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NASA NTRS2002

Initial Assessment of the Effects of Nonmetallic Inclusions on Fatigue Life of Powder-Metallurgy-Processed Udimet(TM) 720

The fatigue lives of modern powder metallurgy (PM) disk alloys are influenced by variabilities in alloy microstructure and mechanical properties. These properties can vary due to the different steps of materials/component processing and machining. One of these variables, the presence of nonmetallic inclusions, has been shown to significantly degrade low-cycle fatigue (LCF) life. Nonmetallic inclusions are inherent defects in powder alloys that are a by-product of powder-processing techniques. Contamination of the powder can occur in the melt, during powder atomization, or during any of the various handling processes through consolidation. In modern nickel disk powder processing facilities, the levels of inclusion contamination have been reduced to less than 1 part per million by weight. Despite the efforts of manufacturers to ensure the cleanliness of their powder production processes, the presence of inclusions remains a source of great concern for the designer. the objective of this study was to investigate the effects on fatigue life of these inclusions. Since natural inclusions occur so infrequently, elevated levels of inclusions were carefully introduced in a nickel-based disk superalloy, Udimet 720 (registered trademark of Special Metals Corporation), produced using PM processing. Multiple strain-controlled fatigue tests were then performed on this material at 650 C. Analyses were performed to compare the LCF lives and failure initiation sites as functions of inclusion content and fatigue conditions. A large majority of the failures in specimens with introduced inclusions occurred at cracks initiating from inclusions at the specimen surface. The inclusions could reduce fatigue life by up to 100 times. These effects were found to be dependent on strain range and strain ratio. Tests at lower strain ranges and higher strain ratios produced larger effects of inclusions on life.

Gabb, T. P.↗

NASA NTRS2002

The Interaction of Spacecraft Cabin Atmospheric Quality and Water Processing System Performance

Although designed to remove organic contaminants from a variety of waste water streams, the planned U.S.- and present Russian-provided water processing systems onboard the International Space Station (ISS) have capacity limits for some of the more common volatile cleaning solvents used for housekeeping purposes. Using large quantities of volatile cleaning solvents during the ground processing and in-flight operational phases of a crewed spacecraft such as the ISS can lead to significant challenges to the water processing systems. To understand the challenges facing the management of water processing capacity, the relationship between cabin atmospheric quality and humidity condensate loading is presented. This relationship is developed as a tool to determine the cabin atmospheric loading that may compromise water processing system performance. A comparison of cabin atmospheric loading with volatile cleaning solvents from ISS, Mir, and Shuttle are presented to predict acceptable limits to maintain optimal water processing system performance.

Perry, Jay L.↗

NASA NTRS2001

Bioregenerative Life Support Systems Test Complex (Bio-Plex) Food Processing System: A Dual System

A Bioregenerative Life Support Test Complex, BIO-Plex, is currently being constructed at the Johnson Space Center (JSC) in Houston, TX. This facility will attempt to answer the questions involved in developing a lunar or planetary base. The Food Processing System (FPS) of the BIO-Plex is responsible for supplying food to the crew in coordination with the chosen mission scenario. Long duration space missions require development of both a Transit Food System and of a Lunar or Planetary Food System. These two systems are intrinsically different since the first one will be utilized in the transit vehicle in microgravity conditions with mostly resupplied foods, while the second will be used in conditions of partial gravity (hypogravity) to process foods from crops grown in the facility. The Transit Food System will consist of prepackaged food of extended shelf life. It will be supplemented with salad crops that will be consumed fresh. Microgravity imposes significant limitation on the ability to handle food and allows only for minimal processing. The challenge is to develop food systems similar to the International Space Station or Shuttle Food Systems but with a shelf life of 3 - 5 years. The Lunar or Planetary Food System will allow for food processing of crops due to the presence of some gravitational force (1/6 to 1/3 that of Earth). Crops such as wheat, soybean, rice, potato, peanut, and salad crops, will be processed to final products to provide a nutritious and acceptable diet for the crew. Not only are constraints imposed on the FPS from the crops (e.g., crop variation, availability, storage and shelf-life) but also significant requirements are present for the crew meals (e.g., RDA, high quality, safety, variety). The FPS becomes a fulcrum creating the right connection from crops to crew meals while dealing with issues of integration within a closed self-regenerative system (e.g., safe processing, waste production, volumes, air contaminations, water usage, etc.). Options for the first test, for duration of 120 days, currently scheduled for late 2003 are outlined.

