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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Split-screw grips for tensile testing provide uniform loading on the specimen shoulders. Holes in the heads enable the screws and specimen to be threaded as an assembly into a grip body, closely controlled guides and seats afford positive seating, and precision machining of mating surfaces minimizes misalignment effects.
Precision machining and repair of radioactive Plum Brook Reactor core fuel grid
A container has been developed for handling, testing, burning-in, and storing discrete microelectronic components without removal from the protective package. The package was designed to accommodate the leadless inverted device and other carrier-mounted active devices and chip-type discrete resistors and capacitors. Before the indicated development, components were handled and tested in various ways, some of which resulted in damage or contamination. The basic design of the container utilizes precision machined printed circuit boards and chemically milled (photoetched) contact springs. Included in this design for protection is an O-ring-sealed cover. Methods of fabrication and limitations of the current hardware are presented. Current applications of and possible extensions to the technology are discussed.
Technique employs computer-controlled light-emitting diode (LED), precision machined mask, and analog-to-digital coverter (ADC). Computer turns on LED which floods masked face of tube. Intensity pattern, generated as tube is electromagnetically swept, is fed to ADC which controls tube calibration.
Valve consists of small geared reversible motor, operated by momentary contact closure, which drives shaft with O-rings placed to seal selected ports. Shaft rotates and also moves axially, causing ports to be alternately connected and disconnected. Electrical control of valve is provided by limit switches and relays. Design has advantage over other available valves: less precision machining of parts is required; machining operations are less expensive. Seals are made with O-rings, which are easily replaceable and inexpensive; valve uses less power. It can be used in any application requiring pilot valves for control devices.
The use of computer generated, reflection holograms in conjunction with high power lasers for precision machining of metals and ceramics was investigated. The Reflection holograms which were developed and made to work at both optical wavelength (He-Ne, 6328 A) and infrared (CO2, 10.6) meet the primary practical requirement of ruggedness and are relatively economical and simple to fabricate. The technology is sufficiently advanced now so that reflection holography could indeed be used as a practical manufacturing device in certain applications requiring low power densities. However, the present holograms are energy inefficient and much of the laser power is lost in the zero order spot and higher diffraction orders. Improvements of laser machining over conventional methods are discussed and addition applications are listed. Possible uses in the electronics industry include drilling holes in printed circuit boards making soldered connections, and resistor trimming.
A new sounding rocket payload that has been developed for X-ray spectroscopic studies of the solar corona is described. The instrument incorporates a grazing incidence Rowland mounted grating spectrograph and an extreme off-axis paraboloic sector feed system to isolate regions of the sun of order 1 x 10 arc seconds in size. The focal surface of the spectrograph is shared by photographic and photoelectric detection systems, with the latter serving as a part of the rocket pointing system control loop. Fabrication and alignment of the optical system is based on high precision machining and mechanical metrology techniques. The spectrograph has a resolution of 16 milliangstroms and modifications planned for future flights will improve the resolution to 5 milliangstroms, permitting line widths to be measured.
Instability phenomena in elastic surfaces subject to compressive stresses are examined theoretically in new report. Theory is potentially applicable to such practical problems as aircraft panel flutter, nondestructive testing, piezoelectric transducer design, distortion of optical surfaces, and tolerance studies of very precise machine parts.
Development of a high accuracy spherical microwave reflector to support contour RMS and pointing requirements for a new series of space instruments is reported. The reflector system is composed of precision machined aluminum tile reflectors supported from a eutectic coated graphite epoxy structure by flexures. Several basic technologies have been integrated into a manufacturing process that accommodates fabrication techniques of both optical and composite constraints. The optical figure and its change due to thermal gradient was measured in a thermal vacuum environment with a Ronchi system. The radiometer system is in support of the Microwave Limb Sounder, an experiment to measure emissions from earth's atmospheric limb thus obtaining wind, temperature, pressure and chemical composition measurements.
