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Reference earth orbital research and applications investigations (blue book). Volume 6: Materials sciences and manufacturing

The development of commercial manufacturing and research activities in space is discussed. The capability is to be installed in space stations in order to exploit the extended free fall which makes many novel manipulations of materials possible and alters the behavior of certain chemical and physical processes. The broad objectives are: (1) to develop technical basis required for commercial use of manned space facilities, (2) to provide indirect economic benefits by exploiting advantages of space laboratory facilities to solve critical experimental problems, and (3) to initiate manufacturing operations in space by private enterprise for commercial purposes and by agencies of the Government for public purposes.

Source record↗

Space Shuttle Propulsion Finishing Strong

Numerous lessons have been documented from the Space Shuttle Propulsion elements. Major events include loss of the SRB's on STS-4 and shutdown of an SSME during ascent on STS- 51F. On STS-112 only half the pyrotechnics fired to release the vehicle from the launch pad, a testament for redundancy. STS-91 exhibited freezing of a main combustion chamber pressure measurement and on STS-93 nozzle tube ruptures necessitated a low liquid level oxygen cut off of the main engines. A number of on pad aborts were experienced during the early program resulting in delays. And the two accidents, STS-51L and STS-107, had unique heritage in history from early Program decisions and vehicle configuration. Following STS-51L significant resources were invested in developing fundamental physical understanding of solid rocket motor environments and material system behavior. Human rating of solid rocket motors was truly achieved. And following STS-107, the risk of ascent debris was better characterized and controlled. Situational awareness during all mission phases improved, and the management team instituted effective risk assessment practices. These major events and lessons for the future are discussed. The last 22 flights of the Space Shuttle, following the Columbia accident, were characterized by remarkable improvement in safety and reliability. Numerous problems were solved in addition to reduction of the ascent debris hazard. The propulsion system elements evolved to high reliability and heavy lift capability. The Shuttle system, though not a operable as envisioned in the 1970's, successfully assembled the International Space Station (ISS) and provided significant logistics and down mass for ISS operations. By the end of the Program, the remarkable Space Shuttle Propulsion system achieved very high performance, was largely reusable, exhibited high reliability, and is a heavy lift earth to orbit propulsion system. The story of this amazing system is discussed in detail in the paper.

Owen, James W.↗

Shuttle Propulsion System Major Events and the Final 22 Flights

Numerous lessons have been documented from the Space Shuttle Propulsion elements. Major events include loss of the Solid Rocket Boosters (SRB's) on STS-4 and shutdown of a Space Shuttle Main Engine (SSME) during ascent on STS-51F. On STS-112 only half the pyrotechnics fired during release of the vehicle from the launch pad, a testament for redundancy. STS-91 exhibited freezing of a main combustion chamber pressure measurement and on STS-93 nozzle tube ruptures necessitated a low liquid level oxygen cut off of the main engines. A number of on pad aborts were experienced during the early program resulting in delays. And the two accidents, STS-51L and STS-107, had unique heritage in history from early program decisions and vehicle configuration. Following STS-51L significant resources were invested in developing fundamental physical understanding of solid rocket motor environments and material system behavior. And following STS-107, the risk of ascent debris was better characterized and controlled. Situational awareness during all mission phases improved, and the management team instituted effective risk assessment practices. The last 22 flights of the Space Shuttle, following the Columbia accident, were characterized by remarkable improvement in safety and reliability. Numerous problems were solved in addition to reduction of the ascent debris hazard. The Shuttle system, though not as operable as envisioned in the 1970's, successfully assembled the International Space Station (ISS). By the end of the program, the remarkable Space Shuttle Propulsion system achieved very high performance, was largely reusable, exhibited high reliability, and was a heavy lift earth to orbit propulsion system. During the program a number of project management and engineering processes were implemented and improved. Technical performance, schedule accountability, cost control, and risk management were effectively managed and implemented. Award fee contracting was implemented to provide performance incentives. The Certification of Flight Readiness and Mission Management processes became very effective. A key to the success of the propulsion element projects was related to relationships between the MSFC project office and support organizations with their counterpart contractor organizations. The teams worked diligently to understand and satisfy requirements and achieve mission success.

