All shut down sequences were nominal and the mission was safely aborted. SSME Avionics hardware and software performed nominally during the incident. A review of vehicle data table (VDT) data and controller software logic revealed no failure indications other than the single FID 111-101, Fuel Flowrate Intra-Channel Test Channel A disqualification. Software logic was executed according to requirements and there was no anomalous controller software operation. Immediately following the abort, a Rocketdyne/NASA failure investigation team was assembled. The team successfully isolated the failure cause to an open circuit in a Fuel Flowrate Sensor. This type of failure has occurred eight previous times in ground testing. The sensor had performed acceptably on three previous flights of the engine and SSME flight history shows 684 combined fuel flow rate sensor channel flights without failure. The disqualification of an Engine 2 (SSME No. 2033) Fuel Flowrate sensor channel was a result of an instrumentation failure and not engine performance. All other engine operations were nominal. This disqualification resulted in an engine shutdown and safe sequential shutdown of all three engines prior to ignition of the solid boosters.

Source record↗
NASA NTRS1994

Evaluation of the prototype dual-axis wall attitude measurement sensor

A prototype dual-axis electrolytic tilt sensor package for angular position measurements was built and evaluated in a laboratory environment. The objective was to investigate the use of this package for making wind tunnel wall attitude measurements for the National Transonic Facility (NTF) at NASA Langley Research Center (LaRC). The instrumentation may replace an existing, more costly, and less rugged servo accelerometer package (angle-of-attack package) currently in use. The dual-axis electrolytic tilt sensor package contains two commercial electrolytic tilt sensors thermally insulated with NTF foam, all housed within a stainless steel package. The package is actively heated and maintained at 160 F using foil heating elements. The laboratory evaluation consisted of a series of tests to characterize the linearity, repeatability, cross-axis interaction, lead wire effect, step response, thermal time constant, and rectification errors. Tests revealed that the total RMS errors for the x-axis sensor is 0.084 degree, and 0.182 degree for the y-axis sensor. The RMS errors are greater than the 0.01 degree specification required for NTF wall attitude measurements. It is therefore not a viable replacement for the angle-of-attack package in the NTF application. However, with some physical modifications, it can be used as an inexpensive 5-degree range dual-axis inclinometer with overall accuracy approaching 0.01 degree under less harsh environments. Also, the data obtained from the tests can be valuable for wind tunnel applications of most types of electrolytic tilt sensors.

Wong, Douglas T.↗
NASA NTRS1993

The application of micromachined sensors to manned space systems

Micromachined sensors promise significant system advantages to manned space vehicles. Vehicle Health Monitoring (VHM) is a critical need for most future space systems. Micromachined sensors play a significant role in advancing the application of VHM in future space vehicles. This paper addresses the requirements that future VHM systems place on micromachined sensors such as: system integration, performance, size, weight, power, redundancy, reliability and fault tolerance. Current uses of micromachined sensors in commercial, military and space systems are used to document advantages that are gained and lessons learned. Based on these successes, the future use of micromachined sensors in space programs is discussed in terms of future directions and issues that need to be addressed such as how commercial and military sensors can meet future space system requirements.

Bordano, Aldo↗
NASA NTRS1994

Ampoule failure sensor time response testing: Experiment 1

The response time of an ampoule failure sensor exposed to a liquid or vapor gallium-arsenide (GaAs) is investigated. The experimental configuration represents the sample/ampoule cartridge assembly used in NASA's Crystal Growth Furnace (CGF). The sensor is a chemical fuse made from a metal with which the semiconductor material reacts more rapidly than it does with the containing cartridge. For the III-IV compound of GaAs, a platinum metal was chosen based on the reaction of platinum and arsenic at elevated temperatures which forms a low melting eutectic. Ampoule failure is indicated by a step change in resistance of the failure sensor on the order of megohms. The sensors will increase the safety of crystal growth experiments by providing an indication that an ampoule has failed. Experimental results indicate that the response times (after a known ampoule failure) for the 0.003 and 0.010 inch ampoule failure sensors are 2.4 and 3.6 minutes, respectively. This ampoule failure sensor will be utilized in the CGF during the second United States Microgravity Laboratory Mission (USML-2) and is the subject of a NASA patent application.

