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NASA NTRS2010

A General Closed-Form Solution for the Lunar Reconnaissance Orbiter (LRO) Antenna Pointing System

The National Aeronautics and Space Administration s (NASA) Lunar Reconnaissance Orbiter (LRO) launched on June 18, 2009 from the Cape Canaveral Air Force Station aboard an Atlas V launch vehicle into a direct insertion trajectory to the Moon LRO, designed, built, and operated by the NASA Goddard Space Flight Center in Greenbelt, MD, is gathering crucial data on the lunar environment that will help astronauts prepare for long-duration lunar expeditions. During the mission s nominal life of one year its six instruments and one technology demonstrator will find safe landing site, locate potential resources, characterize the radiation environment and test new technology. To date, LRO has been operating well within the bounds of its requirements and has been collecting excellent science data images taken from the LRO Camera Narrow Angle Camera (LROC NAC) of the Apollo landing sites have appeared on cable news networks. A significant amount of information on LRO s science instruments is provided at the LRO mission webpage. LRO s Attitude Control System (ACS), in addition to controlling the orientation of the spacecraft is also responsible for pointing the High Gain Antenna (HGA). A dual-axis (or double-gimbaled) antenna, deployed on a meter-long boom, is required to point at a selected Earth ground station. Due to signal loss over the distance from the Moon to Earth, pointing precision for the antenna system is very tight. Since the HGA has to be deployed in spaceflight, its exact geometry relative to the spacecraft body is uncertain. In addition, thermal distortions and mechanical errors/tolerances must be characterized and removed to realize the greatest gain from the antenna system. These reasons necessitate the need for an in-flight calibration. Once in orbit around the moon, a series of attitude maneuvers was conducted to provide data needed to determine optimal parameters to load onboard, which would account for the environmental and mechanical errors at any antenna orientation. The nominal geometry for the HGA involves an outer gimbal axis that is exactly perpendicular to the inner gimbal axis, and a target direction that is exactly perpendicular to the outer gimbal axis. For this nominal geometry, closed-form solutions of the desired gimbal angles are simple to get for a desired target direction specified in the spacecraft body fame. If the gimbal axes and the antenna boresight are slightly misaligned, the nominal closed-form solution is not sufficiently accurate for computing the gimbal angles needed to point at a target. In this situation, either a general closed-form solution has to be developed for a mechanism with general geometries, or a correction scheme has to be applied to the nominal closed-form solutions. The latter has been adopted for Solar Dynamics Observatory (SDO) as can be seen in Reference 1, and the former has been used for LRO. The advantage of the general closed-form solution is the use of a small number of parameters for the correction of nominal solutions, especially in the regions near singularities. Singularities here refer to cases when the nominal closed-form solutions have two or more solutions. Algorithm complexity, however, is the disadvantage of the general closed-form solution.

Shah, Neerav↗

NASA NTRS2005

NASA Interactive Forms Type Interface - NIFTI

A flexible database query, update, modify, and delete tool was developed that provides an easy interface to Oracle forms. This tool - the NASA interactive forms type interface, or NIFTI - features on-the- fly forms creation, forms sharing among users, the capability to query the database from user-entered criteria on forms, traversal of query results, an ability to generate tab-delimited reports, viewing and downloading of reports to the user s workstation, and a hypertext-based help system. NIFTI is a very powerful ad hoc query tool that was developed using C++, X-Windows by a Motif application framework. A unique tool, NIFTI s capabilities appear in no other known commercial-off-the- shelf (COTS) tool, because NIFTI, which can be launched from the user s desktop, is a simple yet very powerful tool with a highly intuitive, easy-to-use graphical user interface (GUI) that will expedite the creation of database query/update forms. NIFTI, therefore, can be used in NASA s International Space Station (ISS) as well as within government and industry - indeed by all users of the widely disseminated Oracle base. And it will provide significant cost savings in the areas of user training and scalability while advancing the art over current COTS browsers. No COTS browser performs all the functions NIFTI does, and NIFTI is easier to use. NIFTI s cost savings are very significant considering the very large database with which it is used and the large user community with varying data requirements it will support. Its ease of use means that personnel unfamiliar with databases (e.g., managers, supervisors, clerks, and others) can develop their own personal reports. For NASA, a tool such as NIFTI was needed to query, update, modify, and make deletions within the ISS vehicle master database (VMDB), a repository of engineering data that includes an indentured parts list and associated resource data (power, thermal, volume, weight, and the like). Since the VMDB is used both as a collection point for data and as a common repository for engineering, integration, and operations teams, a tool such as NIFTI had to be designed that could expedite the creation of database query/update forms which could then be shared among users.