Perchonok, Michele↗

NASA NTRS2003

Sensitivity of Precipitation Processes to Microphysics and Resolution in a Cloud-Resolving Model

The Goddard Cumulus Ensemble (GCE) model is used to examine the impact of various microphysical schemes, and vertical and horizontal resolution on the development, intensity and rainfall associated with mesoscale convective systems, idealized hurricanes and an ensemble of clouds. The model variables include horizontal and vertical velocities, potential temperature, perturbation pressure, turbulent kinetic energy, and mixing ratios of all water phases (vapor, liquid, and ice). The major characteristics of the GCE model are the explicit representation of warm rain and ice microphysical processes, and their complex interactions with solar and infrared radiative transfer processes, and with surface processes. For idealized hurricane, an axisymmetric version of the GCE model was developed and used successfully to simulate the tropical cyclogenesis process using both a Rankin vortex and saturated air within a specified radius as initial conditions. For mesoscale convective systems, the 3-D version of the GCE model was used to simulate squall lines that developed in the western Pacific, South China Sea, eastern Atlantic, South America and central U.S. For the cloud ensemble, the GCE model was integrated for several days in order to have good sampling of cloud statistics. In this paper, the sensitivities of hurricane intensity to various microphysical processes and model grid resolution will be examined. This will be mainly achieved by performing sensitivity tests using various horizontal (from 1- to 5-kilometers) and vertical resolutions (from 20- to 200-meters in the lower troposphere to 200- to 500-m in the middle and upper troposphere). Sensitivity tests using various microphysical schemes (warm rain only, and three ice with either graupel or hail) will also be performed. The PBL and diurnal variation of precipitation processes will also be evaluated. The budgets will be calculated for different regions (i.e., convective and stratiform regions).

Tao, Wei-Kao↗

NASA NTRS2003

Microgravity Effects on Materials Processing: A Review

Materials processing in space has been studied both theoretically and experimentally for over 1/4 of a century. In the beginning, we naively spoke of zero gravity, elimination of convection, growth of perfect crystals, and eventual manufacturing in space. All of these appear to have fallen by the wayside. On the other hand, we have learned an unprecedented amount about the influences of gravity on materials processing. We have had many surprises, and not all experimental results have yet been satisfactorily explained. Gravity was found to influence processes that were thought to be gravity-independent. One consequence is that materials processing on earth has often been improved. And it is difficult to imagine how the materials-processing industries could have flourished without the engineers and scientists who received their training by working on microgravity materials processing.

Wilcox, William R.↗

NASA NTRS2003

Electron Beam Freeform Fabrication: A Rapid Metal Deposition Process

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley REsearch Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. The EBF process introduces metal wire feedstock into a molten pool that is created and sustained using a focused electron beam in a vacuum environment. Thus far, this technique has been demonstrated on aluminum and titanium alloys of interest for aerospace structural applications nickel and ferrous based alloys are also planned. Deposits resulting from 2219 aluminum demonstrations have exhibited a range of grain morphologies depending upon the deposition parameters. These materials ave exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF process is capable of bulk metal deposition at deposition rated in excess of 2500 cubic centimeters per hour (150 cubic inches per our) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

Taminger, Karen M. B.↗

NASA NTRS2001

Technology Assessment of Laser-Assisted Materials Processing in Space

Lasers are useful for performing operations such as joining, machining, built-up freeform fabrication, shock processing, and surface treatments. These attributes are attractive for the supportability of longer-term missions in space due to the multi-functionality of a single tool and the variety of materials that can be processed. However, current laser technology also has drawbacks for space-based applications, specifically size, power efficiency, lack of robustness, and problems processing highly reflective materials. A review of recent laser developments will be used to show how these issues may be reduced and indicate where further improvement is necessary to realize a laser-based materials processing capability in space. The broad utility of laser beams in synthesizing various classes of engineering materials will be illustrated using state-of-the art processing maps for select lightweight alloys typically found on spacecraft. With the advent of recent breakthroughs in diode-pumped solid-state lasers and fiber optic technologies, the potential to perform multiple processing techniques is increasing significantly. Lasers with suitable wavelengths and beam properties have tremendous potential for supporting future space missions to the moon, Mars and beyond.