Johnson, M. L.↗
NASA NTRS1994

Fiber optic (flight quality) sensors for advanced aircraft propulsion

Development of flight prototype, fiber-optic sensing system components for measuring nine sensed parameters (three temperatures, two speeds, three positions, and one flame) on an F404-400 aircraft engine is described. Details of each sensor's design, functionality, and environmental testing, and the electro-optics architecture for sensor signal conditioning are presented. Eight different optical sensing techniques were utilized. Design, assembly, and environmental testing of an engine-mounted, electro-optics chassis unit (EOU), providing MIL-C-1553 data output, are related. Interconnection cables and connectors between the EOU and the sensors are identified. Results of sensor/cable/circuitry integrated testing, and installation and ground testing of the sensor system on an engine in October 1993 and April 1994 are given, including comparisons with the engine control system's electrical sensors. Lessons learned about the design, fabrication, testing, and integration of the sensor system components are included.

Poppel, Gary L.↗
NASA NTRS1995

Long term microparticle impact fluxes on LDEF determined from optical survey of Interplanetary Dust Experiment (IDE) sensors

Many of the IDE metal-oxide-silicon (MOS) capacitor-discharge impact sensors remained active during the entire Long Duration Exposure Facility (LDEF) mission. An optical survey of impact sites on the active surfaces of these sensors has been extended to include all sensors from the low-flux sides of LDEF (i.e. the west or trailing side, the earth end, and the space end) and 5-7 active sensors from each LDEF's high-flux sides (i.e. the east or leading side, the south side, and the north side). This survey was facilitated by the presence of a relatively large (greater than 50 micron diameter) optical signature associated with each impact site on the active sensor surfaces. Of the approximately 4700 impacts in the optical survey data set, 84% were from particles in the 0.5 to 3 micron size range. An estimate of the total number of hypervelocity impacts on LDEF from particles greater than 0.5 micron diameter yields a value of approximately 7 x 10(exp 6). Impact feature dimensions for several dozen large craters on MOS sensors and germanium witness plates are also presented. Impact fluxes calculated from the IDE survey data closely matched surveys of similar size impacts (greater than or equal to 3 micron diameter craters in Al, or marginal penetrations of a 2.4 micron thick Al foil) by other LDEF investigators. Since the first year IDE data were electronically recorded, the flux data could be divided into three long term time periods: the first year, the entire 5.8 year mission, and the intervening 4.8 years (by difference). The IDE data show that there was an order of magnitude decrease in the long term microparticle impact flux on the trailing side of LDEF, from 1.01 to 0.098 x 10(exp -4) m(exp 2)/s, from the first year in orbit compared to years 2-6. The long term flux on the leading edge showed an increase from 8.6 to 11.2 x 10(exp -4) m(exp -2)/s over this same time period. (Short term flux increases up to 10,000 times the background rate were recorded on the leading side during LDEF's first year in orbit.) The overall east/west ratio was 44, but during LDEF's first year in orbit the ratio was 8.5, and during years 2-6 the ratio was 114. Long term microparticle impact fluxes on the space end decreased from 1.12 to 0.55 x 10(exp -4) m(exp -2)/s from the first year in orbit compared to years 2-6. The earth end showed the opposite trend with an increase from 0.16 to 0.38 x 10(exp -4) m(exp -2)/s. Fluxes on rows 6 and 12 decreased from 6.1 to 3.4 and 6.7 to 3.7 x 10(exp -4) m(exp -2)/s, respectively, over the same time periods. This resulted in space/earth microparticle impact flux ratios of 7.1 during the first year and 1.5 during years 2-6, while the south/north, space/north and space/south ratios remained constant at 1.1, 0.16 and 0.17, respectively, during the entire mission. This information indicates the possible identification of long term changes in discrete microparticle orbital debris component contributions to the total impact flux experienced by LDEF. A dramatic decrease in the debris population capable of striking the trailing side was detected that could possibly be attributed to the hiatus of western launch activity experienced from 1986-1989. A significant increase in the debris population that preferentially struck the leading side was also observed and could possibly be attributed to a single breakup event that occurred in September of 1986. A substantial increase in the microparticle debris population that struck the earth end of LDEF, but not the space end, was also detected and could possibly be the result of a single breakup event at low altitude. These results point to the importance of including discrete orbital debris component contribution changes in flux models in order to achieve accurate predictions of the microparticle environment that a particular spacecraft will experience in earth orbit. The only reliable, verified empirical measurements of these changes are reported in this paper. Further time-resolved in-situ measurements of these debris populations are needed to accurately assess model predictions and mitigation practices.