Owen, James W.↗

Kinetics and thermodynamics of ceramic/metal interface reactions related to high T(sub c) superconducting applications

Superconducting ceramic materials, no matter what their form, size or shape, must eventually make contact with non-superconducting materials in order to accomplish current transfer to other parts of a real operating system, or for testing and measurement of properties. Thus, whether the configuration is a clad wire, a bulk superconducting disc, tape, or a thick or thin superconducting film on a substrate, the physical and mechanical behavior of interface (interconnections, joints, etc.) between superconductors and normal conductor materials of all kinds is of extreme importance to the technological development of these systems. Fabrication heat treatments associated with the particular joining process allow possible reactions between the superconducting ceramic and the contact to occur, and consequently influence properties at the interface region. The nature of these reactions is therefore of great broad interest, as these may be a primary determinant for the real capability of these materials. Research related both to fabrication of composite sheathed wire products, and the joining contacts for physical property measurements, as well as, a review of other related literature in the field are described. Comparison are made between 1-2-3, Bi-, and Tl-based ceramic superconductors joined to a variety of metals including Cu, Ni, Fe, Cr, Ag, Ag-Pd, Au, In, and Ga. The morphology of reaction products and the nature of interface degradation as a function of time will be highlighted.

Notis, Michael R.↗

Physical aging and solvent effects on the fracture of LaRC-TPI adhesives

When amorphous materials are quenched below their glass transition temperature, excess enthalpy is trapped in the glassy material because the viscosity is too great to allow the material to remain in volumetric equilibrium. Over time, this excess free volume is reduced as the material slowly approaches its equilibrium configuration. This process, known as physical aging, leads to substantial changes in the constitutive behavior of polymers, as has been widely discussed in the literature. Less is known about the effects of this physical aging process on fracture and fatigue properties of aged materials. The original goal of the summer was to investigate the effects of physical aging on the fracture and fatigue behavior of LaRC-TPI, a thermoplastic polyimide developed at NASA-Langley. Preliminary results are reported, although a lack of equipment availability prevented completion of this task. In the process of making specimens, the current LaRC-TPI was observed to be extremely susceptible to environmental stress cracking. A study of the unique failure patterns resulting from this degradation process in bonded joints was conducted and is also reported herein.

Dillard, David A.↗

Mars - Near-infrared spectral reflectance of surface regions and compositional implications

Both morphological and compositional information are needed to define and characterize surface geologic units on Mars. A description is presented of new, near-infrared spectra (0.65 to 2.50 micrometers) for 11 regions on the Martian surface observed in 1978. The high photometric quality of these data combined with increased near-infrared spectral coverage provide new information about the spectral behavior and, therefore, the composition and physical nature of Martian surface materials. The spectral reflectances were obtained with the aid of a 2.2-m telescope located on Mauna Kea, Hawaii. A cooled (to 77 K) circular variable filter spectrometer with an InSb detector was used to measure alternatively Mars and the standard star Beta Geminorum. Attention is given to general spectral characteristics, the dark region composition, spectral evidence for water, and the 2.3 micrometer absorption.

Mccord, T. B.↗

Microgravity Program strategic plan, 1991

The all encompassing objective of the NASA Microgravity Program is the use of space as a lab to conduct research and development. The on-orbit microgravity environment, with its substantially reduced buoyancy forces, hydrostatic pressures, and sedimentation, enables the conduction of scientific studies not possible on Earth. This environment allows processes to be isolated and controlled with an accuracy that cannot be obtained in the terrestrial environment. The Microgravity Science and Applications Div. has defined three major science categories in order to develop a program structure: fundamental science, including the study of the behavior of fluids, transport phenomena, condensed matter physics, and combustion science; materials science, including electronic and photonic materials, metals and alloys, and glasses and ceramics; and biotechnology, focusing on macromolecular crystal growth as well as cell and molecular science. Experiments in these areas seek to provide observations of complex phenomena and measurements of physical attributes with a precision that is enabled by the microgravity environment.

Source record↗

Extended Analytic Device Optimization Employing Asymptotic Expansion

Analytic optimization of a thermoelectric junction often introduces several simplifying assumptionsincluding constant material properties, fixed known hot and cold shoe temperatures, and thermallyinsulated leg sides. In fact all of these simplifications will have an effect on device performance,ranging from negligible to significant depending on conditions. Numerical methods, such as FiniteElement Analysis or iterative techniques, are often used to perform more detailed analysis andaccount for these simplifications. While numerical methods may stand as a suitable solution scheme,they are weak in gaining physical understanding and only serve to optimize through iterativesearching techniques. Analytic and asymptotic expansion techniques can be used to solve thegoverning system of thermoelectric differential equations with fewer or less severe assumptionsthan the classic case. Analytic methods can provide meaningful closed form solutions and generatebetter physical understanding of the conditions for when simplifying assumptions may be valid.In obtaining the analytic solutions a set of dimensionless parameters, which characterize allthermoelectric couples, is formulated and provide the limiting cases for validating assumptions.Presentation includes optimization of both classic rectangular couples as well as practically andtheoretically interesting cylindrical couples using optimization parameters physically meaningful toa cylindrical couple. Solutions incorporate the physical behavior for i) thermal resistance of hot andcold shoes, ii) variable material properties with temperature, and iii) lateral heat transfer through legsides.

