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NASA NTRS2010

Back-Face Strain for Monitoring Stable Crack Extension in Precracked Flexure Specimens

Calibrations relating back-face strain to crack length in precracked flexure specimens were developed for different strain gage sizes. The functions were verified via experimental compliance measurements of notched and precracked ceramic beams. Good agreement between the functions and experiments occurred, and fracture toughness was calculated via several operational methods: maximum test load and optically measured precrack length; load at 2 percent crack extension and optical precrack length; maximum load and back-face strain crack length. All the methods gave vary comparable results. The initiation toughness, K(sub Ii) , was also estimated from the initial compliance and load.The results demonstrate that stability of precracked ceramics specimens tested in four-point flexure is a common occurrence, and that methods such as remotely-monitored load-point displacement are only adequate for detecting stable extension of relatively deep cracks.

Salem, Jonathan A.↗

NASA NTRS1996

Superconductivity Devices: Commercial Use of Space

The work described in this report covers various aspects of the Rainbow solid-state actuator and sensor technologies. It is presented in five parts dealing with sensor applications, nonlinear properties, stress-optic and electrooptic properties, stacks and arrays, and publications. The Rainbow actuator technology is a relatively new materials development which had its inception in 1992. It involves a new processing technique for preparing pre-stressed, high lead containing piezoelectric and electrostrictive ceramic materials. Ceramics fabricated by this method produce bending-mode actuator devices which possess several times more displacement and load bearing capacity than present-day benders. Since they can also be used in sensor applications, Rainbows are part of the family of materials known as smart ceramics. During this period, PLZT Rainbow ceramics were characterized with respect to their piezoelectric properties for potential use in stress sensor applications. Studies of the nonlinear and stress-optic/electrooptic birefringent properties were also initiated during this period. Various means for increasing the utility of stress-enhanced Rainbow actuators are presently under investigation.

Haertling, Gene↗

NASA NTRS1979

Applications of high power lasers

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.

Angus, J. C.↗

NASA NTRS2000

Active Control Technology at NASA Langley Research Center

NASA Langley has a long history of attacking important technical opportunities from a broad base of supporting disciplines. The research and development at Langley in this subject area range from the test tube to the test flight. The information covered here will range from the development of innovative new materials, sensors and actuators, to the incorporation of smart sensors and actuators in practical devices, to the optimization of the location of these devices, to, finally, a wide variety of applications of these devices utilizing Langley's facilities and expertise. Advanced materials are being developed for sensors and actuators, as well as polymers for integrating smart devices into composite structures. Contributions reside in three key areas: computational materials; advanced piezoelectric materials; and integrated composite structures. The computational materials effort is focused on developing predictive tools for the efficient design of new materials with the appropriate combination of properties for next generation smart airframe systems. Research in the area of advanced piezoelectrics includes optimizing the efficiency, force output, use temperature, and energy transfer between the structure and device for both ceramic and polymeric materials. For structural health monitoring, advanced non-destructive techniques including fiber optics are being developed for detection of delaminations, cracks and environmental deterioration in aircraft structures. The computational materials effort is focused on developing predictive tools for the efficient design of new materials with the appropriate combination of properties for next generation smart airframe system. Innovative fabrication techniques processing structural composites with sensor and actuator integration are being developed.

