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Experimental Techniques Verified for Determining Yield and Flow Surfaces

Structural components in aircraft engines are subjected to multiaxial loads when in service. For such components, life prediction methodologies are dependent on the accuracy of the constitutive models that determine the elastic and inelastic portions of a loading cycle. A threshold surface (such as a yield surface) is customarily used to differentiate between reversible and irreversible flow. For elastoplastic materials, a yield surface can be used to delimit the elastic region in a given stress space. The concept of a yield surface is central to the mathematical formulation of a classical plasticity theory, but at elevated temperatures, material response can be highly time dependent. Thus, viscoplastic theories have been developed to account for this time dependency. Since the key to many of these theories is experimental validation, the objective of this work (refs. 1 and 2) at the NASA Lewis Research Center was to verify that current laboratory techniques and equipment are sufficient to determine flow surfaces at elevated temperatures. By probing many times in the axial-torsional stress space, we could define the yield and flow surfaces. A small offset definition of yield (10 me) was used to delineate the boundary between reversible and irreversible behavior so that the material state remained essentially unchanged and multiple probes could be done on the same specimen. The strain was measured with an off-the-shelf multiaxial extensometer that could measure the axial and torsional strains over a wide range of temperatures. The accuracy and resolution of this extensometer was verified by comparing its data with strain gauge data at room temperature. The extensometer was found to have sufficient resolution for these experiments. In addition, the amount of crosstalk (i.e., the accumulation of apparent strain in one direction when strain in the other direction is applied) was found to be negligible. Tubular specimens were induction heated to determine the flow surfaces at elevated temperatures. The heating system induced a large amount of noise in the data. By reducing thermal fluctuations and using appropriate data averaging schemes, we could render the noise inconsequential. Thus, accurate and reproducible flow surfaces (see the figure) could be obtained.

Lerch, Brad A.↗

The QWIP Focal Plane Assembly for NASA's Landsat Data Continuity Mission

The Thermal Infrared Sensor (TIRS) is a QWIP based instrument intended to supplement the Operational Land Imager (OLI) for the Landsat Data Continuity Mission (LDCM). The TIRS instrument is a dual channel far infrared imager with the two bands centered at 10.8 m and 12.0 m. The focal plane assembly (FPA) consists of three 640x512 GaAs Quantum Well Infrared Photodetector (QWIP) arrays precisely mounted to a silicon carrier substrate that is mounted on an invar baseplate. The two spectral bands are defined by bandpass filters mounted in close proximity to the detector surfaces. The focal plane operating temperature is 43K. The QWIP arrays are hybridized to Indigo ISC9803 readout integrated circuits (ROICs). Two varieties of QWIP detector arrays are being developed for this project, a corrugated surface structure QWIP and a grating surface structure QWIP. This paper will describe the TIRS system noise equivalent temperature difference sensitivity as it affects the QWIP focal plane performance requirements: spectral response, dark current, conversion efficiency, read noise, temperature stability, pixel uniformity, optical crosstalk and pixel yield. Additional mechanical constraints as well as qualification through Technology Readiness Level 6 (TRL 6) will also be discussed.

Jhabvala, M.↗

The QWIP Focal Plane Assembly for NASA's Landsat Data Continuity Mission

The Thermal Infrared Sensor (TIRS) is a QWIP based instrument intended to supplement the Operational Land Imager (OLI) for the Landsat Data Continuity Mission (LDCM). The TIRS instrument is a dual channel far infrared imager with the two bands centered at 10.8[mu]m and 12.0[mu]m. The focal plane assembly (FPA) consists of three 640x512 GaAs Quantum Well Infrared Photodetector (QWIP) arrays precisely mounted to a silicon carrier substrate that is mounted on an invar baseplate. The two spectral bands are defined by bandpass filters mounted in close proximity to the detector surfaces. The focal plane operating temperature is 43K. The QWIP arrays are hybridized to Indigo ISC9803 readout integrated circuits (ROICs). Two varieties of QWIP detector arrays are being developed for this project, a corrugated surface structure QWIP and a grating surface structure QWIP. This paper will describe the TIRS system noise equivalent temperature difference sensitivity as it affects the QWIP focal plane performance requirements: spectral response, dark current, conversion efficiency, read noise, temperature stability, pixel uniformity, optical crosstalk and pixel yield. Additional mechanical constraints as well as qualification through Technology Readiness Level 6 (TRL 6) will also be discussed.

