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NASA NTRS1994

Active weld control

Through the two phases of this contract, sensors for welding applications and parameter extraction algorithms have been developed. These sensors form the foundation of a weld control system which can provide action weld control through the monitoring of the weld pool and keyhole in a VPPA welding process. Systems of this type offer the potential of quality enhancement and cost reduction (minimization of rework on faulty welds) for high-integrity welding applications. Sensors for preweld and postweld inspection, weld pool monitoring, keyhole/weld wire entry monitoring, and seam tracking were developed. Algorithms for signal extraction were also developed and analyzed to determine their application to an adaptive weld control system. The following sections discuss findings for each of the three sensors developed under this contract: (1) weld profiling sensor; (2) weld pool sensor; and (3) stereo seam tracker/keyhole imaging sensor. Hardened versions of these sensors were designed and built under this contract. A control system, described later, was developed on a multiprocessing/multitasking operating system for maximum power and flexibility. Documentation for sensor mechanical and electrical design is also included as appendices in this report.

Powell, Bradley W.↗

NASA NTRS1995

Improved Back-Side Purge-Gas Chambers For Plasma Arc Welding

Improved chambers for inert-gas purging of back sides of workpieces during plasma arc welding in keyhole (full-penetration) mode based on concept of directing flows of inert gases toward, and concentrating them on, hot weld zones. Tapered chamber concentrates flow of inert gas on plasma arc plume and surrounding metal.

Ezell, Kenneth G.↗

NASA NTRS1995

Swirl Ring Improves Performance Of Welding Torch

Plasma-arc welding torch modified to create vortex in plasma gas to focus arc into narrower and denser column. Swirl ring contains four channels with angled exit holes to force gas to swirl as it flows out of torch past tip of electrode. Degradation of electrode and orifice more uniform and need to rotate torch during operation to compensate for asymmetry in arc reduced or eliminated. Used in both keyhole and nonkeyhole welding modes.

Mcgee, William F.↗

NASA NTRS1996

Copper Gas Diffusers For Purging Line-Focus Laser Welds

Modified flow diffusers built for inert-gas purging of welds made with 5-kW CO(2) lasers operating with line-focus optics in conduction mode instead of with point-focus optics in customary keyhole mode. Diffusers made of copper components brazed together, robust enough to withstand strong reflections of line-focused laser energy.

Fonteyne, Steve L.↗

NASA NTRS1996

Role of the micro/macro structure of welds in crack nucleation and propagation in aerospace aluminum-lithium alloy

Al-Li alloys offer the benefits of increased strength, elastic modulus and lower densities as compared to conventional aluminum alloys. Martin Marietta Laboratories has developed an Al-Li alloy designated 2195 which is designated for use in the cryogenic tanks of the space shuttle. The Variable Polarity Plasma Arc (VPPA) welding process is currently being used to produce these welds [1]. VPPA welding utilizes high temperature ionized gas (plasma) to transfer heat to the workpiece. An inert gas, such as Helium, is used to shield the active welding zone to prevent contamination of the molten base metal with surrounding reactive atmospheric gases. [1] In the Space Shuttle application, two passes of the arc are used to complete a butt-type weld. The pressure of the plasma stream is increased during the first pass to force the arc entirely through the material, a practice commonly referred to as keyholing. Molten metal forms on either side of the arc and surface tension draws this liquid together as the arc passes. 2319 Al alloy filler material may also be fed into the weld zone during this pass. During the second pass, the plasma stream pressure is reduced such that only partial penetration of the base material is obtained. Al 2319 filler material is added during this pass to yield a uniform, fully filled welded joint. This additional pass also acts to alter the grain structure of the weld zone to yield a higher strength joint.

