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An Analysis of the Internal Truth Files for a CAST 4000 GPS Simulator for Two Rocket Launches and One Weather Balloon Flight

The CAST GPS 4000 simulator can create scenarios using external trajectories. The following information must be provided: time from a given epoch (a constant sampling rate must be used); position, velocity and acceleration in Earth Centered Earth Fixed (ECEF) coordinates; elements of the matrix that transforms from the body-axis coordinate system to the ECEF frame; and the angular velocity of the body-axis system relative to ECEF coordinates. The initial latitude, longitude, altitude, and UTC time must also be provided during the scenario setup. The simulator recomputes the positions and velocities using the given accelerations and a constant jerk model. The results are the internal "truth file".

Simpson, James C.↗

Global MHD Simulations of Space Plasma Environments: Heliosphere, Comets, Magnetospheres of Plants and Satellites

Magnetohydrodynamics (MHD) provides an approximate description of a great variety of processes in space physics. Accurate numerical solutions of the MHD equations are still a challenge, but in the past decade a number of robust methods have appeared. Once these techniques made the direct solution of MHD equations feasible, a number of global three-dimensional models were designed and applied to many space physics objects. The range of these objects is truly astonishing, including active galactic nuclei, the heliosphere, the solar corona, and the solar wind interaction with planets, satellites, and comets. Outside the realm of space physics, MHD theory has been applied to such diverse problems as laboratory plasmas and electromagnetic casting of liquid metals. In this paper we present a broad spectrum of models of different phenomena in space science developed in the recent years at the University of Michigan. Although the physical systems addressed by these models are different, they all use the MHD equations as a unifying basis.

Kabin, K.↗

A Model-Based Prognostics Approach Applied to Pneumatic Valves

Within the area of systems health management, the task of prognostics centers on predicting when components will fail. Model-based prognostics exploits domain knowledge of the system, its components, and how they fail by casting the underlying physical phenomena in a physics-based model that is derived from first principles. Uncertainty cannot be avoided in prediction, therefore, algorithms are employed that help in managing these uncertainties. The particle filtering algorithm has become a popular choice for model-based prognostics due to its wide applicability, ease of implementation, and support for uncertainty management. We develop a general model-based prognostics methodology within a robust probabilistic framework using particle filters. As a case study, we consider a pneumatic valve from the Space Shuttle cryogenic refueling system. We develop a detailed physics-based model of the pneumatic valve, and perform comprehensive simulation experiments to illustrate our prognostics approach and evaluate its effectiveness and robustness. The approach is demonstrated using historical pneumatic valve data from the refueling system.

Daigle, Matthew J.↗

Developments in convective heat transfer models featuring seamless and selected detail surfaces, employing electroless plating

Several model/instrument concepts employing electroless metallic skin were considered for improvement of surface condition, accuracy, and cost of contoured-geometry convective heat transfer models. A plated semi-infinite slab approach was chosen for development and evaluation in a hypersonic wind tunnel. The plated slab model consists of an epoxy casting containing fine constantan wires accurately placed at specified surface locations. An electroless alloy was deposited on the plastic surface that provides a hard, uniformly thick, seamless skin. The chosen alloy forms a high-output thermocouple junction with each exposed constantan wire, providing means of determining heat transfer during tunnel testing of the model. A selective electroless plating procedure was used to deposit scaled heatshield tiles on the lower surface of a 0.0175-scale shuttle orbiter model. Twenty-five percent of the tiles were randomly selected and plated to a height of 0.001-inch. The purpose was to assess the heating effects of surface roughness simulating misalignment of tiles that may occur during manufacture of the spacecraft.

Stalmach, C. J., Jr.↗

Reflectance Modeling

The main thrust of the work conducted is in the modeling of spectral responses of discontinuous conifer forest canopies, considered as collections of conical forms that are illuminated at an angle and cast shadows on contracting background. The three first-year objectives are: (1) modification of the variance-driven model to incorporate overlapping of shadows and crowns; (2) collection and analysis of photographic data to calibrate tree-spacing functions; and (3) collection of field data to determine height, spacing, and shape of conifers in open and closed stands in the Goosenest (California) test area. Modification of the invertible model uses a linear approximation to correct for the reduction in shadow and canopy area that occurs when shadows fall on crowns or tree crowns intersect. Comparison of the results of the approximation with a series of Monte Carlo simulations shows that the mean area covered by crowns or shadows is approximated quite accurately, but the variance calculated departs significantly from simulated values. The analysis of tree spacing patterns using air photos showed that spacing tended to be somewhat regular at a scale approximately equal to the average distance between trees, but at larger distance scales counts of trees in cells could be approximated acceptably by a Poisson (random) function.