Thermoelectric Generators↗

Crosslink Density and Molecular Weight Effects on the Viscoelastic Response of a Glassy High-Performance Polyimide

Durability and long-term performance are among the primary concerns for the use of advanced polymer matrix composites (PMCs) in modern aerospace structural applications. For a PMC subJected to long-term exposure at elevated temperatures. the viscoelastic nature of the polymer matrix will contribute to macroscopic changes in composite stiffness, strength and fatigue life. Over time. changes in the polymer due to physical aging will have profound effects on tile viscoelastic compliance of the material, hence affecting its long-term durability. Thus, the ability to predict material performance using intrinsic properties, such as crosslink density and molecular weight, would greatly enhance the efficiency of design and development of PMCs. The objective of this paper is to discuss and present the results of an experimental study that considers the effects of crosslink density, molecular weight and temperature on the viscoelastic behavior including physical aging of an advanced polymer. Five distinct variations in crosslink density were used to evaluate the differences in mechanical performance of an advanced polyimide. The physical aging behavior was isolated by conducting sequenced, short-term isothermal creep compliance tests in tension. These tests were performed over a range of sub-glass transition temperatures. The material constants, material master curves and physical aging-related parameters were evaluated as a function of temperature crosslink density and molecular weight using time-temperature and time-aging time superposition techniques.

Nicholson, Lee M.↗

Characterization of Material Response During Arc-Jet Testing with Optical Methods Status and Perspectives

The characterization of ablation and recession of heat shield materials during arc jet testing is an important step towards understanding the governing processes during these tests and therefore for a successful extrapolation of ground test data to flight. The behavior of ablative heat shield materials in a ground-based arc jet facility is usually monitored through measurement of temperature distributions (across the surface and in-depth), and through measurement of the final surface recession. These measurements are then used to calibrate/validate materials thermal response codes, which have mathematical models with reasonably good fidelity to the physics and chemistry of ablation, and codes thus calibrated are used for predicting material behavior in flight environments. However, these thermal measurements only indirectly characterize the pyrolysis processes within an ablative material pyrolysis is the main effect during ablation. Quantification of pyrolysis chemistry would therefore provide more definitive and useful data for validation of the material response codes. Information of the chemical products of ablation, to various levels of detail, can be obtained using optical methods. Suitable optical methods to measure the shape and composition of these layers (with emphasis on the blowing layer) during arc jet testing are: 1) optical emission spectroscopy (OES) 2) filtered imaging 3) laser induced fluorescence (LIF) and 4) absorption spectroscopy. Several attempts have been made to optically measure the material response of ablative materials during arc-jet testing. Most recently, NH and OH have been identified in the boundary layer of a PICA ablator. These species are suitable candidates for a detection through PLIF which would enable a spatially-resolved characterization of the blowing layer in terms of both its shape and composition. The recent emission spectroscopy data will be presented and future experiments for a qualitative and quantitative characterization of the material response of ablative materials during arc-jet testing will be discussed.

Winter, Michael↗

Earth physics and phase transformations program: A concept and proposal

A program to study the geophysical characteristics of the earth is presented as an integration of the different disciplines that constitute the earth sciences, through the foundation of a generalized geodynamic theory of earth physics. A program is considered for defining the physical constants of the earth's material which parametrize the hydrodynamic equation in the microscopic solid state behavior of the crystals of the lithosphere. In addition, in order to lay the foundation for a generalized theory in earth physics, specific research areas are considered, such as the nature of the kinetics of the phase transitions in mineral assemblages, the equilibrium thermodynamic properties of crystals which are major constituents of mineral assemblages, and the transport properties of pure crystals which are major constituents of mineral assemblages.

Bonavito, N. L.↗

Effect of size on cracking of materials

Brittle behavior of large mild steel elements, glass plasticity, and fatigue specimen size sensitivity are manifestations of strain-energy size effect. Specimens physical size effect on material cracking initiation occurs according to flaw distribution statistics. Fracture size effect depends on stability or instability of crack propagation.