Jain, Bobby↗

NASA NTRS2016

Development of a Prototype Model-Form Uncertainty Knowledge Base

Uncertainties are generally classified as either aleatory or epistemic. Aleatory uncertainties are those attributed to random variation, either naturally or through manufacturing processes. Epistemic uncertainties are generally attributed to a lack of knowledge. One type of epistemic uncertainty is called model-form uncertainty. The term model-form means that among the choices to be made during a design process within an analysis, there are different forms of the analysis process, which each give different results for the same configuration at the same flight conditions. Examples of model-form uncertainties include the grid density, grid type, and solver type used within a computational fluid dynamics code, or the choice of the number and type of model elements within a structures analysis. The objectives of this work are to identify and quantify a representative set of model-form uncertainties and to make this information available to designers through an interactive knowledge base (KB). The KB can then be used during probabilistic design sessions, so as to enable the possible reduction of uncertainties in the design process through resource investment. An extensive literature search has been conducted to identify and quantify typical model-form uncertainties present within aerospace design. An initial attempt has been made to assemble the results of this literature search into a searchable KB, usable in real time during probabilistic design sessions. A concept of operations and the basic structure of a model-form uncertainty KB are described. Key operations within the KB are illustrated. Current limitations in the KB, and possible workarounds are explained.

Green, Lawrence L.↗

NASA NTRS2017

Atmospheric Form Drag Coefficients Over Arctic Sea Ice Using Remotely Sensed Ice Topography Data, Spring 2009-2015

Sea ice topography significantly impacts turbulent energy/momentum exchange, e.g., atmospheric (wind) drag, over Arctic sea ice. Unfortunately, observational estimates of this contribution to atmospheric drag variability are spatially and temporally limited. Here we present new estimates of the neutral atmospheric form drag coefficient over Arctic sea ice in early spring, using high-resolution Airborne Topographic Mapper elevation data from NASA's Operation IceBridge mission. We utilize a new three-dimensional ice topography data set and combine this with an existing parameterization scheme linking surface feature height and spacing to form drag. To be consistent with previous studies investigating form drag, we compare these results with those produced using a new linear profiling topography data set. The form drag coefficient from surface feature variability shows lower values [less than 0.5-1 × 10(exp. −3)] in the Beaufort/Chukchi Seas, compared with higher values [greater than 0.5-1 ×10(exp. −3)] in the more deformed ice regimes of the Central Arctic (north of Greenland and the Canadian Archipelago), which increase with coastline proximity. The results show moderate interannual variability, including a strong increase in the form drag coefficient from 2013 to 2014/2015 north of the Canadian Archipelago. The form drag coefficient estimates are extrapolated across the Arctic with Advanced Scatterometer satellite radar backscatter data, further highlighting the regional/interannual drag coefficient variability. Finally, we combine the results with existing parameterizations of form drag from floe edges (a function of ice concentration) and skin drag to produce, to our knowledge, the first pan-Arctic estimates of the total neutral atmospheric drag coefficient (in early spring) from 2009 to 2015.

sea ice↗

NASA NTRSDate not supplied

Alloy Evaluation and Flow Forming Process Modeling for Net Shape Aerospace Structures