Strahler, A. H.↗

Fluid mechanics of directional solidification at reduced gravity

The primary objective of the proposed research is to provide additional groundbased support for the flight experiment 'Casting and Solidification Technology' (CAST). This experiment is to be performed in the International Microgravity Laboratory-1 (IML-1) scheduled to be flown on a space shuttle mission scheduled for 1992. In particular, we will provide data on the convective motion and freckle formation during directional solidification of NH4Cl from its aqueous solution at simulated parameter ranges equivalent to reducing the gravity from the sea-level value down to 0.1 g or lower. The secondary objectives of the proposed research are to examine the stability phenomena associated with the onset of freckles and the mechanisms for their subsequent growth and decline (to eventual demise of some) by state-of-the-art imaging techniques and to formulate mathematical models for the prediction of the observed phenomena.

Chen, C. F.↗

Effect of High-Fidelity Ice Accretion Simulations on the Performance of a Full-Scale Airfoil Model

The simulation of ice accretion on a wing or other surface is often required for aerodynamic evaluation, particularly at small scale or low-Reynolds number. While there are commonly accepted practices for ice simulation, there are no established and validated guidelines. The purpose of this article is to report the results of an experimental study establishing a high-fidelity, full-scale, iced-airfoil aerodynamic performance database. This research was conducted as a part of a larger program with the goal of developing subscale aerodynamic simulation methods for iced airfoils. Airfoil performance testing was carried out at the ONERA F1 pressurized wind tunnel using a 72-in. (1828.8-mm) chord NACA 23012 airfoil over a Reynolds number range of 4.5x10(exp 6) to 16.0 10(exp 6) and a Mach number range of 0.10 to 0.28. The high-fidelity, ice-casting simulations had a significant impact on the aerodynamic performance. A spanwise-ridge ice shape resulted in a maximum lift coefficient of 0.56 compared to the clean value of 1.85 at Re = 15.9x10(exp 6) and M = 0.20. Two roughness and streamwise shapes yielded maximum lift values in the range of 1.09 to 1.28, which was a relatively small variation compared to the differences in the ice geometry. The stalling characteristics of the two roughness and one streamwise ice simulation maintained the abrupt leading-edge stall type of the clean NACA 23012 airfoil, despite the significant decrease in maximum lift. Changes in Reynolds and Mach number over the large range tested had little effect on the iced-airfoil performance.

Broeren, Andy P.↗

A Tabletop Tool for Modeling Life Support Systems

This paper describes the development plan for a comprehensive research and diagnostic tool for aspects of advanced life support systems in space-based laboratories. Specifically it aims to build a high fidelity tabletop model that can be used for the purpose of risk mitigation, failure mode analysis, contamination tracking, and testing reliability. We envision a comprehensive approach involving experimental work coupled with numerical simulation to develop this diagnostic tool. It envisions a 10% scale transparent model of a space platform such as the International Space Station that operates with water or a specific matched index of refraction liquid as the working fluid. This allows the scaling of a 10 ft x 10 ft x 10 ft room with air flow to 1 ft x 1 ft x 1 ft tabletop model with water/liquid flow. Dynamic similitude for this length scale dictates model velocities to be 67% of full-scale and thereby the time scale of the model to represent 15% of the full- scale system; meaning identical processes in the model are completed in 15% of the full- scale time. The use of an index matching fluid (fluid that matches the refractive index of cast acrylic, the model material) allows making the entire model (with complex internal geometry) transparent and hence conducive to non-intrusive optical diagnostics. So using such a system one can test environment control parameters such as core flows (axial flows), cross flows (from registers and diffusers), potential problem areas such as flow short circuits, inadequate oxygen content, build up of other gases beyond desirable levels, test mixing processes within the system at local nodes or compartments and assess the overall system performance. The system allows quantitative measurements of contaminants introduced in the system and allows testing and optimizing the tracking process and removal of contaminants. The envisaged system will be modular and hence flexible for quick configuration change and subsequent testing. The data and inferences from the tests will allow for improvements in the development and design of next generation life support systems and configurations.