Simon, C. G.↗
NASA NTRS1994

Study of development and utilization of a multipurpose atmospheric corrosion sensor

There has been a critical need for analyzing various aspects of atmospheric corrosion and for the development of atmospheric corrosion microsensors. The project work has involved the following activities: (1) making of multielectrode corrosion monitors on dielectric substrates; (2) testing them in the laboratory for functional characteristics; (3) preparing a report on the state of the art of atmospheric corrosion sensor development around the world; and (4) corrosion testing of electrochemical changes of sensor specimens and related fog testing. The study included work on the subject of development and utilization of a multipurpose atmospheric corrosion sensor and this report is the annual report on work carried out on this research project. This has included studies on the development of sensors of two designs, stage 1 and stage 2, and with glass and alumina substrate, experimentation and development and characterization of the coating uniformity, aspects of corrosion monitoring, literature search on the corrosion sensors and their development. A state of the art report on atmospheric corrosion sensor development was prepared and submitted.

Diwan, Ravinder M.↗
NASA NTRS1995

Estimation of attitude sensor timetag biases

This paper presents an extended Kalman filter for estimating attitude sensor timing errors. Spacecraft attitude is determined by finding the mean rotation from a set of reference vectors in inertial space to the corresponding observed vectors in the body frame. Any timing errors in the observations can lead to attitude errors if either the spacecraft is rotating or the reference vectors themselves vary with time. The state vector here consists of the attitude quaternion, timetag biases, and, optionally, gyro drift rate biases. The filter models the timetags as random walk processes: their expectation values propagate as constants and white noise contributes to their covariance. Thus, this filter is applicable to cases where the true timing errors are constant or slowly varying. The observability of the state vector is studied first through an examination of the algebraic observability condition and then through several examples with simulated star tracker timing errors. The examples use both simulated and actual flight data from the Extreme Ultraviolet Explorer (EUVE). The flight data come from times when EUVE had a constant rotation rate, while the simulated data feature large angle attitude maneuvers. The tests include cases with timetag errors on one or two sensors, both constant and time-varying, and with and without gyro bias errors. Due to EUVE's sensor geometry, the observability of the state vector is severely limited when the spacecraft rotation rate is constant. In the absence of attitude maneuvers, the state elements are highly correlated, and the state estimate is unreliable. The estimates are particularly sensitive to filter mistuning in this case. The EUVE geometry, though, is a degenerate case having coplanar sensors and rotation vector. Observability is much improved and the filter performs well when the rate is either varying or noncoplanar with the sensors, as during a slew. Even with bad geometry and constant rates, if gyro biases are independently known, the timetag error for a single sensor can be accurately estimated as long as its boresight is not too close to the spacecraft rotation axis.