Jhabvala, M↗

High-Temperature Modal Survey of a Hot-Structure Control Surface

NASA Dryden is directing a program to test a Carbon-Silicon Carbide (C/SiC) Ruddervator Subcomponent Test Article (RSTA). The RSTA is a truncated version of the full-scale X-37 hot-structure control surface incorporating all major features including the metallic spindle and five major C/SiC quasi isotropic lay-up components secured with C/SiC fasteners. As part of NASA's Aeronautics Research Mission Directorate Hypersonics program, the RSTA will undergo thermal-structural testing to develop an extensive database for future structural design and analysis methodology validation. Ground Vibration Tests (GVTs) are routinely conducted for model validation in supporting flutter analysis for subsonic and supersonic vehicles; however, for hypersonic vehicle applications, GVT techniques are not well-established. New fabrication technologies, high-temperature materials systems, and sensors offer new opportunities to develop techniques for performing GVTs at elevated temperatures. The RSTA is comprised of materials whose stiffness both increases and decreases with increasing temperature. The impact of this type of material system interaction must be understood as it will ultimately affect hypersonic flutter analysis. The test objectives are to perform room-temperature GVTs, develop the capability to conduct high-temperature GVTs and to compare and generate an understanding of the modal characteristics which capture RSTA's material interaction when subjected to temperature varying conditions.

Spivey, Natalie D.↗

Hot Structure Control Surface Progress for X-37 Technology Development Program

The NASA Marshall Space Flight Center (MSFC) has been leading the development of technologies that will enable the development, fabrication, and flight of the automated X-37 Orbital Vehicle (OV). With the Administration s recent announcement of the Vision for Space Exploration, NASA placed the X-37 OV design on hold while developing detailed requirements for a Crew Exploration Vehicle, but has continued funding the development of high-risk, critical technologies for potential future space exploration vehicle applications. Hot Structure Control Surfaces (HSCS) technology development is one of the high-priority areas being funded at this time. The goal of HSCS research is to mitigate risk by qualifying the lightest possible components that meet the stringent X-37 OV weight and performance requirements, including Shuttle-type reen- try environments with peak temperatures of 2800 OF. The small size of the X-37 OV (25.7-feet long and 14.9-foot wingspan) drives the need for advanced HSCS because the vehicle's two primary aerodynamic surfaces, the flaperons and ruddervators, have thicknesses ranging from approximately 5 in. down to 1 in. Traditional metallic or polymer-matrix composites covered with tile or blanket thermal protection system (TPS) materials cannot be used as there is insufficient volume to fabricate such multi-component structures. Therefore, carbon-carbon (C-C) and carbodsilicon-carbide (C-SiC) composite HSCS structures are being developed in parallel by two teams supporting the X-37 prime contractor (The Boeing Company). The Science Applications International Coy. (SAIC) and Carbon-Carbon Advanced Technologies, Inc. (C-CAT) team is developing the C-C HSCS, while the General Electric Energy Power Systems Composites (GE-PSC) and Materials Research and Design (MRD) team is developing the C-SiC HSCS. These two teams were selected to reduce the high level of risk associated with developing advanced control surface components. They have continued HSCS development work as part of the X-37 critical technology development contract. The SAIC/C-CAT team is using Advanced Carbon-Carbon (ACC) because its fabrication is very similar to the process used for Space Shuttle Reinforced Carbon-Carbon fabrication, including the Sic-based pack cementation conversion coating systems using with both materials. ACC was selected over RCC because it has much higher tension and compressions strengths, and because T-300 fiber is readily available, whereas RCC rayon fiber is no longer manufactured. The GE-PSC/MRD team is using a T-300 fiber-reinforced Sic matrix composite material densified by chemical vapor infiltration. The C-Sic material has an Sic-based environmental barrier coating. Major accomplishments have been made over the past year by both HSCS teams. C-C and C- SiC flaperon subcomponents, which are truncated full-scale versions of flight hardware, have been fabricated and are undergoing testing at the NASA Dryden Flight Research Center, NASA Langley Research Center, and U.S. Air Force Research Laboratory. By the end of 2004, ruddervator subcomponents also will be delivered and tested. As NASA moves forward in realizing the Vision for Space Exploration, it will continue to invest in advanced research and development aimed at making new generations of spacecraft safer, more reliable, and more affordable. The X-37 HSCS effort ultimately will benefit the Agency's vision and mission.