Ramachandran, N.↗

Space Laboratory on a Table Top: A Next Generative ECLSS design and diagnostic tool

This paper describes the development plan for a comprehensive research and diagnostic tool for aspects of advanced life support systems in space-based laboratories. Specifically it aims to build a high fidelity tabletop model that can be used for the purpose of risk mitigation, failure mode analysis, contamination tracking, and testing reliability. We envision a comprehensive approach involving experimental work coupled with numerical simulation to develop this diagnostic tool. It envisions a 10% scale transparent model of a space platform such as the International Space Station that operates with water or a specific matched index of refraction liquid as the working fluid. This allows the scaling of a 10 ft x 10 ft x 10 ft room with air flow to 1 ft x 1 ft x 1 ft tabletop model with water/liquid flow. Dynamic similitude for this length scale dictates model velocities to be 67% of full-scale and thereby the time scale of the model to represent 15% of the full- scale system; meaning identical processes in the model are completed in 15% of the full- scale-time. The use of an index matching fluid (fluid that matches the refractive index of cast acrylic, the model material) allows making the entire model (with complex internal geometry) transparent and hence conducive to non-intrusive optical diagnostics. So using such a system one can test environment control parameters such as core flows (axial flows), cross flows (from registers and diffusers), potential problem areas such as flow short circuits, inadequate oxygen content, build up of other gases beyond desirable levels, test mixing processes within the system at local nodes or compartments and assess the overall system performance. The system allows quantitative measurements of contaminants introduced in the system and allows testing and optimizing the tracking process and removal of contaminants. The envisaged system will be modular and hence flexible for quick configuration change and subsequent testing. The data and inferences from the tests will allow for improvements in the development and design of next generation life support systems and configurations. Preliminary experimental and modeling work in this area will be presented. This involves testing of a single inlet-exit model with detailed 3-D flow visualization and quantitative diagnostics and computational modeling of the system.

Ramachandran, N.↗

Decadal Prediction Skill in the GEOS-5 Forecast System

A suite of decadal predictions has been conducted with the NASA Global Modeling and Assimilation Office's (GMAO's) GEOS-5 Atmosphere-Ocean general circulation model. The hind casts are initialized every December 1st from 1959 to 2010, following the CMIP5 experimental protocol for decadal predictions. The initial conditions are from a multivariate ensemble optimal interpolation ocean and sea-ice reanalysis, and from GMAO's atmospheric reanalysis, the modern-era retrospective analysis for research and applications. The mean forecast skill of a three-member-ensemble is compared to that of an experiment without initialization but also forced with observed greenhouse gases. The results show that initialization increases the forecast skill of North Atlantic sea surface temperature compared to the uninitialized runs, with the increase in skill maintained for almost a decade over the subtropical and mid-latitude Atlantic. On the other hand, the initialization reduces the skill in predicting the warming trend over some regions outside the Atlantic. The annual-mean Atlantic meridional overturning circulation index, which is defined here as the maximum of the zonally-integrated overturning stream function at mid-latitude, is predictable up to a 4-year lead time, consistent with the predictable signal in upper ocean heat content over the North Atlantic. While the 6- to 9-year forecast skill measured by mean squared skill score shows 50 percent improvement in the upper ocean heat content over the subtropical and mid-latitude Atlantic, prediction skill is relatively low in the sub-polar gyre. This low skill is due in part to features in the spatial pattern of the dominant simulated decadal mode in upper ocean heat content over this region that differ from observations. An analysis of the large-scale temperature budget shows that this is the result of a model bias, implying that realistic simulation of the climatological fields is crucial for skillful decadal forecasts.

Decadal Prediction↗

Rock Abrasion and Ventifact Formation on Mars from Field Analog, Theoretical, and Experimental Studies