Sedlak, J.↗
NASA NTRS1995

Climate Suite Study for the National Polar-Orbiting Operational Environmental Satellite System Internal Concepts Study: Ozone Sensors - Part A

Our recommendations to NPOESS for the sensors it should adopt to meet threshold requirements for global monitoring of ozone and, to some extent, of aerosols and of atmospheric temperature, pressure, and water vapor content are summarized in this report. The degree to which these sensors fulfill other NPOESS requirements than ozone is also summarized. The number of sensors that should be in the constellation is discussed in terms of desired reliability, continuity of coverage, and the ability to cross-calibrate successive sensors. Our recommendations for specific ozone measurement requirements, IORD item 4.1.6.2.28, are given. We make the case that the monitoring of three minor constituents in the upper atmosphere (N20, ClO or ClONO2, and HNO3) should be added to the list of NPOESS requirements because of their importance to long-term ozone studies and the small additional cost required (ozone sensors are already designed to measure them). Specific measurement requirements, which should be regarded as supplementary to the ozone requirement, are given here. The necessity of using two types of sensors, nadir-viewers and limb-scanners, for atmospheric studies is discussed.

Lucke, R. L.↗
NASA NTRS1995

Lightweight Fiber Optic Gas Sensor for Monitoring Regenerative Food Production

In this final report, Physical Optics Corporation (POC) describes its development of sensors for oxygen, carbon dioxide, and relative humidity. POC has constructed a phase fluorometer that can detect oxygen over the full concentration range from 0 percent to 100 percent. Phase-based measurements offer distinct advantages, such as immunity to source fluctuation, photobleaching, and leaching. All optics, optoelectronics, power supply, and the printed circuit board are included in a single box; the only external connections to the fluorometer are the optical fiber sensor and a power cord. The indicator-based carbon dioxide sensor is also suitable for short-term and discrete measurements over the concentration range from 0 percent to 100 percent. The optical fiber-based humidity sensor contains a porous core for direct interaction of the light beam with water vapor within fiber pores; the detection range for the humidity sensor is 10 percent to 100 percent, and response time is under five minutes. POC is currently pursuing the commercialization of these oxygen and carbon dioxide sensors for environmental applications.

Schmidlin, Edward↗
NASA NTRS1997

The Development of a PdCr Integral Weldable Strain Measurement System Based on NASA Lewis PdCr/Pt Strain Sensor for User-Friendly Elevated Temperature Strain Measurements

This report describes the development of a user friendly weldable strain gage employing the NASA Lewis PdCr/Pt wire strain sensor. The NASA sensors are pre-attached to Hastelloy X or Titanium alloy shims using name spray techniques developed under previous NASA programs. The weldable sensors are then pre-stabilized for 50 hours at 780 C in air. A weldable terminal and high temperature cable is then connected to the sensor and the assembly is pre-calibrated over the full test temperature range. Calibrated resistors are inserted into a bridge completion module at the cool end of the cable to condition the sensor in half or full bridge configuration. The sensor is attached to the structure using a common capacitive discharge spot welder. No additional high temperature stabilization or calibration is required. The resultant device is a pre-calibrated strain transducer which can be plugged into any common variety strain instrumentation.

Wnuk, S. P., Jr.↗
NASA NTRS1997

Development of High Temperature Gas Sensor Technology

The measurement of engine emissions is important for their monitoring and control. However, the ability to measure these emissions in-situ is limited. We are developing a family of high temperature gas sensors which are intended to operate in harsh environments such as those in an engine. The development of these sensors is based on progress in two types of technology: (1) The development of SiC-based semiconductor technology; and (2) Improvements in micromachining and microfabrication technology. These technologies are being used to develop point-contact sensors to measure gases which are important in emission control especially hydrogen, hydrocarbons, nitrogen oxides, and oxygen. The purpose of this paper is to discuss the development of this point-contact sensor technology. The detection of each type of gas involves its own challenges in the fields of materials science and fabrication technology. Of particular importance is sensor sensitivity, selectivity, and stability in long-term, high temperature operation. An overview is presented of each sensor type with an evaluation of its stage of development. It is concluded that this technology has significant potential for use in engine applications but further development is necessary.