Reaction control thrustor injector requires precisely machined orifices and slots. Tooling setup consists of rotary table, numerical control system and torque sensitive drill press. Components used to drill oxidizer orifices. Electric discharge machine drills fuel-feed orifices. Device automates production of identical parts so several are completed in less time than previously.
Magnetic properties of metallic reference standards duplicated and stabilized for eddy-current coil measurements over long times. Concept uses precisely machined notched samples of known annealed materials as reference standards.
Carbon extension for dies used in forming silicon ribbon crystals machined precisely with help of special tool. Die extension has edges beveled toward narrow flats at top, with slot precisely oriented and centered between flats and bevels. Cutting tool assembled from standard angle cutter and circular saw or saws. Angle cutters cuts bevels while slot saw cuts slot between them. In alternative version, custom-ground edges or additional circular saws also cut flats simultaneously.
Small subvalves opened and closed simultaneously. Precisely-machined mating rings act as valves. Rings seal against each other to stop fluid flow. Rings deformed or moved relative to each other to uncover holes and permit flow. Valve controls flow rate of fuel into burner.
The experimental portion of a joint government/industry/university research study on the vibrational characteristics of twisted cantilevered plates is presented. The overall purpose of the research study was to assess the capabilities and limitations of existing analytical methods in predicting the vibratory characteristics of twisted plates. Thirty cantilevered plates were precision machined at the Air Force's Aero Propulsion Laboratory. These plates, having five different degrees of twist, two thicknesses, and three aspect ratios representative of turbine engine blade geometries, were tested for their vibration mode shapes and frequencies. The resulting nondimensional frequencies and selected mode shapes are presented as a function of plate tip twist. The trends of the natural frequencies as a function of the governing geometric parameters are discussed. The effect of support compliance on the plate natural frequency and its impact on numerically modeling twisted plates is also presented.
The glow discharge or ion assisted vacuum deposition techniques, primarily sputtering and ion plating, have rapidly emerged and offer great potential to deposit solid lubricants. The increased energizing of these deposition processes lead to improved adherence and coherence, favorable morphological growth, higher density, and reduced residual stresses in the film. These techniques are of invaluable importance where high precision machines tribo-components require very thin, uniform lubricating films (0.2 m), which do not interface with component tolerances. The performance of sputtered MoS2 films and ion plated Au and Pb films are described in terms of film thickness, coefficient of friction, and wear lives.
Tight joints achieved without precisely machined parts. Hinge for foldable structures locked with minimum force by human operator. Once locked, hinge makes strong, tight joint. Loose fit, or joint slop, common to commercial locking hinges eliminated. Despite tight fit, new hinge concept does not impose close tolerances on manufacture of its parts. Developed for erecting unfoldable structures in space, hinge used on collapsible scaffolds and similar terrestrial structures.
Features include ease of fabrication and wide range of operating frequencies. Planar antennas on thick dielectric substrates built for use at millimeter wavelengths from 40 to 400 GHZ. Antennas of this type quasi-optical structures, for which expensive, precisely machined waveguides not required. Made easily by standard photolithography and integrated with planar mixers or detectors to form arrays.
Leakage rates of an innovative hypersonic engine seal were measured using a specially developed static high temperature seal test fixture at NASA Lewis Research Center. The three foot long structural panel-edge seal is designed to minimize leakage of high temperature, high pressure gases past the movable panels of advanced ramjet/scramjet engines. The seal is made of a stack of precision machined ceramic wafer pieces that are inserted into a closely conforming seal channel in the movable engine panel. The wafer seal accommodates the significant distortions in the adjacent engine walls through relative sliding between adjacent wafers. Seal leakage rates are presented for engine simulated air temperatures up to 1350 F and for engine pressures up to 100 psi. Leakage rates are also presented for the seal, sealing both a flat wall condition, and an engine simulated distorted wall condition in which the distortion was 0.15 in. in only an 18 in. span. Seal leakage rates were low, meeting an industry-established tentative leakage limit for all combinations of temperature, pressure, and wall conditions considered. Comparisons are made between the measured leakage rates and leakage rates predicted using a seal leakage model developed from externally-pressurized gas film bearing theory.