Rocks observed by the Viking Landers and Pathfinder Lander/Sojourner rover exhibit a suite of perplexing rock textures. Among these are pits, spongy textures, penetrative flutes, lineaments, crusts, and knobs Fluvial, impact, chemical alteration, and aeolian mechanisms have been proposed for many of these. In an effort to better understand the origin and characteristics of Martian rock textures, abraded rocks in the Mojave Desert and other regions have been studied. We find that most Martian rock textures, as opposed to just a few, bear close resemblance to terrestrial aeolian textures and can most easily be explained by wind, not other, processes. Flutes, grooves, and some pits on Mars are consistent with abrasion by saltating particles, as described previously. However, many other rock textures probably also have an aeolian origin. Sills at the base of rocks that generally lie at high elevations, such as Half Dome, are consistent with such features on Earth that are related to moats or soil ramps that shield the basal part of the rock from erosion. Crusts consisting of fluted fabrics, such as those on Stimpy and Chimp, are similar to fluted crusts on Earth that spall off over time. Knobby and lineated rocks are similar to terrestrial examples of heterogeneous rocks that differentially erode. The location of specific rock textures on Mars also gives insight into their origin. Many of the most diagnostic ventifacts found at the Pathfinder site are located on rocks that lie near the crests or the upper slopes of ridges. On Earth, the most active ventifact formation occurs on sloped or elevated topography, where windflow is accelerated and particle kinetic energy and flux are increased. Integrated 0 together, these observations point to significant aeolian 0 modification of rocks on Mars and cast doubt on whether many primary textures resulting from other processes are preserved. Experimental simulations of abrasion in the presence of abundant sand indicate that rocks on Mars should erode at a rate of 7.7 to 210 micrometers/yr. These rates cannot have operated over the entire history of the Pathfinder site or elsewhere on Mars, because craters, knobs, and other obstacles would be quickly worn away. More likely, rock abrasion occurs over short time periods when sand supplies are sufficient and saltation friction speeds are frequently reached. Depletion or exhaustion of sand and a decline in wind fluxes at speeds greater than that of saltation friction will then act to reduce the rate of further abrasion. We are currently engaged in a new set of wind tunnel experiments coupled with theoretical models and field studies that address rock abrasion and ventifact formation on Mars and Earth. These studies have implications for the Noachian, when sand supplies were probably more plentiful and the threshold friction speed was possibly lower because of a more dense atmosphere. Under these conditions, erosion rates from the wind could have been much greater than to day, contributing, along with probable fluvial erosion, to the Noachian landscape that is in limited preservation today.

Bridges, N. T.↗

Space Resources Roundtable 2

Contents include following: Developing Technologies for Space Resource Utilization - Concept for a Planetary Engineering Research Institute. Results of a Conceptual Systems Analysis of Systems for 200 m Deep Sampling of the Martian Subsurface. The Role of Near-Earth Asteroids in Long-Term Platinum Supply. Core Drilling for Extra-Terrestrial Mining. Recommendations by the "LSP and Manufacturing" Group to the NSF-NASA Workshop on Autonomous Construction and Manufacturing for Space Electrical Power Systems. Plasma Processing of Lunar and Planetary Materials. Percussive Force Magnitude in Permafrost. Summary of the Issues Regarding the Martian Subsurface Explorer. A Costing Strategy for Manufacturing in Orbit Using Extraterrestrial Resources. Mine Planning for Asteroid Orebodies. Organic-based Dissolution of Silicates: A New Approach to Element Extraction from LunarRegohth. Historic Frontier Processes Active in Future Space-based Mineral Extraction. The Near-Earth Space Surveillance (NIESS) Mission: Discovery, Tracking, and Characterization of Asteroids, Comets, and Artificial Satellites with a microsatellite. Privatized Space Resource Property Ownership. The Fabrication of Silicon Solar Cells on the Moon Using In-Situ Resources. A New Strategy for Exploration Technology Development: The Human Exploration and Development of Space (HEDS) Exploratiori/Commercialization Technology Initiative. Space Resources for Space Tourism. Recovery of Volatiles from the Moon and Associated Issues. Preliminary Analysis of a Small Robot for Martian Regolith Excavation. The Registration of Space-based Property. Continuous Processing with Mars Gases. Drilling and Logging in Space; An Oil-Well Perspective. LORPEX for Power Surges: Drilling, Rock Crushing. An End-To-End Near-Earth Asteroid Resource Exploitation Plan. An Engineering and Cost Model for Human Space Settlement Architectures: Focus on Space Hotels and Moon/Mars Exploration. The Development and Realization of a Silicon-60-based Economy in CisLunar Space. Our Lunar Destiny: Creating a Lunar Economy. Cost-Effective Approaches to Lunar Passenger Transportation. Lunar Mineral Resources: Extraction and Application. Space Resources Development - The Link Between Human Exploration and the Long-term Commercialization of Space. Toward a More Comprehensive Evaluation of Space Information. Development of Metal Casting Molds by Sol-Gel Technology Using Planetary Resources. A New Concept in Planetary Exploration: ISRU with Power Bursts. Bold Space Ventures Require Fervent Public Support. Hot-pressed Iron from Lunar Soil. The Lunar Dust Problem: A Possible Remedy. Considerations on Use of Lunar Regolith in Lunar Constructions. Experimental Study on Water Production by Hydrogen Reduction of Lunar Soil Simulant in a Fixed Bed Reactor.