Hunter, Gary W.↗
NASA NTRS1997

Microfabricated Ice-Detection Sensor

Knowledge of ice conditions on important aircraft lift and control surfaces is critical for safe operation. These conditions can be determined with conventional ice-detection sensors, but these sensors are often expensive, require elaborate installation procedures, and interrupt the airflow. A micromachined, silicon-based, flush-mounted sensor which generates no internal heat has been designed, batch fabricated, packaged, and tested. The sensor is capable of distinguishing between an ice-covered and a clean surface. It employs a bulk micromachined wafer with a 7 micrometer-thick, boron-doped, silicon diaphragm which serves as one plate of a parallel-plate capacitor. This is bonded to a second silicon wafer which contains the fixed electrodes, one to drive the diaphragm by application of a voltage, the other to measure the deflection by a change in capacitance. The diaphragm sizes ranged from 1x1 mm to 3x3 mm, and the gap between parallel-plate capacitors is 2 micrometers. A 200 V d.c. was applied to the driving electrode which caused the capacitance to increase approximately 0.6pf, from a nominal capacitance of 0.6pf, when the surface was ice free. After the sensor was cooled below the freezing point of water, the same voltage range was applied to the drive electrode. The capacitance increased by the same amount. Then a drop of water was placed over the diaphragm and allowed to freeze. This created an approximately 2mm-thick ice layer. The applied 200V d.c. produced no change in capacitance, confirming that the diaphragm was locked to the ice layer. Since the sensor uses capacitive actuation, it uses very little power and is an ideal candidate for inclusion in a wireless sensing system.

DeAnna, Russell G.↗
NASA NTRS1998

Experimental Performance of a Micromachined Heat Flux Sensor

Steady-state and frequency response calibration of a microfabricated heat-flux sensor have been completed. This sensor is batch fabricated using standard, micromachining techniques, allowing both miniaturization and the ability to create arrays of sensors and their corresponding interconnects. Both high-frequency and spatial response is desired, so the sensors are both thin and of small cross-sectional area. Thin-film, temperature-sensitive resistors are used as the active gauge elements. Two sensor configurations are investigated: (1) a Wheatstone-bridge using four resistors; and (2) a simple, two-resistor design. In each design, one resistor (or pair) is covered by a thin layer (5000 A) thermal barrier; the other resistor (or pair) is covered by a thick (5 microns) thermal barrier. The active area of a single resistor is 360 microns by 360 microns; the total gauge area is 1.5 mm square. The resistors are made of 2000 A-thick metal; and the entire gauge is fabricated on a 25 microns-thick flexible, polyimide substrate. Heat flux through the surface changes the temperature of the resistors and produces a corresponding change in resistance. Sensors were calibrated using two radiation heat sources: (1) a furnace for steady-state, and (2) a light and chopper for frequency response.

TEMPERATURE SENSITIVE ELEMENTS↗
NASA NTRS1998

Microfabricated Chemical Sensors for Safety and Emission Control Applications

Chemical sensor technology is being developed for leak detection, emission monitoring, and fire safety applications. The development of these sensors is based on progress in two types of technology: 1) Micromachining and microfabrication (MicroElectroMechanical Systems (MEMS)-based) technology to fabricate miniaturized sensors. 2) The development of high temperature semiconductors, especially silicon carbide. Using these technologies, sensors to measure hydrogen, hydrocarbons, nitrogen oxides, carbon monoxide, oxygen, and carbon dioxide are being developed. A description is given of each sensor type and its present stage of development. It is concluded that microfabricated sensor technology has significant potential for use in a range of aerospace applications.

Hunter, G. W.↗
NASA NTRS1999

Improved Earth Sensor Performance Using a Sequentially Correlated Noise Model

Spacecraft attitude estimation by means of an extended Kalman filter requires a reasonably true model of the inherent noise of each sensor. For some sensors, the largest uncorrected noise comes not from the sensor itself, but from errors in the model for the predicted observations. This is certainly the case for Earth horizon sensors. The Earth horizon as seen from low Earth orbit is nearly a circle whose radius depends primarily on altitude. A straightforward latitude-dependent correction is added to this to account for the oblateness of the Earth. There also are both seasonal and stochastic variations in the horizon height. The seasonal variations can be predicted to some limited degree based on models de(ived from historical data. The stochastic component characteristically shows variations that are correlated both in time and space but which are unpredictable over long time spans. This work investigates whether Earth horizon sensor performance can be improved by solving for its systematic error as an augmentation of an attitude Kalman filter. It is found that using only Earth and Sun sensors, the augmented state is not fully observable. Even when magnetometer data is included, only the pitch axis component of the error can be improved; the roll component is unobservable.