Talia, George E.↗

NASA NTRS2002

Visions of our Planet's Atmosphere, Land and Oceans: Spectacular Visualizations of our Blue Marble

Hasler, A. F.↗

NASA NTRS2002

Visions of our Planet's Atmosphere, Land & Oceans

The NASA/NOAA Electronic Theater presents Earth science observations and visualizations in a historical perspective. Fly in from outer space to South Africa, Cape Town and Johannesburg using NASA Terra MODIS data, Landsat data and 1m IKONOS "Spy Satellite" data. Zoom in to any place South Africa using Earth Viewer 3D from Keyhole Inc. and Landsat data at 30 m resolution. Go back to the early weather satellite images from the 1960s and see them contrasted with the latest US and international global satellite weather movies including hurricanes & "tornadoes". See the latest visualizations of spectacular images from NASA/NOAA remote sensing missions like Terra, GOES, TRMM, SeaWiFS, Landsat 7 including 1 - min GOES rapid scan image sequences of Nov 9th 2001 Midwest tornadic thunderstorms and have them explained. See how High-Definition Television (HDTV) is revolutionizing the way we present science to the public. See dust storms and flooding in Africa and smoke plumes from fires in Mexico. See visualizations featured on the covers of Newsweek, TIME, National Geographic, Popular Science & on National & International Network TV. New computer software tools allow us to roam & zoom through massive global images e.g. Landsat tours of the US, and Africa, showing desert and mountain geology as well as seasonal changes in vegetation. See animations of the north and south polar ice packs and with icebergs on the coasts of Greenland and off the coast of Antarctica. Spectacular new visualizations of the global land, atmosphere & oceans are shown. Listen to the pulse of our planet. See how land vegetation, ocean plankton, clouds and temperatures respond to the sun & seasons. See vortexes and currents in the global oceans that bring up the nutrients to feed tiny algae and draw the fish, whales and fisherman. See the how the ocean blooms in response to these currents and El Nino/La Nina climate changes. See the city lights, fishing fleets, gas flares and biomass burning of the Earth at night observed by the "night-vision" DMSP military satellite. The presentation will be made using the latest HDTV and video projection technology that is now done from a laptop computer through an entirely digital path.

Hasler, Arthur F.↗

NASA NTRS2002

Visions of our Planet's Atmosphere, Land and Oceans

Hasler, A. F.↗

NASA NTRS2004

Plasma Arc Welding: How it Works

The physical principles of PAW from basic arcs to keyholing to variable polarity are outlined. A very brief account of the physics of PAW with an eye to the needs of a welder is presented. Understanding is usually (but not always) superior to handbooks and is required (unless dumb luck intervenes) for innovation. And, in any case, all welders by nature desire to know. A bit of history of the rise and fall of the Variable Polarity (VP) PA process in fabrication of the Space Shuttle External Tank is included.

Nunes, Arthur↗

NASA NTRS2005

An Hour of Spectacular Visualization

The NASA/NOAA Electronic Theater presents Earth science observations and visualizations from space in a historical perspective. Fly in from outer space to Athens and site of the 2004 Summer Olympics and the Far East using 1 m IKONOS "Spy Satellite" data. Contrast the 1972 Apollo 17 "Blue Marble" image of the Earth with the latest US and International global satellite images that allow us to view our Planet from any vantage point. See the latest spectacular images from NASA/NOAA/Commercial remote sensing missions like Terra, GOES, TRMM, SeaWiFS, & Landsat 7, QuickBird of the SE Asia Tsunami, devastation of Hurricane Katrina this year in New Orleans, and the LA/San Diego Fires of 2003. See how High Definition Television (HDTV) is revolutionizing the way we do science communication. Take the pulse of the planet on a daily, annual and 30-year time scale. See daily thunderstorms, the annual blooming of the northern hemisphere land masses and oceans, fires in Africa, dust storms in Iraq, and carbon monoxide exhaust from global burning. See visualizations featured on Newsweek, TIME, National Geographic, Popular Science covers & National & International Network TV. Spectacular new global visualizations of the observed and simulated atmosphere & oceans are shown. See the currents and vortexes in the oceans that bring up the nutrients to feed tiny plankton and draw the fish, whales and fishermen. See the how the ocean blooms in response to El Nino/La Nina climate changes. The Etheater will be presented using the latest High Definition TV (HDTV) and video projection technology on a large screen. See city lights around the globe and in your area observed by the "night-vision" DMSP satellite, Also see how Keyhole and Google Maps are using satellite and aerial photography to help you find your house and plan your vacation.