Ignatiev, A.↗

Ablative Rocket Deflector Testing and Computational Modeling

A deflector risk mitigation program was recently conducted at the NASA Stennis Space Center. The primary objective was to develop a database that characterizes the behavior of industry-grade refractory materials subjected to rocket plume impingement conditions commonly experienced on static test stands. The program consisted of short and long duration engine tests where the supersonic exhaust flow from the engine impinged on an ablative panel. Quasi time-dependent erosion depths and patterns generated by the plume impingement were recorded for a variety of different ablative materials. The erosion behavior was found to be highly dependent on the material s composition and corresponding thermal properties. For example, in the case of the HP CAST 93Z ablative material, the erosion rate actually decreased under continued thermal heating conditions due to the formation of a low thermal conductivity "crystallization" layer. The "crystallization" layer produced near the surface of the material provided an effective insulation from the hot rocket exhaust plume. To gain further insight into the complex interaction of the plume with the ablative deflector, computational fluid dynamic modeling was performed in parallel to the ablative panel testing. The results from the current study demonstrated that locally high heating occurred due to shock reflections. These localized regions of shock-induced heat flux resulted in non-uniform erosion of the ablative panels. In turn, it was observed that the non-uniform erosion exacerbated the localized shock heating causing eventual plume separation and reversed flow for long duration tests under certain conditions. Overall, the flow simulations compared very well with the available experimental data obtained during this project.

Allgood, Daniel C.↗

Large-Eddy Simulation of Conductive Flows at Low Magnetic Reynolds Number

In this paper we study the LES method with dynamic procedure in the context of conductive flows subject to an applied external magnetic field at low magnetic Reynolds number R(sub m). These kind of flows are encountered in many industrial applications. For example, in the steel industry, applied magnetic fields can be used to damp turbulence in the casting process. In nuclear fusion devices (Tokamaks), liquid-lithium flows are used as coolant blankets and interact with the surrounding magnetic field that drives and confines the fusion plasma. Also, in experimental facilities investigating the dynamo effect, the flow consists of liquid-sodium for which the Prandtl number and, as a consequence, the magnetic Reynolds number is low. Our attention is focused here on the case of homogeneous (initially isotropic) decaying turbulence. The numerical simulations performed mimic the thought experiment described in Moffatt in which an initially homogeneous isotropic conductive flow is suddenly subjected to an applied magnetic field and freely decays without any forcing. Note that this flow was first studied numerically by Schumann. It is well known that in that case, extra damping of turbulence occurs due to the Joule effect and that the flow tends to become progressively independent of the coordinate along the direction of the magnetic field. Our comparison of filtered direct numerical simulation (DNS) predictions and LES predictions show that the dynamic Smagorinsky model enables one to capture successfully the flow with LES, and that it automatically incorporates the effect of the magnetic field on the turbulence. Our paper is organized as follows. In the next section we summarize the LES approach in the case of MHD turbulence at low R(sub m) and recall the definition of the dynamic Smagorinsky model. In Sec. 3 we describe the parameters of the numerical experiments performed and the code used. Section 4 is devoted to the comparison of filtered DNS results and LES results. Conclusions are presented in Sec. 5.

Knaepen, B.↗

Comments on "Atlantic Tropical Cyclogenetic Processes during SOP-3 NAMMA in the GEOS-5 Global Data Assimilation and Forecast System"