Nagarathnam, Karthik↗

NASA NTRS2005

NASA Remote Sensing Data in Earth Sciences: Processing, Archiving, Distribution, Applications at the GES DISC

The NASA Goddard Earth Sciences Data and Information Services Center (GES DISC) is one of the major Distributed Active Archive Centers (DAACs) archiving and distributing remote sensing data from the NASA's Earth Observing System. In addition to providing just data, the GES DISC/DAAC has developed various value-adding processing services. A particularly useful service is data processing a t the DISC (i.e., close to the input data) with the users' algorithms. This can take a number of different forms: as a configuration-managed algorithm within the main processing stream; as a stand-alone program next to the on-line data storage; as build-it-yourself code within the Near-Archive Data Mining (NADM) system; or as an on-the-fly analysis with simple algorithms embedded into the web-based tools (to avoid downloading unnecessary all the data). The existing data management infrastructure at the GES DISC supports a wide spectrum of options: from data subsetting data spatially and/or by parameter to sophisticated on-line analysis tools, producing economies of scale and rapid time-to-deploy. Shifting processing and data management burden from users to the GES DISC, allows scientists to concentrate on science, while the GES DISC handles the data management and data processing at a lower cost. Several examples of successful partnerships with scientists in the area of data processing and mining are presented.

Leptoukh, Gregory G.↗

NASA NTRS2000

Near-Net-Shape Processing of Sintered Fibrous Ceramics Achieved

A variety of sintered fibrous ceramic (SFC) materials have been developed over the last 50 years as thermal barrier materials for reentry applications. SFC materials typically exhibit very low thermal conductivities combined with low densities and good thermal stability up to 2500 F. These materials have flown successfully on the space shuttle orbiters since the 1960's. More recently, the McDonnell Douglas Corporation successfully used SFC tiles as a heat shield on the underside of its DC X test vehicle. For both of these applications, tiles are machined from blocks of a specific type of SFC called an alumina-enhanced thermal barrier (AETB). The sizes of these blocks have been limited by the manufacturing process. In addition, as much as 80 to 90 percent of the material can be lost during the machining of tiles with significant amounts of curvature. To address these problems, the NASA Glenn Research Center at Lewis Field entered a cooperative contract with the Boeing Company to develop a vacuum-assisted forming process that can produce large (approximately 4 square feet), severely contoured panels of AETB while saving costs in comparison to the conventional cast-and-machine billet process. For shuttle use, AETB is slurry cast, drained, and fired to form square billets conforming to the shape of the filtration box. The billets are then cut into tiles of the appropriate size for thermally protecting the space shuttle. Processing techniques have limited the maximum size of AETB billets to 21.5 square inches by 6.5-in. thick, but the space shuttles use discrete heat shield tiles no more than 8 to 12 square inches. However, in other applications, large, complex shapes are needed, and the tiling approach is undesirable. For such applications, vacuum-assisted forming can produce large parts with complex shapes while reducing machining waste and eliminating cemented joints between bonded billets. Because it allows contoured shapes to be formed, material utilization is inherently high. Initial estimates show that the amount of material lost during machining can be reduced by 50 percent or more. In addition, a fiber alignment favorable for minimum heat transfer is maintained for all panel shapes since the fibers are aligned parallel to the contoured surface of the forming tool or mold. The vacuum-assisted forming process can complete the entire forming operation in a matter of minutes and can produce multiple parts whose size is limited only by the size of the forming tool. To date, panels as large as 2 square feet have been demonstrated The vacuum-assisted forming process starts with the fabrication of a permeable forming tool, or mold, with the proper part contour. This reusable tool is mounted over an internal rib support structure, as depicted in the diagram, such that a vacuum can be pulled on the bottom portion of the tool. AETB slurry is then poured over and around the tool, liquid is drawn from the slurry, and the part forms over the tool surface. The part is then dried, fired, and finished machined. Future plans include an evaluation of the need for additional coatings and surface-toughness treatments to extend the durability and performance of this material.