Over the past decade, NASA Langley Research Center (LaRC) has led several manufacturing demonstration projects exploiting flow forming technology. The work has resulted in the commercial-scale manufacture of 10-ft. diameter single-piece, integrally stiffened cylinders. Near-net-shape flow forming offers simplified manufacturing schedules and cost savings through reduced part count. Reduction or elimination of machining, welding, and/or riveting can also lead to significant performance gains. NASA LaRC recently established a flow forming research facility to investigate new alloys and stiffener geometries for fuselage and launch vehicle cryotank applications. Candidate aluminum alloys and heat treatment combinations have been characterized through advanced mechanical testing and microscopy to maximize workability during flow forming trials. Elasto-plastic deformation simulations of the forming process have been performed using the finite element software DEFORM and correlated with forming trial results. The overall objective is to optimize structural performance through a combination of innovative materials, processes, and designs.

single-piece↗

NASA NTRS2026

Development and Experimental Validation of a Path-Dependent Spin Forming Finite Element Model

Spin forming is an advanced manufacturing process widely used in the aerospace and defense sectors to produce lightweight, high-strength cylindrical components with tight dimensional tolerances. This study explores the applicability of the path-dependent Mechanical Threshold Stress (MTS) constitutive model by simulating the evolution of geometry, machining forces, and plastic deformation during the spin forming of a 10-mm thick 6061-O aluminum cylinder. While numerical modeling of spin forming has advanced substantially over the past decade, systematic verification and experimental validation of material models remain limited, particularly in predicting through-thickness process evolution. The MTS model, incorporating a Voce hardening rule, is employed for its ability to represent cyclic loading, rapidly varying temperature fields, and strain rates characteristic of spin forming. Numerical convergence analysis indicates discretization uncertainties between 0.3% and 9.2% for key quantities of interest. Experimental validation demonstrates that the MTS model, when implemented with a verified mesh, accurately reproduces both elastic and plastic behavior of 6061-O aluminum, predicting peak roller loads within 11–18% of measurements, geometric tolerances within 3%, and plastic strain distributions within 10% of experimental values. Collectively, these results establish a validated computational framework for predictive spin-forming simulations with quantified confidence, providing a foundation for extension to other alloys, geometries, and forming conditions.

Spin forming↗

NASA NTRS1978

Morphometry of streamlined forms in terrestrial and Martian channels

Streamlined erosional forms in the Channeled Scabland are compared with streamline features recognized in the region of the Kasei Vallis on Mars shown in Viking imagery. The morphometric analysis considers three physical parameters, length, measured parallel to the suggested flow direction; width, taken as the maximum width of the streamlined form perpendicular to the flow direction; and area, measured with a grid placed over the surface. These parameters are used to calculate a dimensionless parameter k, defined as the square of the length multiplied by pi over four times the area. For the 137 Scabland forms studied k values range from 1.0 to 8.3 with an average of 3.2. The k values for 47 Martian streamlined forms range from 1.5 to 12.0 with an average of 3.8. The rough similarity of these results suggests that the terrestrial and Martian features were formed by similar processes. The forms appear to have developed an ideal shape, sufficiently elongated to reduce pressure drag in the fluid creating them, but not so long as to create excessive skin resistance.

Baker, V. R.↗

NASA NTRS1984

The alpha-form of the hydroxides of bivalent metals

X-ray analyses were made of the hydroxides of the bivalent metals. The freshly pptd. hydroxide is usually in the alpha-form, which on standing is converted to another form or other forms. The alpha and c grating dimensions of the alpha-form and the C6-type of Co, Zn, C, Co-Zn and Ni-Zn hydroxides are tabulated. Ni hydroxide does not exhibit an alpha-form. The alpha-Co(OH)2, the blue form, is stabilized by sugar or by the higher alcohols: these compounds do not stabilize alpha-Zn(OH)2.