Sedlak, Joseph↗
NASA NTRS1996

The Clouds and the Earth's Radiant Energy System (CERES) Sensors and Preflight Calibration Plans

The Clouds and the Earth's Radiant Energy System (CERES) spacecraft sensors are designed to measure broadband earth-reflected solar shortwave (0.3-5 microns) and earth-emitted longwave (5- > 100 microns) radiances at the top of the atmosphere as part of the Mission to Planet Earth program. The scanning thermistor bolometer sensors respond to radiances in the broadband shortwave (0.3-5 microns) and total-wave (0.3- > 100 microns) spectral regions, as well as to radiances in the narrowband water vapor window (8-12 microns) region. 'ne sensors are designed to operate for a minimum of 5 years aboard the NASA Tropical Rainfall Measuring Mission and Earth Observing System AM-1 spacecraft platforms that are scheduled for launches in 1997 and 1998, respectively. The flight sensors and the in-flight calibration systems will be calibrated in a vacuum ground facility using reference radiance sources, tied to the international temperature scale of 1990. The calibrations will be used to derive sensor gains, offsets, spectral responses, and point spread functions within and outside of the field of view. The shortwave, total-wave, and window ground calibration accuracy requirements (1 sigma) are +/-0.8, +/-0.6, and +/-0.3 W /sq m/sr, respectively, while the corresponding measurement precisions are +/-O.5% and +/-1.0% for the broadband longwave and shortwave radiances, respectively. The CERES sensors, in-flight calibration systems, and ground calibration instrumentation are described along with outlines of the preflight and in-flight calibration approaches.

Lee, Robert B., III↗
NASA NTRS1999

Chemical Sensors Based on IR Spectroscopy and Surface-Modified Waveguides

Sol-gel processing techniques have been used to apply thin porous films to the surfaces of planar infrared (IR) waveguides to produce widely useful chemical sensors. The thin- film coating serves to diminish the concentration of water and increase the concentration of the analyte in the region probed by the evanescent IR wave. These porous films are composed of silica, and therefore, conventional silica surface modification techniques can be used to give the surface a specific functional character. The sol-gel film was surface-modified to make the film highly hydrophobic. These sensors were shown to be capable of detecting non-polar organic analytes, such as benzonitrile, in aqueous solution with detection limits in the ppb range. Further, these porous sol-gel structures allow the analytes to diffuse into and out of the films rapidly, thus reaching equilibrium in less than ten seconds. These sensors are unique because of the fact that their operation is based on the measurement of an IR absorption spectrum. Thus, these sensors are able to identify the analytes as well as measure concentration with high sensitivity. These developments have been documented in previous reports and publications. Recently, we have also targeted detection of the polar organic molecules acetone and isopropanol in aqueous solution. Polar organics are widely used in industrial and chemical processes, hence it is of interest to monitor their presence in effluents or decontamination process flows. Although large improvements in detection limits were expected with non-polar organic molecules in aqueous solutions using very hydrophobic porous sol-gel films on silicon attenuated total reflectance (Si ATR) waveguides, it was not as clear what the detection enhancements might be for polar organic molecules. This report describes the use of modified sol-gel-coated Si ATR sensors for trace detection and quantitation of small polar organic molecules in aqueous solutions. The detection of both acetone and isopropanol molecules in aqueous solution has been previously reported for chalcogenide fiber optic sensors. The sol-gel film was produced using a mixture of ethyltriethoxysilane and tetraethoxysilane and the surface modification was carried out using trimethylchlorosilane. We have demonstrated that this film concentrates the target polar analytes from aqueous solution in the region probed by the evanescent wave to improve detection limits by as much as a factor of 450.

Lopez, Gabriel P.↗