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NASA NTRSDate not supplied

Laser Beam Welding Advancements for In-Space Servicing, Assembly, and Manufacturing

NASA is currently working to develop in-space servicing, assembly, and manufacturing (ISAM) capabilities for low Earth orbit and the lunar surface. One crucial technology for this effort is laser beam welding. Laser systems can perform joining, cleaning, cutting, and repair activities, which will enable the construction of large in-space structures that could not fit on a single launch vehicle, such as trusses for solar panels, radiators, or communications infrastructure. Multiple projects studying laser welding for space applications are currently underway at NASA Marshall Space Flight Center. One of these, the DIsk-Shaped Configurable and Modular vAcuum uNit (DISCMAN), is a compact vacuum chamber designed to support parameter development for laser welding in microgravity. It contains a rotating platen with weld samples made from aluminum, steel, and titanium, a high-power infrared laser, and integrated pumps for pulling vacuum inside the sample cartridge. The DISCMAN payload is planned to launch to the International Space Station, where welds will be performed under sustained microgravity inside the Bishop Airlock. Another effort underway at Marshall is the Lunar Assembly and Servicing by Autonomous Robotics (LASAR) initiative. This project uses a space-rated robotic arm equipped with a laser weld head, wire feeder, and multiple cameras to perform welds in a thermal vacuum chamber simulating the lunar surface environment. Some of these welds are done on snowflake joints, which are specially designed to slot together to join segments of trussN structures, allowing for the construction of tall surface infrastructure. DISCMAN, LASAR, and other projects are being carried out to advance the technological maturity of in-space laser beam welding, collect data to inform computational models, and learn reliable processes for creating weld joints in space. This work supports NASA’s greater goals to expand humanity’s presence in low Earth orbit, establish a permanent moon base, and eventually send crewed missions to Mars and beyond.

Manufacturing↗

NASA NTRSDate not supplied

Laser Beam Welding Advancements for In-Space Servicing, Assembly, and Manufacturing

Robotics↗

NASA NTRS1984

Demonstration test of burner liner strain measuring system

A demonstration test was conducted for two systems of static strain measurement that had been shown to have potential for application jet engine combustors. A modified JT12D combustor was operated in a jet burner test stand while subjected simultaneously to both systems of instrumentation, i.e., Kanthal A-1 wire strain gages and laser speckle photography. A section of the burner was removed for installation and calibration of the wire gages, and welded back into the burner. The burner test rig was modified to provide a viewing port for the laser speckle photography such that the instrumented section could be observed during operation. Six out of ten wire gages survived testing and showed excellent repeatability. The extensive precalibration procedures were shown to be effective in compensating for the large apparent strains associated with these gages. Although all portions of the speckle photography system operated satisfactorily, a problem was encountered in the form of optical inhomogeneities in the hot, high-pressure gas flowing by the combustor case which generate large and random apparent strain distributions.

Stetson, K. A.↗

NASA NTRS1974

Calculation of turbulent shear stress in supersonic boundary layer flows

Turbulent shear stress distributions for supersonic boundary layer flows have been computed from experimental mean boundary layer data. The computations have been made by numerically integrating the time averaged continuity and streamwise momentum equations. Distributions have been obtained for flows upstream and downstream of shock-wave-boundary layer interactions and for both two-dimensional and axisymmetric flows. The computed results are compared with recently reported shear stress measurements which were obtained by hot wire anemometer and laser velocimeter techniques.

Sun, C. C.↗

NASA NTRS1974

Calculation of turbulent shear stress in supersonic boundary layer flows

An analysis of turbulent boundary layer flow characteristics and the computational procedure used are discussed. The integrated mass and momentum flux profiles and differentials of the integral quantities are used in the computations so that local evaluation of the streamwise velocity gradient is not necessary. The computed results are compared with measured shear stress data obtained by using hot wire anemometer and laser velocimeter techniques. The flow measurements were made upstream and downstream of an adiabatic unseparated interaction of an oblique shock wave with the turbulent boundary layer on the flat wall of a two dimensional wind tunnel. A comparison of the numerical analysis and actual measurements is made and the effects of small differences in mean flow profiles on the computed shear stress distributions are discussed.

Sun, C. C.↗

NASA NTRS1980

Manufacturing process applications team (MATeam)

The objectives and activities of an aerospace technology transfer group are outlined and programs in various stages of progress are described including the orbital tube flaring device, infrared proximity sensor for robot positioning, laser stripping magnet wire, infrared imaging as welding process tracking system, carbide coating of cutting tools, nondestructive fracture toughness testing of titanium welds, portable solar system for agricultural applications, and an anerobic methane gas generator.

