Search NASA⌕ Search

SEARCH · Search NASA

Results for “surface assembly”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 91 records · Page 5

Precision machining technology and metrology for AXAF study

The optical surfaces for the Advanced X-ray Astrophysical Facility (AXAF), was studied. The applicability of precision machining technology to the manufacture of the AXAF objective mirrors and the proposed and alternative methods for manufacturing and testing; (1) the AXAF technology mirrors and (2) the AXAF high resolution mirror assembly were reviewed. Surface shape and smoothness metrology for grazing incidence X-ray surfaces and the feasibility of applying heterodyne surface profilometry to nonflat surfaces were investigated. Three sets of scattering flats with known surface profiles and microtopographic character produced by precision machining and polished precision machine surfaces were analyzed.

Sanger, G. M.↗

Processes for fabricating and load testing NASA scatterometer antenna assemblies

The purpose of this paper is to present the processes used to fabricate and load test the NASA Scatterometer Antenna Assemblies. The fabrication processes include layup, curing and machining of antenna components, and the bonding and assembly of the components into the final antenna configuration. The design of each antenna consists of an aluminum waveguide bonded to a sandwich structure of Nomex honeycomb core with graphite/epoxy skins. A titanium end fitting with fiberglass/epoxy transitions is bonded into one end of each antenna. Several antenna components are fabricated using a process where aluminum foil is co-cured to a composite surface. The antenna assemblies are radiographically inspected, thermally cycled, and load tested prior to shipment.

Barth, James R.↗

Nondestructive examination of the Tropical Rainfall Measuring Mission (TRMM) reaction control subsystem (RCS) propellant tanks

This paper assesses the feasibility of using eddy current nondestructive examination to determine flaw sizes in completely assembled hydrazine propellant tanks. The study was performed by the NASA Goddard Space Flight Center for the Tropical Rainfall Measuring Mission (TRMM) project to help determine whether existing propellant tanks could meet the fracture analysis requirements of the current pressure vessel specification, MIL-STD-1522A and, therefore be used on the TRMM spacecraft. After evaluating several nondestructive test methods, eddy current testing was selected as the most promising method for determining flaw sizes on external and internal surfaces of completely assembled tanks. Tests were conducted to confirm the detection capability of the eddy current NDE, procedures were developed to inspect two candidate tanks, and the test support equipment was designed. The non-spherical tank eddy current NDE test program was terminated when the decision was made to procure new tanks for the TRMM propulsion subsystem. The information on the development phase of this test program is presented in this paper as a reference for future investigation on the subject.

Free, James M.↗

Nondestructive examination of the TRMM RCS propellant tanks

This paper assesses the feasibility of using eddy current nondestructive examination of determine flaw sizes in completely assembled hydrazine propellant tanks. The study was performed by the NASA Goddard Space Flight Center for the Tropical Rainfall Measuring Mission (TRMM) project to help determine whether existing propellant tanks could meet the fracture analysis requirements of the current pressure vessel specification, MIL-STD-1522A and, therefore be used on the TRMM spacecraft. After evaluating several nondestructive test methods, eddy current testing was selected as the most promising method for determining flaw sizes on external and internal surfaces of completely assembled tanks. Tests were conducted to confirm the detection capability of the eddy current NDE, procedures were developed to inspect two candidate tanks, and the test support equipment was designed. The non-spherical tank eddy current NDE test program was terminated when the decision was made to procure new tanks for the TRMM propulsion subsystem. The information on the development phase of this test program is presented in this paper as a reference for future investigation on the subject.

Free, James M.↗

UV-Resistant Non-Spore-Forming Bacteria From Spacecraft-Assembly Facilities

Four species of non-spore-forming bacteria collected from clean-room surfaces in spacecraft-assembly facilities could survive doses of ultraviolet (UV) radiation that would suffice to kill most known cultivable bacterial species. In a previous study, high UV resistance was found in spores of the SAFR-032 strain of Bacillus pumilus, as reported in "Ultraviolet- Resistant Bacterial Spores," NASA Tech Briefs, Vol. 31, No. 9 (September 2007), page 94. These studies are parts of a continuing effort to understand the survival of hardy species of bacteria under harsh conditions, and develop means of sterilizing spacecraft to prevent biocontamination of Mars that could in turn interfere with future life detection missions. The four species investigated were Arthrobacter sp. KSC_Ak2i, Microbacterium schleiferi LMA_AkK1, Brevundimonas diminuta KSC_Ak3a, and Sphingomonas trueperi JSC_Ak7-3. In the study, cells of these species were mixed into Atacama Desert soil (to elucidate the shadowing effect of soil particles) and the resulting mixtures were tested both in solution and in a desiccated state under simulated Martian atmospheric and UV conditions. The UV-survival indices of Arthrobacter sp. and Microbacterium schleiferi were found to be comparable to those of Bacillus pumilus spores.