Considerable attention has been given to the potential negative impacts of the Saharan air layer (SAL) in recent years. Researchers recently raised questions about the negative impacts of Dunion and Velden and other studies in terms of storms that reached at least tropical storm strength and suggested that the SAL was an intrinsic part of the tropical cyclone environment for both storms that weaken after formation and those that intensify. Braun also suggested that several incorrect assumptions underlie many of the studies on the negative impacts of the SAL, including assumptions that most low-to-midlevel dry tropical air is SAL air, that the SAL is dry throughout its depth, and that the proximity of the SAL to storms struggling to intensify implies some role in that struggle. The recent paper by Reale et al.(RL1) is an example of the problems inherent in some of these assumptions. In their paper, RL1 analyze a simulation from the Global Earth Observing System (GEOS-5) global model and describe an extensive tongue of warm, dry air that stretches southward from at least 30 deg N (the northern limit of their plots) and wraps into a low pressure system during the period 26-29 August 2006, suppressing convection and possibly development of the African easterly wave associated with that low pressure system. They attributed the warm, dry tongue to the SAL (i.e., heating of the air mass during passage over the Sahara and radiative warming of the dust layer). Whether it was their intention, the implication is that this entire feature is due solely to the SAL and not to other possible sources of dry air or warmth. In addition, they suggested that a cool tongue of air in the boundary layer located directly beneath the elevated warm, dry tongue (forming a thermal dipole) was possibly the result of reduced solar radiation caused by an overlying dust layer. They stated that "the cool anomaly in the lower levels does not have any plausible explanation relying only on transport." In this comment, evidence from satellite and global meteorological analyses is presented that casts considerable doubt upon RL1 s interpretation of the GEOS-5 forecasts and their conclusion that the results implied a negative role of the SAL. We show that the major portion of the warm, dry air aloft was located in a nearly dust-free slot between two Saharan dust outbreaks, had a significant source from the midlatitudes (>30 N), and was likely driven by strong subsidence warming and drying. In addition, when wind fields are examined in a reference frame moving with the wave, National Centers for Environmental Prediction (NCEP) global meteorological analyses suggest that the cool tongue in the boundary layer can be readily explained by transport of cooler air from higher latitudes. At the very least, it offers a plausible alternative explanation for the cool tongue that does not rely on radiative impacts of the dust.

Braun, Scott A.↗

Demonstration of a Real Time Capability to Produce Tidal Heights and Currents for Naval Operational Use: A Cast Study for the West Coast of Africa (Liberia)

This report documents an existing capability to produce operationally relevant products on sea level and currents from a tides/storm surge model for any coastal region around the world within 48 hours from the time of the request. The model is ready for transition to the Naval Oceanographic Office (NAVOCEANO) for potential contingency use anywhere around the world. A recent application to naval operations offshore Liberia illustrates this. Mississippi State University, in collaboration with the University of Colorado and NAVOCEANO, successfully deployed the Colorado University Rapidly Relocatable Nestable Tides and Storm Surge (CURReNTSS) model that predicts sea surface height, tidal currents and storm surge, and provided operational products on tidal sea level and currents in the littoral region off south-western coast of Africa. This report summarizes the results of this collaborative effort in an actual contingency use of the relocatable model, summarizes the lessons learned, and provides recommendations for further evaluation and transition of this modeling capability to operational use.

CASE STUDIES↗

Development of a New Membrane Casting Apparatus for Studying Macrovoid Defects in Low-G