Angel, Paul W.↗

NASA NTRS2007

Space Plasma Ion Processing of Ilmenite in the Lunar Soil: Insights from In-Situ TEM Ion Irradiation Experiments

Space weathering on the moon and asteroids results largely from the alteration of the outer surfaces of regolith grains by the combined effects of solar ion irradiation and other processes that include deposition of impact or sputter-derived vapors. Although no longer considered the sole driver of space weathering, solar ion irradiation remains a key part of the space weathering puzzle, and quantitative data on its effects on regolith minerals are still in short supply. For the lunar regolith, previous transmission electron microscope (TEM) studies performed by ourselves and others have uncovered altered rims on ilmenite (FeTiO3) grains that point to this phase as a unique "witness plate" for unraveling nanoscale space weathering processes. Most notably, the radiation processed portions of these ilmenite rims consistently have a crystalline structure, in contrast to radiation damaged rims on regolith silicates that are characteristically amorphous. While this has tended to support informal designation of ilmenite as a "radiation resistant" regolith mineral, there are to date no experimental data that directly and quantitatively compare ilmenite s response to ion radiation relative to lunar silicates. Such data are needed because the radiation processed rims on ilmenite grains, although crystalline, are microstructurally and chemically complex, and exhibit changes linked to the formation of nanophase Fe metal, a key space weathering process. We report here the first ion radiation processing study of ilmenite performed by in-situ means using the Intermediate Voltage Electron Microscope- Tandem Irradiation facility (IVEM-Tandem) at Argonne National Laboratory. The capability of this facility for performing real time TEM observations of samples concurrent with ion irradiation makes it uniquely suited for studying the dose-dependence of amorphization and other changes in irradiated samples.

Christoffersen, R.↗

NASA NTRS2007

A Software Platform for Post-Processing Waveform-Based NDE

Ultrasonic, microwave, and terahertz nondestructive evaluation imaging systems generally require the acquisition of waveforms at each scan point to form an image. For such systems, signal and image processing methods are commonly needed to extract information from the waves and improve resolution of, and highlight, defects in the image. Since some similarity exists for all waveform-based NDE methods, it would seem a common software platform containing multiple signal and image processing techniques to process the waveforms and images makes sense where multiple techniques, scientists, engineers, and organizations are involved. This presentation describes NASA Glenn Research Center's approach in developing a common software platform for processing waveform-based NDE signals and images. This platform is currently in use at NASA Glenn and at Lockheed Martin Michoud Assembly Facility for processing of pulsed terahertz and ultrasonic data. Highlights of the software operation will be given. A case study will be shown for use with terahertz data. The authors also request scientists and engineers who are interested in sharing customized signal and image processing algorithms to contribute to this effort by letting the authors code up and include these algorithms in future releases.

Roth, Donald J.↗

NASA NTRS1998

Parallel processing spacecraft communication system

An uplink controlling assembly speeds data processing using a special parallel codeblock technique. A correct start sequence initiates processing of a frame. Two possible start sequences can be used; and the one which is used determines whether data polarity is inverted or non-inverted. Processing continues until uncorrectable errors are found. The frame ends by intentionally sending a block with an uncorrectable error. Each of the codeblocks in the frame has a channel ID. Each channel ID can be separately processed in parallel. This obviates the problem of waiting for error correction processing. If that channel number is zero, however, it indicates that the frame of data represents a critical command only. That data is handled in a special way, independent of the software. Otherwise, the processed data further handled using special double buffering techniques to avoid problems from overrun. When overrun does occur, the system takes action to lose only the oldest data.