Venkateswaran, Kasthuri↗

Adhesive Joining of Composite Laminates Using Epoxy Resins with Stoichiometric Offset

Polymer matrix composites are used in high performance structures because of their excellent specific strength, toughness and stiffness along the fiber. To realize the full performance advantages of composites, complex, built-up structures must be assembled with adhesive, but uncertainty in bond strength requires manufacturers to install bolts or other crack arrest features to ensure safety in critical applications. The inherent uncertainty in adhesive bonds stems from the material discontinuity at the composite-to-adhesive interfaces, which are susceptible to contamination. In contrast, composites made by co-curing, although limited in size and complexity, result in predictable structures that may be certifiable for commercial aviation with reduced dependence on redundant load paths.1 The pro-posed technology uses a stoichiometric offset of the hardener-to-epoxy ratio on the faying surfaces of laminates. Assembly of the components in a subsequent “secondary-co-cure” process results in a joint with no material discontinuities.

Palmieri, Frank L.↗

Unlocking the Spacecraft and Human Habitat Microbiome to Enable the Next Generation of Space Exploration

Planetary protection is the discipline that prevents harmful contamination of the solar system during exploration activities. The current international guidelines and NASA policy addressing biological contamination on spacecraft surfaces contains prescriptive guidelines of spore requirements (e.g., 300 spores/m2, 5×105 spores per spacecraft) applicable to spacecraft bound for Mars. To verify these requirements spacecraft engineers sample spacecraft surfaces throughout the assembly, test and launch operations phase of the mission using damp water cotton swabs and polyester wipes. After sampling, the potential biological contamination is enumerated using a series of traditional microbiology techniques to include sonication, heat shocking at 80°C for 15min to select for spores, and growth on tryptic soy agar at 32°C for 72 hours. To enable crewed missions to Mars and robotic exploration of the Ocean Worlds a risk informed decision making / performance-based approach to assess biological contamination offers a promising solution in the trade space. Recognizing the need for a performance-based approach, NASA’s new Planetary Protection policies now incorporate the agility for missions to be able to leverage a performance or prescriptive approach. One of top contenders in the option space is a coupled quantitative, descriptive and functional based approach to be able to assess the quantity, types and capabilities of the biological contamination present on spacecraft surfaces. A tailored, mission by mission assurance case could then be formulated by building an argument around the target body, projected capabilities surrounding the types of organisms their potential for survival and proliferation, and ability to be transported on the target body to contaminate an area of biological interest. A performance-based requirement would then be used to demonstrate the mission’s compliance in protecting the planetary environment safety objectives. This symposium talk will showcase the background and need case for NASA to develop such a capability as well as provide an update on the efforts underway in developing a transparent and responsible performance-based approach to biological contamination assessments on spacecraft surfaces.

Habitat Microbiome↗

Thermal Stability of the Dot-in-Well Gain Medium for Photonic Crystal Surface Emitting Lasers

Self-assembled quantum dots (QDs) embedded in InGaAs quantum wells (QWs) are used as active regions for photonic-crystal surface-emitting lasers (PCSELs). An epitaxial regrowth method is developed to fabricate the dot-in-well (DWELL) PCSELs. Here, the epitaxial regrowth starts with the growth of a partial laser structure containing bottom cladding, waveguide, active region, and the photonic crystal (PC) layer. The PC layer is patterned to realize the cavity. Subsequently a top cladding layer is regrown to complete the laser structure. During the regrowth of the top cladding layer, the partial laser structure is subjected to high growth temperatures in excess of 600 °C resulting in an unintentional annealing of the active region. This annealing of the active region can alter the QDs by changing their size resulting in a blue shift in photoluminescence (PL) and narrowing PL emission. This effect results in the misaligning of the gain peak and the cavity resonance, resulting in sub-optimal lasing performance. DWELL active regions are known to have better thermal stability compared to both QDs and QWs and could be an ideal candidate for regrown PCSELs. We successfully demonstrate an optically-pumped epitaxially-regrown DWELL PCSEL with an emission wavelength of 1230 nm operating at room temperature. Furthermore, the DWELL active region shows excellent emission wavelength stability and intensity despite the high temperature regrowth process.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