Feitknecht, W.↗

NASA NTRS1992

Superplastic forming of ceramic insulation

Superplasticity has been demonstrated in many fine-grained structural ceramics and ceramic composites, including yttria-stabilized tetragonal zirconia polycrystal (YTZP), alumina, and Al2O3-reinforced zirconia (Al2O3/YTZ) duplex composites and SiC-reinforced Si3N4. These superplastic ceramics obviously offer the potential benefit of forming net shape or near net shape parts. This could be particularly useful for forming complicated shapes that are difficult to achieve using conventional forming techniques, or require elaborate, subsequent machining. In the present study, we successfully demonstrated the following: (1) superplastic 3Y-TXP and 20 percent Al2O3/YTZ composite have for the first time been successfully deformed into hemispherical caps via a biaxial gas-pressure forming technique; (2) no experimental difficulty was encountered in applying the required gas pressures and temperatures to achieve the results, thus, it is certain that higher rates of deformation than those presented in this study will be possible by using the current test apparatus at higher temperatures and pressures; and (3) an analytical model incorporating material parameters, such as variations during forming in the strain rate sensitivity exponent and grain growth-induced strain hardening, is needed to model accurately and therefore precisely control the biaxial gas-pressure forming of superplastic ceramics. Based on the results of this study, we propose to fabricate zirconia insulation tubes by superplastic extrusion of zirconia polycrystal. This would not only reduce the cost, but also improve the reliability of the tube products.

Nieh, T. G.↗

NASA NTRS1993

INEL Spray-forming Research

Spray forming is a near-net-shape fabrication technology in which a spray of finely atomized liquid droplets is deposited onto a suitably shaped substrate or mold to produce a coherent solid. The technology offers unique opportunities for simplifying materials processing without sacrificing, and oftentimes substantially improving, product quality. Spray forming can be performed with a wide range of metals and nonmetals, and offers property improvements resulting from rapid solidification (e.g., refined microstructures, extended solid solubilities and reduced segregation). Economic benefits result from process simplification and the elimination of unit operations. Researchers at the Idaho National Engineering Laboratory (INEL) are developing spray-forming technology for producing near-net-shape solids and coatings of a variety of metals, polymers, and composite materials. Results from several spray forming programs are presented to illustrate the range of capabilities of the technique as well as the accompanying technical and economic benefits. Low-carbon steel strip greater than 0.75 mm thick and polymer membranes for gas/gas and liquid/liquid separations that were spray formed are discussed; recent advances in spray forming molds, dies, and other tooling using low-melting-point metals are described.

Mchugh, Kevin M.↗

NASA NTRS1993

Canonical forms of multidimensional steady inviscid flows

Canonical forms and canonical variables for inviscid flow problems are derived. In these forms the components of the system governed by different types of operators (elliptic and hyperbolic) are separated. Both the incompressible and compressible cases are analyzed, and their similarities and differences are discussed. The canonical forms obtained are block upper triangular operator form in which the elliptic and non-elliptic parts reside in different blocks. The full nonlinear equations are treated without using any linearization process. This form enables a better analysis of the equations as well as better numerical treatment. These forms are the analog of the decomposition of the one dimensional Euler equations into characteristic directions and Riemann invariants.