Hasler, Arthur F.↗

NASA NTRS2008

Providing Internet Access to High-Resolution Lunar Images

The OnMoon server is a computer program that provides Internet access to high-resolution Lunar images, maps, and elevation data, all suitable for use in geographical information system (GIS) software for generating images, maps, and computational models of the Moon. The OnMoon server implements the Open Geospatial Consortium (OGC) Web Map Service (WMS) server protocol and supports Moon-specific extensions. Unlike other Internet map servers that provide Lunar data using an Earth coordinate system, the OnMoon server supports encoding of data in Moon-specific coordinate systems. The OnMoon server offers access to most of the available high-resolution Lunar image and elevation data. This server can generate image and map files in the tagged image file format (TIFF) or the Joint Photographic Experts Group (JPEG), 8- or 16-bit Portable Network Graphics (PNG), or Keyhole Markup Language (KML) format. Image control is provided by use of the OGC Style Layer Descriptor (SLD) protocol. Full-precision spectral arithmetic processing is also available, by use of a custom SLD extension. This server can dynamically add shaded relief based on the Lunar elevation to any image layer. This server also implements tiled WMS protocol and super-overlay KML for high-performance client application programs.

Plesea, Lucian↗

NASA NTRS2008

Providing Internet Access to High-Resolution Mars Images

The OnMars server is a computer program that provides Internet access to high-resolution Mars images, maps, and elevation data, all suitable for use in geographical information system (GIS) software for generating images, maps, and computational models of Mars. The OnMars server is an implementation of the Open Geospatial Consortium (OGC) Web Map Service (WMS) server. Unlike other Mars Internet map servers that provide Martian data using an Earth coordinate system, the OnMars WMS server supports encoding of data in Mars-specific coordinate systems. The OnMars server offers access to most of the available high-resolution Martian image and elevation data, including an 8-meter-per-pixel uncontrolled mosaic of most of the Mars Global Surveyor (MGS) Mars Observer Camera Narrow Angle (MOCNA) image collection, which is not available elsewhere. This server can generate image and map files in the tagged image file format (TIFF), Joint Photographic Experts Group (JPEG), 8- or 16-bit Portable Network Graphics (PNG), or Keyhole Markup Language (KML) format. Image control is provided by use of the OGC Style Layer Descriptor (SLD) protocol. The OnMars server also implements tiled WMS protocol and super-overlay KML for high-performance client application programs.

Plesea, Lucian↗

NASA NTRS2006

Versatile Friction Stir Welding/Friction Plug Welding System

A proposed system of tooling, machinery, and control equipment would be capable of performing any of several friction stir welding (FSW) and friction plug welding (FPW) operations. These operations would include the following: Basic FSW; FSW with automated manipulation of the length of the pin tool in real time [the so-called auto-adjustable pin-tool (APT) capability]; Self-reacting FSW (SRFSW); SR-FSW with APT capability and/or real-time adjustment of the distance between the front and back shoulders; and Friction plug welding (FPW) [more specifically, friction push plug welding] or friction pull plug welding (FPPW) to close out the keyhole of, or to repair, an FSW or SR-FSW weld. Prior FSW and FPW systems have been capable of performing one or two of these operations, but none has thus far been capable of performing all of them. The proposed system would include a common tool that would have APT capability for both basic FSW and SR-FSW. Such a tool was described in Tool for Two Types of Friction Stir Welding (MFS- 31647-1), NASA Tech Briefs, Vol. 30, No. 10 (October 2006), page 70. Going beyond what was reported in the cited previous article, the common tool could be used in conjunction with a plug welding head to perform FPW or FPPW. Alternatively, the plug welding head could be integrated, along with the common tool, into a FSW head that would be capable of all of the aforementioned FSW and FPW operations. Any FSW or FPW operation could be performed under any combination of position and/or force control.