Bolotin, Gary S.↗

NASA NTRS2008

The Impact of Aerosols on Cloud and Precipitation Processes: Cloud-Resolving Model Simulations

Aerosols and especially their effect on clouds are one of the key components of the climate system and the hydrological cycle [Ramanathan et al., 2001]. Yet, the aerosol effect on clouds remains largely unknown and the processes involved not well understood. A recent report published by the National Academy of Science states "The greatest uncertainty about the aerosol climate forcing - indeed, the largest of all the uncertainties about global climate forcing - is probably the indirect effect of aerosols on clouds [NRC, 2001]." The aerosol effect on clouds is often categorized into the traditional "first indirect (i.e., Twomey)" effect on the cloud droplet sizes for a constant liquid water path [Twomey, 1977] and the "semi-direct" effect on cloud coverage [e.g., Ackerman et al ., 2001]." Enhanced aerosol concentrations can also suppress warm rain processes by producing a narrow droplet spectrum that inhibits collision and coalescence processes [e.g., Squires and Twomey, 1961; Warner and Twomey, 1967; Warner, 1968; Rosenfeld, 19991. The aerosol effect on precipitation processes, also known as the second type of aerosol indirect effect [Albrecht, 1989], is even more complex, especially for mixed-phase convective clouds. Table 1 summarizes the key observational studies identifying the microphysical properties, cloud characteristics, thermodynamics and dynamics associated with cloud systems from high-aerosol continental environments. For example, atmospheric aerosol concentrations can influence cloud droplet size distributions, warm-rain process, cold-rain process, cloud-top height, the depth of the mixed phase region, and occurrence of lightning. In addition, high aerosol concentrations in urban environments could affect precipitation variability by providing an enhanced source of cloud condensation nuclei (CCN). Hypotheses have been developed to explain the effect of urban regions on convection and precipitation [van den Heever and Cotton, 2007 and Shepherd, 2005]. Please see Tao et al. (2007) for more detailed description on aerosol impact on precipitation. Recently, a detailed spectral-bin microphysical scheme was implemented into the Goddard Cumulus Ensemble (GCE) model. Atmospheric aerosols are also described using number density size-distribution functions. A spectral-bin microphysical model is very expensive from a computational point of view and has only been implemented into the 2D version of the GCE at the present time. The model is tested by studying the evolution of deep tropical clouds in the west Pacific warm pool region and summertime convection over a mid-latitude continent with different concentrations of CCN: a low "clean" concentration and a high "dirty" concentration. The impact of atmospheric aerosol concentration on cloud and precipitation will be investigated.

Tao, Wei-Kuo↗

NASA NTRS2008

Carbothermal Processing of Lunar Regolith Using Methane

The processing of lunar regolith for the production of oxygen is a key component of the In-Situ Resource Utilization plans currently being developed by NASA. Among various candidate processes, the modeling of oxygen production by hydrogen reduction, molten salt electrolysis, and carbothermal processing are presently being pursued. In the carbothermal process, a portion of the surface of the regolith in a container is heated by exposure to a heat source such as a laser beam or a concentrated solar heat flux, so that a small zone of molten regolith is established. The molten zone is surrounded by solid regolith particles that are poor conductors of heat. A continuous flow of methane is maintained over the molten regolith zone. Our model is based on a mechanism where methane pyrolyzes when it comes in contact with the surface of the hot molten regolith to form solid carbon and hydrogen gas. Carbon is deposited on the surface of the melt, and hydrogen is released into the gas stream above the melt surface. We assume that the deposited carbon mixes in the molten regolith and reacts with metal oxides in a reduction reaction by which gaseous carbon monoxide is liberated. Carbon monoxide bubbles through the melt and is released into the gas stream. Oxygen is produced subsequently by (catalytically) processing the carbon monoxide downstream. In this paper, we discuss the development of a chemical conversion model of the carbothermal process to predict the rate of production of carbon monoxide.