Taasan, Shlomo↗

NASA NTRS1993

Optical beam forming techniques for phased array antennas

Conventional phased array antennas using waveguide or coax for signal distribution are impractical for large scale implementation on satellites or spacecraft because they exhibit prohibitively large system size, heavy weight, high attenuation loss, limited bandwidth, sensitivity to electromagnetic interference (EMI) temperature drifts and phase instability. However, optical beam forming systems are smaller, lighter, and more flexible. Three optical beam forming techniques are identified as applicable to large spaceborne phased array antennas. They are (1) the optical fiber replacement of conventional RF phased array distribution and control components, (2) spatial beam forming, and (3) optical beam splitting with integrated quasi-optical components. The optical fiber replacement and the spatial beam forming approaches were pursued by many organizations. Two new optical beam forming architectures are presented. Both architectures involve monolithic integration of the antenna radiating elements with quasi-optical grid detector arrays. The advantages of the grid detector array in the optical process are the higher power handling capability and the dynamic range. One architecture involves a modified version of the original spatial beam forming approach. The basic difference is the spatial light modulator (SLM) device for controlling the aperture field distribution. The original liquid crystal light valve SLM is replaced by an optical shuffling SLM, which was demonstrated for the 'smart pixel' technology. The advantages are the capability of generating the agile beams of a phased array antenna and to provide simultaneous transmit and receive functions. The second architecture considered is the optical beam splitting approach. This architecture involves an alternative amplitude control for each antenna element with an optical beam power divider comprised of mirrors and beam splitters. It also implements the quasi-optical grid phase shifter for phase control and grid amplifier for RF power. The advantages are no SLM is required for this approach, and the complete antenna system is capable of full monolithic integration.

Wu, Te-Kao↗

NASA NTRS1994

Composite hot drape forming

This program was initiated to replace labor-intensive ply-by-ply layup of composite I-beam posts and angle stiffeners used in the Space Station Freedom (SSF) rack structure. Hot drape forming (HDF) has been successfully implemented by BCAG for 777 composite I-stringers and by Bell Helicopter/Textron for the V-22 I-stingers. The two companies utilize two vastly different approaches to the I-beam fabrication process. A drape down process is used by Bell Helicopter where the compacted ply charge is placed on top of a forming mandrel and heated. When the heated ply charge reached a set temperature, vacuum pressure is applied and the plies are formed over the mandrel. The BCAG 777 process utilizes an inverted forming process where the ply stack is placed on a forming table and the mandrel is inverted and placed upon the ply stack. A heating and vacuum bladder underneath the ply stack form the play stack up onto the mandrels after reaching the temperature setpoint. Both methods have their advantages, but the drape down process was selected for SSF because it was more versatile and could be fabricated from readily available components.

Ott, Thomas↗

NASA NTRS2003

Vacuum Plasma Spray Forming of Copper Alloy Liners for Regeneratively Cooled Liquid Rocket Combustion Chambers

Vacuum plasma spray (VPS) has been demonstrated as a method to form combustion chambers from copper alloys NARloy-Z and GRCop-84. Vacuum plasma spray forming is of particular interest in the forming of CuCrNb alloys such as GRCop-84, developed by NASA s Glenn Research Center, because the alloy cannot be formed using conventional casting and forging methods. This limitation is related to the levels of chromium and niobium in the alloy, which exceed the solubility limit in copper. Until recently, the only forming process that maintained the required microstructure of CrNb intermetallics was powder metallurgy formation of a billet from powder stock, followed by extrusion. This severely limits its usefulness in structural applications, particularly the complex shapes required for combustion chamber liners. This paper discusses the techniques used to form combustion chambers from CuCrNb and NARloy-Z, which will be used in regeneratively cooled liquid rocket combustion chambers.

Zimmerman, Frank↗

NASA NTRS1998

Bioavailability of intranasal promethazine dosage forms in dogs

Intramuscular promethazine (PMZ) is used aboard the US Space Shuttle to ameliorate symptoms of space motion sickness. Bioavailability after an oral dose of PMZ during space flight is thought to be impaired because of gastrointestinal disturbances associated with weightlessness and space motion sickness. In an attempt to find an alternative dosage form for use in space, we evaluated two intranasal (i.n.) dosage forms of PMZ in dogs for absorption and bioavailability relative to that of an equivalent intramuscular dose. Promethazine (5 mg kg-1) was administered as two intranasal dosage forms and as an intramuscular (i.m.) dose to three dogs in a randomised cross-over design. Serial blood samples were taken and analysed for PMZ concentrations and the absorption and bioavailability of PMZ were calculated for the three dosage forms. PMZ absorption from the carboxymethyl cellulose microsphere i.n. dosage form was more rapid and complete than from the myverol cubic gel formulation or from an i.m. injection. Bioavailability of the microsphere formulation was also greater than that of the gel formulation (AUC 3009 vs 1727 ng h ml-1). The bioavailability of the two i.n. dosage forms (relative to that of the i.m. injection) were 94% (microsphere) and 54% (gel). The i.n. microsphere formulation of PMZ offers great promise as an effective non-invasive alternative for treating space motion sickness due to its rapid absorption and bioavailability equivalent to the i.m. dose.