Synthesis and characterization of low-dimensional N-heterocyclic carbene lattices

The covalent interaction of N-heterocyclic carbenes (NHCs) with transition metal atoms gives rise to distinctive frontier molecular orbitals (FMOs). These emergent electronic states have spurred the widespread adoption of NHC ligands in chemical catalysis and functional materials. Although formation of carbene-metal complexes in self-assembled monolayers on surfaces has been explored, design and electronic structure characterization of extended low-dimensional NHC-metal lattices remains elusive. Here, in this work, we demonstrate a modular approach to engineering one-dimensional (1D) metal-organic chains and two-dimensional (2D) Kagome lattices using the FMOs of NHC–Au–NHC junctions to create low-dimensional molecular networks exhibiting intrinsic metallicity. Scanning tunneling spectroscopy and first-principles density functional theory reveal the contribution of C–Au–C π-bonding states to dispersive bands that imbue 1D- and 2D-NHC lattices with exceptionally small work functions.

Qie, Boyu↗

Effects of service environments on aluminum-brazed titanium (ABTi)

Aluminum brazed titanium (ABTi) structures were evaluated during prolonged exposure to extreme environments: elevated temperature exposure to airline service fluids, hydraulic fluid, and seawater, followed by laboratory corrosion tests. Solid-face and perforated face honeycomb sandwich panel specimens, stressed panel assemblies, and faying surface brazed joints were tested. The corrosion resistance of ABTi is satisfactory for commercial airline service. Unprotected ABTi proved inherently resistant to attack by all of the extreme service aircraft environments except: seawater at 700 K (800 F) and above, dripping phosphate ester hydraulic fluid at 505 K (450 F), and a marine environment at ambient temperature. The natural oxides and deposits present on titanium surfaces in airline service provide protection against hot salt corrosion pitting. Coatings are required to protect titanium dripping phosphate ester fluid at elevated temperatures and to protect exposed acoustic honeycomb parts against corrosion in a marine environment.

Cotton, W. L.↗

Durable Bipolar Plates For Lead/Acid Batteries

New structure for positive faces of bipolar plates increases longevity of lead/acid batteries. Divides positive-electrode layer into many isolated segments so defects cannot spread across layer. Surfaces treated before assembly to promote adhesion. Ridges on body divide possible electrode into isolated squares, each typically 1 in. on side. Materials supporting electrochemically active components lightweight and resistant to acid.

Clough, Thomas J.↗

Low cost tooling material and process for graphite and Kevlar composites

An Extruded Sheet Tooling Compound (ESTC) was developed for use in quickly building low cost molds for fabricating composites. The ESTC is a very highly mineral-filled resin system formed into a 6 mm thick sheet. The sheet is laid on the pattern, vacuum (bag) is applied to remove air from the pattern surface, and the assembly is heat cured. The formed ESTC is then backed and/or framed and ready for use. The cured ESTC exhibits low coefficient of thermal expansion and maintains strength at temperatures of 180 to 200 C. Tools were made and used successfully for: Compression molding of high strength epoxy sheet molding compound, stamping of aluminum, resin transfer molding of polyester, and liquid resin molding of polyester. Several variations of ESTC can be made for specific requirements. Higher thermal conductivity can be achieved by using an aluminum particle filler. Room temperature gel is possible to allow use of foam patterns.

Childs, William I.↗

The influence of lunar propellant production on the cost-effectiveness of cislunar transportation systems