Glucklick, J.↗

Viking heat sterilization - Progress and problems

The Viking Mars landers to be launched in 1975 will carry experiments in biology, planetology, and atmospheric physics. A terminal dry-heat sterilization process using an inert gas was chosen to meet planetary quarantine requirements and preclude contamination of the biology experiment by terrestrial organisms. Deep sterilization is performed at the component level and terminal surface sterilization at the system level. Solutions to certain component problems relating to sterilization are discussed, involving the gyroscope, tape recorder, battery, electronic circuitry, and outgassing. Heat treatment placed special requirements on electronic packaging, including fastener preload monitoring and solder joints. Chemical and physical testing of nonmetallic materials was performed to establish data on their behavior in heat-treatment and vacuum environments. A Thermal Effects Test Model and a Proof Test Capsule were used. It is concluded that a space vehicle can be designed and fabricated to withstand heat sterilization requirements.

Daspit, L. P.↗

Physical aging effects on the compressive linear viscoelastic creep of IM7/K3B composite

An experimental study was undertaken to establish the viscoelastic behavior of 1M7/K3B composite in compression at elevated temperature. Creep compliance, strain recovery and the effects of physical aging on the time dependent response was measured for uniaxial loading at several isothermal conditions below the glass transition temperature (T(g)). The IM7/K3B composite is a graphite reinforced thermoplastic polyimide with a T(g) of approximately 240 C. In a composite, the two matrix dominated compliance terms associated with time dependent behavior occur in the transverse and shear directions. Linear viscoelasticity was used to characterize the creep/recovery behavior and superposition techniques were used to establish the physical aging related material constants. Creep strain was converted to compliance and measured as a function of test time and aging time. Results included creep compliance master curves, physical aging shift factors and shift rates. The description of the unique experimental techniques required for compressive testing is also given.

Veazie, David R.↗

Effects of Aging-Time Reference on the Long Term Behavior of the IM7/K3B Composite

An analytical study was undertaken to investigate the effects of the time-based shift reference on the long term behavior of the graphite reinforced thermoplastic polyimide composite IM7/K3B at elevated temperature. Creep compliance and the effects of physical aging on the time dependent response was measured for uniaxial loading at several isothermal conditions below the glass transition temperature (T(sub g). Two matrix dominated loading modes, shear and transverse, were investigated in tension and compression. The momentary sequenced creep/aging curves were collapsed through a horizontal (time) shift using the shortest, middle and longest aging time curve as the reference curve. Linear viscoelasticity was used to characterize the creep/recovery behavior and superposition techniques were used to establish the physical aging related material constants. The use of effective time expressions in a laminated plate model allowed for the prediction of long term creep compliance. The effect of using different reference curves with time/aging-time superposition was most sensitive to the physical aging shift rate at lower test temperatures. Depending on the loading mode, the reference curve used can result in a more accurate long term prediction, especially at lower test temperatures.

Veazie, David R.↗

Physical Invariants of Intelligence

A program of research is dedicated to development of a mathematical formalism that could provide, among other things, means by which living systems could be distinguished from non-living ones. A major issue that arises in this research is the following question: What invariants of mathematical models of the physics of systems are (1) characteristic of the behaviors of intelligent living systems and (2) do not depend on specific features of material compositions heretofore considered to be characteristic of life? This research at earlier stages has been reported, albeit from different perspectives, in numerous previous NASA Tech Briefs articles. To recapitulate: One of the main underlying ideas is to extend the application of physical first principles to the behaviors of living systems. Mathematical models of motor dynamics are used to simulate the observable physical behaviors of systems or objects of interest, and models of mental dynamics are used to represent the evolution of the corresponding knowledge bases. For a given system, the knowledge base is modeled in the form of probability distributions and the mental dynamics is represented by models of the evolution of the probability densities or, equivalently, models of flows of information. At the time of reporting the information for this article, the focus of this research was upon the following aspects of the formalism: Intelligence is considered to be a means by which a living system preserves itself and improves its ability to survive and is further considered to manifest itself in feedback from the mental dynamics to the motor dynamics. Because of the feedback from the mental dynamics, the motor dynamics attains quantum-like properties: The trajectory of the physical aspect of the system in the space of dynamical variables splits into a family of different trajectories, and each of those trajectories can be chosen with a probability prescribed by the mental dynamics. From a slightly different perspective, the mechanism of decision-making is feedback from the mental dynamics to the motor dynamics, and this mechanism provides a quantum-like collapse of a random motion into an appropriate deterministic state, such that entropy undergoes a pronounced decrease. The existence of this mechanism is considered to be an invariant of intelligent behavior of living systems, regardless of the origins and material compositions of the systems.

Zak, Michail↗