Carter, Robert↗

NASA NTRS2013

Dynamic Server-Based KML Code Generator Method for Level-of-Detail Traversal of Geospatial Data

Web-based geospatial client applications such as Google Earth and NASA World Wind must listen to data requests, access appropriate stored data, and compile a data response to the requesting client application. This process occurs repeatedly to support multiple client requests and application instances. Newer Web-based geospatial clients also provide user-interactive functionality that is dependent on fast and efficient server responses. With massively large datasets, server-client interaction can become severely impeded because the server must determine the best way to assemble data to meet the client applications request. In client applications such as Google Earth, the user interactively wanders through the data using visually guided panning and zooming actions. With these actions, the client application is continually issuing data requests to the server without knowledge of the server s data structure or extraction/assembly paradigm. A method for efficiently controlling the networked access of a Web-based geospatial browser to server-based datasets in particular, massively sized datasets has been developed. The method specifically uses the Keyhole Markup Language (KML), an Open Geospatial Consortium (OGS) standard used by Google Earth and other KML-compliant geospatial client applications. The innovation is based on establishing a dynamic cascading KML strategy that is initiated by a KML launch file provided by a data server host to a Google Earth or similar KMLcompliant geospatial client application user. Upon execution, the launch KML code issues a request for image data covering an initial geographic region. The server responds with the requested data along with subsequent dynamically generated KML code that directs the client application to make follow-on requests for higher level of detail (LOD) imagery to replace the initial imagery as the user navigates into the dataset. The approach provides an efficient data traversal path and mechanism that can be flexibly established for any dataset regardless of size or other characteristics. The method yields significant improvements in userinteractive geospatial client and data server interaction and associated network bandwidth requirements. The innovation uses a C- or PHP-code-like grammar that provides a high degree of processing flexibility. A set of language lexer and parser elements is provided that offers a complete language grammar for writing and executing language directives. A script is wrapped and passed to the geospatial data server by a client application as a component of a standard KML-compliant statement. The approach provides an efficient means for a geospatial client application to request server preprocessing of data prior to client delivery. Data is structured in a quadtree format. As the user zooms into the dataset, geographic regions are subdivided into four child regions. Conversely, as the user zooms out, four child regions collapse into a single, lower-LOD region. The approach provides an efficient data traversal path and mechanism that can be flexibly established for any dataset regardless of size or other characteristics.

Baxes, Gregory↗

NASA NTRS2013

Sally Ride EarthKAM - Automated Image Geo-Referencing Using Google Earth Web Plug-In

Sally Ride EarthKAM is an educational program funded by NASA that aims to provide the public the ability to picture Earth from the perspective of the International Space Station (ISS). A computer-controlled camera is mounted on the ISS in a nadir-pointing window; however, timing limitations in the system cause inaccurate positional metadata. Manually correcting images within an orbit allows the positional metadata to be improved using mathematical regressions. The manual correction process is time-consuming and thus, unfeasible for a large number of images. The standard Google Earth program allows for the importing of KML (keyhole markup language) files that previously were created. These KML file-based overlays could then be manually manipulated as image overlays, saved, and then uploaded to the project server where they are parsed and the metadata in the database is updated. The new interface eliminates the need to save, download, open, re-save, and upload the KML files. Everything is processed on the Web, and all manipulations go directly into the database. Administrators also have the control to discard any single correction that was made and validate a correction. This program streamlines a process that previously required several critical steps and was probably too complex for the average user to complete successfully. The new process is theoretically simple enough for members of the public to make use of and contribute to the success of the Sally Ride EarthKAM project. Using the Google Earth Web plug-in, EarthKAM images, and associated metadata, this software allows users to interactively manipulate an EarthKAM image overlay, and update and improve the associated metadata. The Web interface uses the Google Earth JavaScript API along with PHP-PostgreSQL to present the user the same interface capabilities without leaving the Web. The simpler graphical user interface will allow the public to participate directly and meaningfully with EarthKAM. The use of similar techniques is being investigated to place ground-based observations in a Google Mars environment, allowing the MSL (Mars Science Laboratory) Science Team a means to visualize the rover and its environment.