It is well known that propellants produced at the points of destination such as the Moon or Mars will help the economy of space transportation, particularly if round trips with a crew are involved. The construction and operation of a lunar base shortly after the turn of the century is one of the space programs under serious consideration at the present time. Space transportation is one of the major cost drivers. With present technology, if expendable launchers were employed, the specific transportation costs of one-way cargo flights would be approximately 10,000 dollars/kg (1985) at life-cycle cumulative 100,000 ton payload to the lunar surface. A fully reusable space transportation system using lunar oxygen and Earth-produced liquid hydrogen (LH2) would reduce the specific transportation costs by one order of magnitude to less than 1000 dollars/kg at the same payload volume. Another case of primary interest is the delivery of construction material and consumables from the lunar surface to the assembly site of space solar power plants in geostationary orbit (GEO). If such a system were technically and economically feasible, a cumulative payload of about 1 million tons or more would be required. At this level a space freighter system could deliver this material from Earth for about 300 dollars/kg (1985) to GEO. A lunar space transportation system using lunar oxygen and a fuel mixture of 50 percent Al and 50 percent LH2 (that has to come from Earth) could reduce the specific transportation costs to less than half, approximately 150 dollars/kg. If only lunar oxygen were available, these costs would come down to 200 dollars/kg. This analysis indicates a sizable reduction of the transportation burden on this type of mission. It should not be overlooked, however, that there are several uncertainties in such calculations. It is quite difficult at this point to calculate the cost of lunar-produced O and/or Al. This will be a function of production rate and life-cycle length. In quoting any cost of this nature, it is very important to state the cumulative transportation volume, since this is a very sensitive parameter. Nevertheless, cost models must be developed now to understand fully the interdependencies of a large number of parameters and to provide the best possible data for planning purposes. Without such data, mission modes and vehicle designs or sizes cannot be selected intelligently.

Koelle, H. H.↗

Hollow Retroreflectors Offer Solid Benefits

A technician who lead a successful team of scientists, engineers, and other technicians in the design, fabrication, and characterization of cryogenic retroreflectors for the NASA Cassini/Composite Infrared Spectrometer (CIRS) mission to Saturn, developed a hollow retroreflector technology while working at NASA Goddard Space Flight Center. With 16 years of NASA experience, the technician teamed up with another NASA colleague and formed PROSystems, Inc., of Sharpsburg, Maryland, to provide the optics community with an alternative source for precision hollow retroreflectors. The company's hollow retroreflectors are front surface glass substrates assembled to provide many advantages over existing hollow retroreflectors and solid glass retroreflectors. Previous to this new technology, some companies chose not to use hollow retroreflectors due to large seam widths and loss of signal. The "tongue and groove" facet design of PROSystems's retroreflector allows for an extremely small seam width of .001 inches. Feedback from users is very positive regarding this characteristic. Most of PROSystems's primary customers mount the hollow retroreflectors in chrome steel balls for laser tracker targets in applications such as automobile manufacturing and spacecraft assembly.

Source record↗

Comparison of full-aperture interferometry to sub-aperture stitched interferometry for a large diameter fast mirror

The Herschel Space Observatory (formerly known as FIRST) consists of a 3.5 m space telescope. Stitching sub aperture interferograms may offer considerable cost savings during testing of the flight telescope as compared to other techniques. A comparative demonstration is presented of interferogram stitching techniques that enable a composite map of a 3-D surface to be assembled from a sequence of sub-aperture measurements. This paper describes the fundamental procedures for stitching together component data sets and demonstrates such techniques with real data sets.

carbon fiber composite cryogenic optics high slope↗

IR DirectFET Extreme Environments Evaluation Final Report

In 2007, International Rectifier (IR) introduced a new version of its DirectFET metal oxide semiconductor field effect transistor (MOSFET) packaging. The new version (referred to as 'Version 2') enhances device moisture resistance, makes surface mount (SMT) assembly of these devices to printed wiring boards (PWBs) more repeatable, and subsequent assembly inspection simpler. In the present study, the National Aeronautics Space Administration (NASA) Jet Propulsion Laboratory (JPL), in collaboration with Stellar Microelectronics (Stellar), continued an evaluation of the DirectFET that they started together in 2006. The present study focused on comparing the two versions of the DirectFET and examining the suitability of the DirectFET devices for space applications. This study evaluated both versions of two DirectFET packaged devices that had both been shown in the 2006 study to have the best electrical and thermal properties: the IRF6635 and IRF6644. The present study evaluated (1) the relative electrical and thermal performance of both versions of each device, (2) the performance through high reliability testing, and (3) the performance of these devices in combination with a range of alternate solder alloys in the extreme thermal environments of deep space....

electronic parts packaging↗

Bond Assembly FOD Zones - A Procedure for Assuring Acceptable Adhesion

Rocket motor components are primarily assembled by adhesion. a) For example, the RSRM (Reusable Solid Rocket Motor - part of the Space Shuttle Boosters) system contains 10,000 sq ft of bondline area. b) Rocket motors contain a variety of adhesive/substrate bond systems c) Bond system performance requirements also vary. To assemble reliable components, ATK Space Systems and customers invest substantial resources to the study of bond assembly processes. a) Surface and adhesion science; b) Adhesive chemistry; c) Process parameters; d) Contamination effects.

Evans, Kurt↗