Balasubramaniam, R.↗

NASA NTRS2008

Orchestrator Telemetry Processing Pipeline

Orchestrator is a software application infrastructure for telemetry monitoring, logging, processing, and distribution. The architecture has been applied to support operations of a variety of planetary rovers. Built in Java with the Eclipse Rich Client Platform, Orchestrator can run on most commonly used operating systems. The pipeline supports configurable parallel processing that can significantly reduce the time needed to process a large volume of data products. Processors in the pipeline implement a simple Java interface and declare their required input from upstream processors. Orchestrator is programmatically constructed by specifying a list of Java processor classes that are initiated at runtime to form the pipeline. Input dependencies are checked at runtime. Fault tolerance can be configured to attempt continuation of processing in the event of an error or failed input dependency if possible, or to abort further processing when an error is detected. This innovation also provides support for Java Message Service broadcasts of telemetry objects to clients and provides a file system and relational database logging of telemetry. Orchestrator supports remote monitoring and control of the pipeline using browser-based JMX controls and provides several integration paths for pre-compiled legacy data processors. At the time of this reporting, the Orchestrator architecture has been used by four NASA customers to build telemetry pipelines to support field operations. Example applications include high-volume stereo image capture and processing, simultaneous data monitoring and logging from multiple vehicles. Example telemetry processors used in field test operations support include vehicle position, attitude, articulation, GPS location, power, and stereo images.

Powell, Mark↗

NASA NTRS2008

Solar Concentrator Demonstrator for Lunar Regolith Processing

NASA at the Marshall Space Flight Center (MSFC) is building a portable inflatable solar concentrator ground demonstrator for use in testing in-situ resource utilization (ISRU) lunar regolith processing methods. Of primary interest is the production of oxygen as a propellant oxidizer and for life support. There are various processes being proposed for the in-situ reduction of the lunar regolith, the leading processes are hydrogen reduction, carbothermal reduction and vapor phase pyrolysis. The concentrator system being built at MSFC could support demonstrations of all of these processes. The system consists of a light inflatable concentrator that will capture sunlight and focus it onto a receiver inside a vacuum chamber. Inflatable concentrators are good for space based applications due to their low weight and dense packaging at launch. The hexapod design allows the spot size to be increased to reduce the power density if needed for the process being demonstrated. In addition to the hardware development, a comprehensive simulation model is being developed and will be verified and validated using the system hardware. The model will allow for the evaluation of different lunar locations and operational scenarios for the lunar regolith processing with a high confidence in the predicted results.

Fikes, John C.↗

NASA NTRS2009

Carbothermal Processing of Lunar Regolith Using Methane

Balasubramaniam, R.↗

NASA NTRS2010

History of Nebular Processing Traced by Silicate Stardust in IDPS

Chondritic porous interplanetary dust particles (CP-IDPs) may be the best preserved remnants of primordial solar system materials, in part because they were not affected by parent body hydrothermal alteration. Their primitive characteristics include fine grained, unequilibrated, anhydrous mineralogy, enrichment in volatile elements, and abundant molecular cloud material and silicate stardust. However, while the majority of CP-IDP materials likely derived from the Solar System, their formation processes and provenance are poorly constrained. Stardust abundances provide a relative measure of the extent of processing that the Solar System starting materials has undergone in primitive materials. For example, among primitive meteorites silicate stardust abundances vary by over two orders of magnitude (less than 10-200 ppm). This range of abundances is ascribed to varying extents of aqueous processing in the meteorite parent bodies. The higher average silicate stardust abundances among CP-IDPs (greater than 375 ppm) are thus attributable to the lack of aqueous processing of these materials. Yet, silicate stardust abundances in IDPs also vary considerably. While the silicate stardust abundance in IDPs having anomalous N isotopic compositions was reported to be 375 ppm, the abundance in IDPs lacking N anomalies is less than 10 ppm. Furthermore, these values are significantly eclipsed among some IDPs with abundances ranging from 2,000 ppm to 10,000 ppm. Given that CP-IDPs have not been significantly affected by parent body processes, the difference in silicate stardust abundances among these IDPs must reflect varying extents of nebular processing. Here we present recent results of a systematic coordinated mineralogical/isotopic study of large cluster IDPs aimed at (1) characterizing the mineralogy of presolar silicates and (2) delineating the mineralogical and petrographic characteristics of IDPs with differing silicate stardust abundances. One of the goals of this study is to better understand the earliest stages of evolution of the Solar System starting materials.

Messenger, Scott R.↗