Bangs, E. R.↗

NASA NTRS1980

Applications of advanced electric/electronic technology to conventional aircraft

The desirability of seven advanced technologies as applied to three commercial aircraft of 1985 to 1995 was investigated. Digital fly by wire, multiplexing, ring laser gyro, integrated avionics, all electric airplane, electric load management, and fiber optics were considered for 500 passenger, 50 passenger, and 30 passenger aircraft. The major figure of merit used was Net Value of Technology based on procurement and operating cost over the life of the aircraft. An existing computer program, ASSET, was used to resize the aircraft and evalute fuel usage and maintenance costs for each candidate configuration. Conclusions were that, for the 500 passenger aircraft, all candidates had a worthwhile payoff with the all electric airplane having a large payoff.

Heimbold, R. L.↗

NASA NTRS1981

Highly separated transonic flows

Attention is given to the wind tunnel, to photographic visualization of the flow, and to measurements by pressure probes, hot wire anemometry and laser anemometry. The simultaneous use of different means of measurement provided a good description of the phenomenon, and indicated the existence of shocks and their stability, as well as the existence of the bubble, its dimensions, and in particular, the reattachment of its front. The results show that the bursting (or transition) of the bubble front is produced at an unstable position and creates a point of turbulent intensity which diffuses over the entire height of the flow.

Farcy, A.↗

NASA NTRS1982

Experimental measurements of unsteady turbulent boundary layers near separation

Investigations conducted to document the behavior of turbulent boundary layers on flat surfaces that separate due to adverse pressure gradients are reported. Laser and hot wire anemometers measured turbulence and flow structure of a steady free stream separating turbulent boundary layer produced on the flow of a wind tunnel section. The effects of sinusoidal and unsteadiness of the free stream velocity on this separating turbulent boundary layer at a reduced frequency were determined. A friction gage and a thermal tuft were developed and used to measure the surface skin friction and the near wall fraction of time the flow moves downstream for several cases. Abstracts are provided of several articles which discuss the effects of the periodic free stream unsteadiness on the structure or separating turbulent boundary layers.

Simpson, R. L.↗

NASA NTRS1988

The pros and cons of code validation

Computational and wind tunnel error sources are examined and quantified using specific calculations or experimental data, and a substantial comparison of theoretical and experimental results, or a code validation, is discussed. Wind tunnel error sources considered include wall interference, sting effects, Reynolds number effects, flow quality and transition, and instrumentation such as strain gage balances, electronically scanned pressure systems, hot film gages, hot wire anemometers, and laser velocimeters. Computational error sources include math model equation sets, the solution algorithm, artificial viscosity/dissipation, boundary conditions, the uniqueness of solutions, grid resolution, turbulence modeling, and Reynolds number effects. It is concluded that although improvements in theory are being made more quickly than in experiments, wind tunnel research has the advantage of the more realistic transition process of a right turbulence model in a free-transition test.

Bobbitt, Percy J.↗

NASA NTRS1988

The pros and cons of code validation

Computational and wind tunnel error sources are examined and quantified using specific calculations of experimental data, and a substantial comparison of theoretical and experimental results, or a code validation, is discussed. Wind tunnel error sources considered include wall interference, sting effects, Reynolds number effects, flow quality and transition, and instrumentation such as strain gage balances, electronically scanned pressure systems, hot film gages, hot wire anemometers, and laser velocimeters. Computational error sources include math model equation sets, the solution algorithm, artificial viscosity/dissipation, boundary conditions, the uniqueness of solutions, grid resolution, turbulence modeling, and Reynolds number effects. It is concluded that, although improvements in theory are being made more quickly than in experiments, wind tunnel research has the advantage of the more realistic transition process of a right turbulence model in a free-transition test.

Bobbitt, Percy J.↗

NASA NTRS1989

Instrumentation advances for transonic testing

New and improved instrumentation, like new and improved wind tunnels, provide capabilities which stimulate innovative research and discovery. During the past few years there have been a number of instrumentation developments which have aided and abetted the acquisition of more accurate aerodynamic data and have led to new physical insights as well. Some of these advances are reviewed, particularly in the area of thin film gages, hot wire anemometry, and laser instrumentation. A description is given of the instruments and/or techniques and some sample results are shown.

Bobbitt, Percy J.↗

NASA NTRS1992

Some aspects of unsteady separation

Unsteady separation can be forced in a variety of ways and in this presentation two fundamental means will be considered: (1) the introduction of convected vorticular disturbances into the flow; and (2) the influence of a specific type of three-dimensional geometry. In both situations a response of the viscous flow near the wall is provoked wherein the fluid near the surface abruptly focuses into a narrow region that erupts from the surface into the mainstream. In two-dimensional flows, the eruption takes the form of a narrow, explosively-growing spike, while in three-dimensional situations, examples are presented which indicate that the eruption is along a narrow zone in the shape of a crescent-shaped plume. The nature of the three-dimensional flow near a circular cylinder, which is mounted normal to a flat plate, is also examined in this study. Here the three-dimensional geometry induces complex three-dimensional separations periodically. The dynamics of the generation process is studied experimentally in a water channel using hydrogen bubble wires and a laser sheet, and the main features of the laminar regime through to transition are documented.