A new membrane-casting apparatus is developed for studying macrovoid defects in polymeric membranes made by the wet- and dry-casting process in low-gravity. Macrovoids are large (10-50 micron), open cavities interspersed among the smaller pores in the substructure under the gelled skin surface layer of the cast membrane. Although their occurrence is considered endemic to the wet- and dry-casting process since they can lead to compaction or skin rupture in the membrane process, recent studies suggest several useful applications such as transdermal and osmotic drug delivery systems, miniature bioreactors, etc. However, lack of knowledge about the macrovoid formation mechanism is an obstacle to further development of applications using them. An on-going debate is the role of the surface-tension-driven solutocapillary convection during macrovoid formation. The rapid growth of macrovoids within 1-5 seconds and the high polymer concentration in and near macrovoids make it difficult to explain the mechanism of macrovoid growth by diffusion alone, which is the widely accepted hypothesis proposed by Reuvers et al. The hypothesis advanced by our research group can explain this rapid growth via a mechanism that involves diffusion from the casting solution in the meta-stable region to the macrovoid enhanced by solutocapillary convection induced by the steep nonsolvent concentration gradient in the vicinity of the macrovoid. Since macrovoid growth is hypothesized to be the interplay of a solutocapillary-induced driving force counteracted by viscous drag and buoyancy, eliminate the latter provides a means for testing this hypothesis. Moreover, free convection mass transfer in the nonsolvent immersion bath used to cause phase-separation in membrane casting complicates developing a model for both the wet-casting process and macrovoid growth. The low-g environment minimizes gravitationally induced free convection thereby permitting a tractable solution to the ternary diffusion equations that characterize membrane formation. NASA's Parabolic Flight Research Aircraft provides a small window of low-g (approximately 25 s) that can be used to study macrovoid development in both wet- and dry-cast membranes if an appropriate casting apparatus is used. This casting apparatus should be able to cast the membrane in both low- and high-g in a manner so that essential one-dimensional mass transfer conditions are achieved to insure lateral uniformity in the membrane. The apparatus used in previous research on membrane casting in low-gravity was operated with the plunger driven mechanism. The spring-loaded plunger pushes the bottom block containing the polymer casting solution well directly under the absorbent chamber located in the upper stationary block. However, membranes made via this casting apparatus often displayed lateral nonuniformities that precluded obtaining quantitative information on the macrovoid growth process. Thus, it was necessary to determine the reason for these structural irregularities observed in the low-g casting apparatus. Both experimental as well as computer simulation studies of the low-g casting apparatus established that the impulsive action of the plunger caused the undesired structural nonuniformities. The simulation results showed that the width-to-depth aspect ratio of the shallow well that contains the casting solution in this apparatus was not an important factor in minimizing this problem. Even for a 40:1 (width : depth) aspect ratio, any convection induced by the horizontal motion of the interface of the casting solution will be damped out within 6.25x10(exp 4) seconds. However, the experimental studies revealed that the impulsive motion of the plunger caused a 'sloshing' of the casting solution that had to be eliminated. Therefore, the plungerdriven mechanism was changed to a cam-driven mechanism that did not cause any impulsive motion of the casting solution. Other refinements to this new membrane-casting apparatus include provision for removing the membranes from the casting wells in a less destructive manner. This was accomplished by using a slit geometry for the casting well that permitted disassembly for removal of the cast membrane. The materials used in the construction of this casting apparatus were chosen to insure wetting at the side walls and to maintain precise control of the thickness of the polymer solution in the casting well. An additional provision in this new casting apparatus is the ability to carry out both wet- as well as dry-casting. As such, this apparatus permitted the first studies of the wet-casting of polymeric membranes in low-g. Both wet- and dry-casting experiments on NASA's KC-135 research aircraft employing this new membrane-casting apparatus are scheduled in July 2002. The morphology of the resulting membranes will be characterized using an environmental scanning electron microscope (ESEM). The results of these low-g studies will be reported later.

Lee, Hanyong↗

Ceramic Inclusions in Powder Metallurgy Disk Alloys: Characterization and Modeling

Powder metallurgy alloys are increasingly used in gas turbine engines, especially in turbine disk applications. Although powder metallurgy materials have many advantages over conventionally cast and wrought alloys (higher strength, higher temperature capability, etc.), they suffer from the rare occurrence of ceramic defects (inclusions) that are inherent to the powder atomization process. These inclusions can have a potentially large detrimental effect on the durability of individual components. An inclusion in a high stress location can act as a site for premature crack initiation and thereby considerably reduce the fatigue life. Because these inclusions are exceedingly rare, they typically do not reveal themselves in the process of characterizing the material for a particular application (the cumulative volume of the test bars in a fatigue life characterization is typically on the order of a single actual component). Ceramic inclusions have, however, been found to be the root cause of a number of catastrophic engine failures. To investigate the effect of these inclusions in detail, we have undertaken a study where known populations of ceramic particles, whose composition and morphology are designed to mimic the "natural" inclusions, are added to the precursor powder. Surface-connected inclusions have been found to have a particularly large detrimental effect on fatigue life; therefore, the quantity of ceramic "seeds" added is calculated to ensure that a minimum number will intersect the surface of the fatigue test bars. Because the ceramic inclusions are irregularly shaped and have a tendency to break up in the process of extrusion and forging, a method of calculating the probability of occurrence and expected intercepted surface area was needed. We have developed a Monte Carlo simulation to determine the distributions of these parameters and have verified the simulated results with observations of ceramic inclusions found in macroscopic slices from extrusions and forgings. Fatigue specimens have been machined from Udimet 720 (a powder metallurgy superalloy) forgings, to determine the effects of the inclusions on fatigue life. The ultimate goal of this study will be to use probabilistic methods to determine the reliability detriment that can be attributed to these ceramic inclusions. This work has been supported by the Ultra Safe and Ultra- Efficient Engine Technologies programs.

Bonacuse, Peter J.↗