Andres, Paul M.↗

NASA NTRS2014

NASA's Optical Measurement Program 2014

The Optical Measurements Group (OMG) within the NASA Orbital Debris Program Office (ODPO) addresses U.S. National Space Policy goals by monitoring and characterizing debris. Since 2001, the OMG has used the Michigan Orbital Debris Survey Telescope (MODEST) at Cerro Tololo Inter-American Observatory (CTIO) in Chile for general orbital debris survey. The 0.6-m Schmidt MODEST provides calibrated astronomical data of GEO targets, both catalogued and uncatalogued debris, with excellent image quality. The data are utilized by the ODPO modeling group and are included in the Orbital Debris Engineering Model (ORDEM) v. 3.0. MODEST and the CTIO/SMARTS (Small and Moderate Aperture Research Telescope System) 0.9 m both acquire filter photometric data, as well as synchronously observing targets in selected optical filters. This information provides data used in material composition studies as well as longer orbital arc data on the same target, without time delay or bias from a rotating, tumbling, or spinning target. NASA, in collaboration with the University of Michigan, began using the twin 6.5-m Magellan telescopes at Las Campanas Observatory in Chile for deep imaging (Baade) and spectroscopic data (Clay) in 2011. Through the data acquired on Baade, debris have been detected that are ~3 magnitudes fainter than detections with MODEST, while the data from Clay provide better resolved information used in material characterization analyses via selected bandpasses. To better characterize and model optical data, the Optical Measurements Center (OMC) at NASA/JSC has been in operation since 2005, resulting in a database of comparison laboratory data. The OMC is designed to emulate illumination conditions in space using equipment and techniques that parallel telescopic observations and source-target-sensor orientations. Lastly, the OMG is building the Meter Class Autonomous Telescope (MCAT) at Ascension Island. The 1.3-m telescope is designed to observe GEO and LEO targets, using a modified Ritchey-Chrétien configuration on a double horseshoe equatorial mount to allow tracking objects at LEO rates through the dome's keyhole at zenith. Through the data collection techniques employed at these unique facilities, NASA's ODPO has developed a multi-faceted approach to characterize the orbital debris risk to satellites in various altitudes and provide material characterization of debris via photometric and spectroscopic measurements. Ultimately, the data are used in conjunction with in-situ and radar measurements to provide accurate data for models of our space environment and service spacecraft risk assessment.

Cowardin, H.↗

NASA NTRS2014

NASA's Optical Measurement Program 2014

The Optical Measurements Group (OMG) within the NASA Orbital Debris Program Office (ODPO) addresses U.S. National Space Policy goals by monitoring and characterizing debris. Since 2001, the OMG has used the Michigan Orbital Debris Survey Telescope (MODEST) at Cerro Tololo Inter-American Observatory (CTIO) in Chile for general orbital debris surveys. The 0.6-m Schmidt MODEST provides calibrated astronomical data of GEO targets, both catalogued and uncatalogued debris, with excellent image quality. The data are utilized by the ODPO modeling group and are included in the Orbital Debris Engineering Model (ORDEM) v. 3.0. MODEST and the CTIO/SMARTS (Small and Moderate Aperture Research Telescope System) 0.9 m are both employed to acquire filter photometry data as well as synchronously observe targets in selected optical filters. Obtaining data synchronously yields data for material composition studies as well as longer orbital arc data on the same target without time delay or bias from a rotating, tumbling, or spinning target. Observations of GEO orbital debris using the twin 6.5-m Magellan telescopes at Las Campanas Observatory in Chile for deep imaging (Baade) and spectroscopic data (Clay) began in 2011. Through the data acquired on Baade, debris has been detected that reaches approx. 3 magnitudes fainter than detections with MODEST, while the spectral data from Clay provide better resolved information used in material characterization analyses. To better characterize and model optical data, the Optical Measurements Center (OMC) at NASA/JSC has been in operation since 2005, resulting in a database of comparison laboratory data. The OMC is designed to emulate illumination conditions in space using equipment and techniques that parallel telescopic observations and sourcetarget- sensor orientations. Lastly, the OMG is building the Meter Class Autonomous Telescope (MCAT) at Ascension Island. The 1.3-m telescope is designed to observe GEO and LEO targets, using a modified Ritchey-Chrétien configuration on a double horseshoe equatorial mount to allow tracking objects at LEO rates through the dome's keyhole at zenith. Through the data collection techniques employed at these unique facilities, NASA's ODPO has developed a multifaceted approach to characterize the orbital debris risk to satellites in various altitudes and provide insight leading toward material characterization of debris via photometric and spectroscopic measurements. Ultimately, the data are used in conjunction with in-situ and radar measurements to provide accurate data for models of our space environment and for facilitating spacecraft risk assessment.