Smith, C. R.↗

NASA NTRS1997

Health Monitoring of Composite Material Structures using a Vibrometry Technique

Large composite material structures such as aircraft and Reusable Launch Vehicles (RLVS) operate in severe environments comprised of vehicle dynamic loads, aerodynamic loads, engine vibration, foreign object impact, lightning strikes, corrosion, and moisture absorption. These structures are susceptible to damage such as delamination, fiber breaking/pullout, matrix cracking, and hygrothermal strain. To ensure human safety and load-bearing integrity, these structures must be inspected to detect and locate often invisible damage and faults before becoming catastrophic. Moreover, nearly all future structures will need some type of in-service inspection technique to increase their useful life and reduce maintenance and overall costs. Possible techniques for monitoring the health and indicating damage on composite structures include: c-scan, thermography, acoustic emissions using piezoceramic actuators or fiber-optic wires with gratings, laser ultrasound, shearography, holography, x-ray, and others. These techniques have limitations in detecting damage that is beneath the surface of the structure, far away from a sensor location, or during operation of the vehicle. The objective of this project is to develop a more global method for damage detection that is based on structural dynamics principles, and can inspect for damage when the structure is subjected to vibratory loads to expose faults that may not be evident by static inspection. A Transmittance Function Monitoring (TFM) method is being developed in this project for ground-based inspection and operational health monitoring of large composite structures as a RLV. A comparison of the features of existing health monitoring approaches and the proposed TFM method is given.

Schulz, Mark J.↗

NASA NTRSDate not supplied

A Comparison of Microstructure and Mechanical Performance of Inconel 718 Manufactured via L-PBF, LP-DED, and WAAM Technologies

The microstructure and mechanical properties of additively manufactured (AM) alloys can be significantly affected by variations in cooling rates, resulting from different process conditions across different additive manufacturing (AM) platforms. Therefore, it is crucial to understand the effect of manufacturing process on the microstructure and mechanical properties of AM Inconel 718. This study examines three AM processes: laser powder bed fusion, laser powder directed energy deposition, and wire arc additive manufacturing. Results show that fully heat treated laser powder bed fused (L-PBF) and wire arc additively manufactured (WAAM) Inconel 718 specimens exhibit higher strength compared to laser powder directed energy deposited (LP-DED) ones due to finer grain structure in L-PBF and retained dendritic microstructure in WAAM. The ductility in LP-DED Inconel 718 was slightly higher compared to WAAM and L-PBF due to relatively small carbide size, which causes stress concentration in a small material volume, leading to delayed fracture.

Additive manufacturing (AM)↗

NASA NTRS1989

Accuracy Of Hot-Wire Anemometry In Supersonic Turbulence

Sensitivity of hot-wire probe compared to laser-induced-florescence measurements. Report discusses factors affecting readings of hot-wire anemometer in turbulent supersonic boundary layer. Presents theoretical analysis of responses of hot-wire probe to changes in flow; also compares measurements by hot-wire probe with measurements of same flows by laser-induced fluorescence (LIF). Because LIF provides spatially and temporally resolved data on temperature, density, and pressure, provides independent means to determine responses of hot-wire anemometers to these quantities.

Logan, Pamela↗

NASA NTRS1985

Fast laser-induced aerosol formation for visualization of gas flows

A technique for aerosol seeding of gas flows by laser-induced particle formation is demonstrated using a pulsed Nd:YAG laser (1.06 microns) for optical breakdown of a mixture of SF6 and H2 in an inert carrier gas. It is noted that, contrary to the smoke-wire approach, the laser-induced particles form first in zones of high turbulence, since mixing enhances coagulation. The method also allows seeding to be performed in locations hardly accessible otherwise and is mechanically nonintrusive. Finally, a study of the mixture and the breakdown effects indicates that for H2:SF6 ratios between 3:1 and 15:1 the particle formation is only limited by the physics of the gas/particle conversion.

Hassa, C.↗

NASA NTRS1980

Cycle II.5 aircraft aero-optical turbulent boundary-layer/shear-layer measurements

The aero-optical effects associated with propagating a laser beam through aircraft turbulent boundary layers and shear layers were examined. Observed laser optical performance levels were compared with those inferred from aerodynamic measurements of unsteady densities and correlation lengths within these random flows. Optical instrumentation included a fast shearing interferometer (FSI). A 9 cm diameter collimated helium neon laser beam made a double pass through the aircraft random flow via an airfoil mirror located one meter from the fuselage. Typical aircraft turbulent boundary layer thickness measured 0.3 meters. Averaging many FSI generated modulation transfer functions (MTFs) and Fourier transforming, this average yields the expected far field intensity degradation associated with an aircraft mounted laser system. Aerodynamic instrumentation included fine wire probes to measure unsteady temperature and mass flux. A laser doppler velocimeter measured unsteady velocity within the flows. An analysis of these data yielded point measurements of unsteady density and correlation length.

Gilbert, K.↗