Valentine, P. G.↗

Lunar and Martian Sub-surface Habitat Structure Technology Development and Application

NASA's human exploration initiative poses great opportunity and great risk for manned missions to the Moon and Mars. Subsidace structures such as caves and lava tubes offer readily available and existing in-situ habitat options. Sub-surface dwellings can provide complete radiation, micro-meteorite and exhaust plume shielding and a moderate and constant temperature environment; they are, therefore, excellent pre-existing habitat risk mitigation elements. Technical challenges to subsurface habitat structure development include surface penetration (digging and mining equipment), environmental pressurization, and psychological environment enhancement requirements. Lunar and Martian environments and elements have many beneficial similarities. This will allow for lunar testing and design development of subsurface habitat structures for Martian application; however, significant differences between lunar and Martian environments and resource elements will mandate unique application development. Mars is NASA's ultimate exploration goal and is known to have many very large lava tubes. Other cave types are plausible. The Moon has unroofed rilles and lava tubes, but further research will, in the near future, define the extent of Lunar and Martian differences and similarities. This paper will discuss Lunar and Martian subsurface habitation technology development challenges and opportunities.

Boston, Penelope J.↗

High-Temperature Modal Survey of a Hot-Structure Control Surface

Ground vibration tests are routinely conducted for supporting flutter analysis for subsonic and supersonic vehicles; however, for hypersonic vehicles, thermoelastic vibration testing techniques are neither well established nor routinely performed. New high-temperature material systems, fabrication technologies and high-temperature sensors expand the opportunities to develop advanced techniques for performing ground vibration tests at elevated temperatures. When high-temperature materials, which increase in stiffness when heated, are incorporated into a hot-structure that contains metallic components that decrease in stiffness when heated, the interaction between those materials can affect the hypersonic flutter analysis. A high-temperature modal survey will expand the research database for hypersonics and improve the understanding of this dual-material interaction. This report discusses the vibration testing of the carbon-silicon carbide Ruddervator Subcomponent Test Article, which is a truncated version of a full-scale hot-structure control surface. Two series of room-temperature modal test configurations were performed in order to define the modal characteristics of the test article during the elevated-temperature modal survey: one with the test article suspended from a bungee cord (free-free) and the second with it mounted on the strongback (fixed boundary). Testing was performed in the NASA Dryden Flight Research Center Flight Loads Laboratory Large Nitrogen Test Chamber.

Spivey, Natalie D.↗

An observation of the Gulf Stream surface front structure by ship, aircraft, and satellite.

Evaluation of observations of surface temperature and salinity along the western edge of the Gulf Stream made from a ship and of concurrent temperature observations obtained by instrumented aircraft at six altitudes. The major feature along a five-kilometer line normal to the Stream's edge is a temperature gradient of about 0.75 C/kilometer within which are embedded two abrupt temperature increases of about 1.5 C. Temperature variations were compensated by salinity variations, yielding nearly constant density through the frontal zone; a sharp lateral current shear was associated with the thermohaline mixing region between the steps. The attenuation of surface temperature measured by the airborne radiometer was compared with a theoretical model. The analysis supports the view that a two-part correction technique is required: one part for bulk-skin temperature differences, and another for atmospheric attenuation of sea surface emission due to the mass and temperature of interfering gases.

Maul, G. A.↗

High-Temperature Modal Survey of a Hot-Structure Control Surface

Ground vibration tests or modal surveys are routinely conducted for supporting flutter analysis for subsonic and supersonic vehicles; however, for hypersonic vehicle applications, thermoelastic vibration testing techniques are not well established and are not routinely performed for supporting hypersonic flutter analysis. New high-temperature material systems, fabrication technologies and high-temperature sensors expand the opportunities to develop advanced techniques for performing ground vibration tests at elevated temperatures. High-temperature materials have the unique property of increasing in stiffness when heated. When these materials are incorporated into a hot-structure, which includes metallic components that decrease in stiffness with increasing temperature, the interaction between the two materials systems needs to be understood because that interaction could ultimately affect the hypersonic flutter analysis. Performing a high-temperature modal survey will expand the research database for hypersonics and will help build upon the understanding of the dual material interaction. This paper will discuss the vibration testing of the Carbon-Silicon Carbide Ruddervator Subcomponent Test Article which is a truncated version of the full-scale X-37 hot-structure control surface. In order to define the modal characteristics of the test article during the elevated-temperature modal survey, two series of room-temperature modal test configurations had to be performed. The room-temperature test series included one with the test article suspended from a bungee cord (free-free) and the second with it mounted on the strongback (fixed boundary condition) in NASA Dryden's Flight Loads Lab large nitrogen test chamber.