Cowardin, H.↗

NASA NTRS2014

CEO Sites Mission Management System (SMMS)

Late in fiscal year 2011, the Crew Earth Observations (CEO) team was tasked to upgrade its science site database management tool, which at the time was integrated with the Automated Mission Planning System (AMPS) originally developed for Earth Observations mission planning in the 1980s. Although AMPS had been adapted and was reliably used by CEO for International Space Station (ISS) payload operations support, the database structure was dated, and the compiler required for modifications would not be supported in the Windows 7 64-bit operating system scheduled for implementation the following year. The Sites Mission Management System (SMMS) is now the tool used by CEO to manage a heritage Structured Query Language (SQL) database of more than 2,000 records for Earth science sites. SMMS is a carefully designed and crafted in-house software package with complete and detailed help files available for the user and meticulous internal documentation for future modifications. It was delivered in February 2012 for test and evaluation. Following acceptance, it was implemented for CEO mission operations support in April 2012. The database spans the period from the earliest systematic requests for astronaut photography during the shuttle era to current ISS mission support of the CEO science payload. Besides logging basic image information (site names, locations, broad application categories, and mission requests), the upgraded database management tool now tracks dates of creation, modification, and activation; imagery acquired in response to requests; the status and location of ancillary site information; and affiliations with studies, their sponsors, and collaborators. SMMS was designed to facilitate overall mission planning in terms of site selection and activation and provide the necessary site parameters for the Satellite Tool Kit (STK) Integrated Message Production List Editor (SIMPLE), which is used by CEO operations to perform daily ISS mission planning. The CEO team uses the SMMS for three general functions - database queries of content and status, individual site creation and updates, and mission planning. The CEO administrator of the science site database is able to create or modify the content of sites and activate or deactivate them based on the requirements of the sponsors. The administrator supports and implements ISS mission planning by assembling, reporting, and activating mission-specific site selections for management; deactivating sites as requirements are met; and creating new sites, such as International Charter sites for disasters, as circumstances warrant. In addition to the above CEO internal uses, when site planning for a specific ISS mission is complete and approved, the SMMS can produce and export those essential site database elements for the mission into XML format for use by onboard Earth-location systems, such as Worldmap. The design, development, and implementation of the SMMS resulted in a superior database management system for CEO science sites by focusing on the functions and applications of the database alone instead of integrating the database with the multipurpose configuration of the AMPS. Unlike the AMPS, it can function and be modified within the existing Windows 7 environment. The functions and applications of the SMMS were expanded to accommodate more database elements, report products, and a streamlined interface for data entry and review. A particularly elegant enhancement in data entry was the integration of the Google Earth application for the visual display and definition of site coordinates for site areas defined by multiple coordinates. Transfer between the SMMS and Google Earth is accomplished with a Keyhole Markup Language (KML) expression of geographic data (see figures 3 and 4). Site coordinates may be entered into the SMMS panel directly for display in Google Earth, or the coordinates may be defined on the Google Earth display as a mouse-controlled polygonal definition and transferred back into the SMMS as KML input. This significantly reduces the possibility of errors in coordinate entries and provides visualization of the scale of the site being defined. CEO now has a powerful tool for managing and defining sites on the Earth's surface for both targets of astronaut photography or other onboard remote sensing systems. It can also record and track results by sponsor, collaborator, or type of study.

Trenchard, Mike↗