NASA Center JSC↗

NASA NTRS2014

Development of Aluminum-Lithium 2195 Gores by the Stretch Forming Process

Aluminum-Lithium alloy 2195 exhibits higher mechanical properties and lower density than aluminum alloy 2219, which is the current baseline material for Space Launch System (SLS) cryogenic tank components. Replacement of Al 2219 with Al-Li 2195 would result in substantial weight savings, as was the case when this replacement was made on the shuttle external tank. A key component of cryogenic tanks are the gores, which are welded together to make the rounded ends of the tanks. The required thicknesses of these gores depend on the specific SLS configuration and may exceed the current experience base in the manufacture of such gores by the stretch forming process. Here we describe the steps taken to enhance the formability of Al-Li 2195 by optimizing the heat treatment and stretch forming processes for gore thicknesses up to 0.75", which envelopes the maximum expected gore thicknesses for SLS tanks. An annealing treatment, developed at Marshall Space Flight Center, increased the forming range and strain hardening exponent of Al-Li 2195 plates. Using this annealing treatment, one 0.525" thick and two 0.75" thick gores were manufactured by the stretch forming process. The annealing treatment enabled the stretch forming of the largest ever cross sectional area (thickness x width) of an Al-Li 2195 plate achieved by the manufacturer. Mechanical testing of the gores showed greater than expected ultimate tensile strength, yield strength, modulus, and elongation values. The gores also exhibited acceptable fracture toughness at room and LN2 temperatures. All of the measured data indicate that the stretch formed gores have sufficient material properties to be used in flight domes.

Volz, M. P.↗

NASA NTRS2014

Development of Aluminum-Lithium 2195 Gores by the Stretch Forming Process

Volz, M. P.↗

NASA NTRS2015

Spin Forming Aluminum Crew Module (CM) Metallic Aft Pressure Vessel Bulkhead (APVBH) - Phase II

The principal focus of this project was to assist the Multi-Purpose Crew Vehicle (MPCV) program in developing a spin forming fabrication process for manufacture of the Orion crew module (CM) aft pressure vessel bulkhead. The spin forming process will enable a single piece aluminum (Al) alloy 2219 aft bulkhead resulting in the elimination of the current multiple piece welded construction, simplify CM fabrication, and lead to an enhanced design. Phase I (NASA TM-2014-218163, (1)) of this assessment explored spin forming the single-piece CM forward pressure vessel bulkhead. The MPCV Program and Lockheed Martin (LM) recently made two critical decisions relative to the NESC Phase I work scope: (1) LM selected the spin forming process to manufacture a singlepiece aft bulkhead for the Orion CM, and (2) the aft bulkhead will be manufactured from Al 2219. Based on the Program's new emphasis related to the spin forming process, the NESC was asked to conduct a Phase II assessment to assist in the LM manufacture of the aft bulkhead and to conduct a feasibility study into spin forming the Orion CM cone. This activity was approved on June 19, 2013. Dr. Robert Piascik, NASA Technical Fellow for Materials at the Langley Research Center (LaRC), was selected to lead this assessment. The project plan was approved by the NASA Engineering and Safety Center (NESC) Review Board (NRB) on July 18, 2013. The primary stakeholders for this assessment are the NASA and LM MPCV Program offices. Additional benefactors are commercial launch providers developing CM concepts.

Hoffman, Eric K.↗