Spivey, Natalie Dawn↗

Broadband Infrared Antireflection Structured Silicon Surfaces

Silicon and germanium are materials often used for IR windows and optical elements. However they have a very high index of refraction, in the order of three to four, which causes large reflection losses on each surface. These losses are especially high under large angles of incidence which are often desirable if signals are faint and fast optics are to be used. Solid antireflection coatings are either not available because materials with appropriate index of refraction do not exist, or their use is limited to a small wavelength range and small angles of incidence. We will present the status of our work to calculate, create, and test the performance of graded structures in Si to reduce its surface reflection. The structures are expected to work over the very broad wavelength range of 10 microns to 1000 microns and a wide range of angle of incidence. We have identified several high aspect ratio MEMS process techniques to create the structures and have done 3D electromagnetic modeling, which predicts significant effects. Measurements on different samples have validated our modeling.

Stewart, Kenneth↗

Broadband Infrared Antireflection Structured Silicon Surfaces

Silicon and germanium are materials often used for IR windows and optical elements. However they have a very high index of refraction, in the order of three to four, which causes large reflection losses on each surface. These losses are especially high under large angles of incidence which are often desirable if signals are faint and fast optics are to be used. Solid antireflection coatings are either not available because materials with appropriate index of refraction do not exist, or their use is limited to a small wavelength range and small angles of incidence. We will present the status of our work to calculate, create, and test the performance of graded structures in Si to reduce its surface reflection. The structures are expected to work over the very broad wavelength range of 10 to 1000 micrometers and a wide range of angle of incidence. We have identified several high aspect ratio MEMS process techniques to Create the structures and have done 3D electromagnetic modeling, which predicts significant effects. Measurements on different samples have validated our modeling.

Stewart, Kenneth↗

Broadband Infrared Antireflection Structured Silicon Surfaces

Silicon and germanium are materials often used for infrared (IR) windows and optical elements. However they have a very high index of refraction, in the order of three to four, which causes large reflection losses on each surface. These losses are especially high under large angles of incidence which are often desirable if signals are faint and fast optics are to be used. Solid antireflection coatings are either not available because materials with appropriate index of refraction do not exist, or their use is limited to a small wavelength range and small angles of incidence. We will present the status of our work to calculate, create, and test the performance of graded structures in Si to reduce its surface reflection. The structures are expected to work over the very broad wavelength range of 10 micron to 1000 micron and a wide range of angle of incidence. We.have identified several high aspect ratio MEMS process techniques to create the structures and have done 3D electromagnetic modeling, which predicts significant effects. Measurements on different samples have validated our modeling.

Stewart, Kenneth↗

User's manual for FRAC3D: Supplement to report on stress analysis for structures with surface cracks

The FRAC3D computer program, designed for use in analyzing stresses in structures (including plates, bars, or blocks) which may contain part-circular surface cracks or embedded circular cracks is described. Instructions are provided for preparing input, including that for the supporting programs LATTICE and MATSOL as well as for FRAC3D. The course of a substantial illustrative calculation is shown with both input and output. The formulas underlying the calculations are summarized and related to the subroutines in which they are used. Many issues of strategy in using this program for analysing stresses around surface cracks are elucidated.

Bell, J. C.↗

Miniature pressure transducer for stressed member application

Miniature pressure transducer responds to static or dynamic pressures acting against a structural surface without introducing errors caused by stresses in the structural surface. This is accomplished by a thin stainless steel pressure sensing diaphragm with an attached foil strain gage.

Walker, R. R.↗

Software Package Completed for Alloy Design at the Atomic Level

As a result of a multidisciplinary effort involving solid-state physics, quantum mechanics, and materials and surface science, the first version of a software package dedicated to the atomistic analysis of multicomponent systems was recently completed. Based on the BFS (Bozzolo, Ferrante, and Smith) method for the calculation of alloy and surface energetics, this package includes modules devoted to the analysis of many essential features that characterize any given alloy or surface system, including (1) surface structure analysis, (2) surface segregation, (3) surface alloying, (4) bulk crystalline material properties and atomic defect structures, and (5) thermal processes that allow us to perform phase diagram calculations. All the modules of this Alloy Design Workbench 1.0 (ADW 1.0) are designed to run in PC and workstation environments, and their operation and performance are substantially linked to the needs of the user and the specific application.

Bozzolo, Guillermo H.↗