Antcliff, Richard R.↗

NASA NTRSDate not supplied

MAB Phase Ceramics for Lunar Applications

During the ten-week internship my work focused on designing characterization protocol for 3D printed MAB phase ceramics on steel and Tiplates. I was mentored by Dr. Samuel Hocker of NASA and advised by Dr. Gupta from University of North Dakota. I also collaborated with Mackenzie Short from the University of North Dakota. The characterization protocol was divided into following steps; initially, we performed visual inspection of the plates. During this process, the coatings which spalled or delaminated were discarded for further evaluation. During the next step, we performed optical microscopy to discern and document surface features and porosities of the samples. We also noted some decomposition under the optical microscope as well. Thereafter, profilometry analysis was performed to understand the effect of power density on the surface roughness. Due to the deposited powder over the samples, the profilometry was inconclusive. We then cleaned the samples on the steel plate using ethanol and cotton swabs to wipe up the loose powder covering the samples. Detailed SEM analysis was then performed on the cleaned specimens. In parallel, the 3D printed samples on the Tiplate were cleaned by using an ultrasonic bath for 1h. Optical imaging showed that this cleaning process was more effective for cleaning except that small cracks propagated through the layered ceramics. The profilometry data gathered on the titanium plate after cleaning was more conclusive. The SEM data on the steel plate showed that there is decomposition at all wattages although at 100 W the extent of decomposition was lower. We are planning to characterize the steel samples after cleaning in ultrasonic bath for 5-10 min to minimize cracking during the cleaning process. In addition, we are also planning to study the fractured surface by SEM analysis.

Additive Manufacturing, Laser Powder Bed Fusion, S↗

NASA NTRS1974

Improved coating for silica fiber based ceramic Reusable Surface Insulation (CRSI)

A series of coatings was developed for the space shuttle type silica fiber insulation system and characterized for optical and physical properties. Reentry simulation tests were run using a radiant panel and also using a hypersonic plasma arc. The coatings produced had improved physical and optical properties as well as greater reuse capability over the GE version of the JSC-0042 coating.

Ormiston, T. J.↗

NASA NTRS2000

All-Optical Micro Motors Based on Moving Gratings in Photosensitive Media

An all-optical micro motor with a rotor driven by a traveling wave of surface deformation of a stator being in contact with the rotor is being studied. Instead of an ultrasonic wave produced by an electrically driven piezoelectric actuator as in ultrasonic motors, the wave is a result of a photo induced surface deformation of a photosensitive material produced by a traveling holographic grating. Two phase modulated coherent optical beams generate the grating. Several types of photosensitive materials are studied such as photorefractive crystals, photosensitive piezoelectric ceramics, and side-chain liquid crystalline polyesters. In order to be considered as a possible candidate for micro motors, the material should exhibit surface deformation produced by moving grating of the order of 10 micron. Deformations produced by static holographic gratings are studied in photorefractive crystals of LiNbO3 using high vertical resolution surface profilometer Dektak 3 and surface interferometer WYKO. An experimental set-up with moving grating has been developed. The set-up uses a two-beam interferometry configuration with one beam being reflected by a thin mirror mounted on a loud speaker. A ramp voltage signal generator drives the speaker. Changing voltage, polarity, and frequency of the signal can easily generate vibrating gratings or moving gratings in both directions. A vibrating grating has been applied to a photorefractive crystal of BSO controlled by an external electric field of the order of 104 V/cm. We have additionally studied effects of moving grating interaction with light absorbing fluids such as solutions of 2,9,16,23-Tetrakis(phenylthio)-29H, 31 Hphthalocyanine in chlorobenzene in capillary tubes. The purpose of using a liquid is to show that the moving gratings can force a liquid to shift. The interaction of a single low power focused laser beam at 633 nm with such fluid produced an intensive circular motion, which also might be applied to all-optical micro motors or actuators.

Curley, M.↗

NASA NTRS1997

Optical Microactuation in Piezoceramics

Optically/electrically operable flexible film microactuators that can offer upto two orders higher efficiency of photonic to mechanical conversion compared to ceramic actuators are conceptualised.

Piezoceramics↗

NASA NTRS1972

Research study to determine critical optical/mechanical properties of materials considered for selection as substrates for the primary mirror on a large telescope

An investigation was conducted to evaluate the stability of a specific low expansion glass-ceramic material relative to its use as a large, lightweight mirror substrate for diffraction-limited spaceborne optical applications. These evaluations were made on a segment (0.44 meter diameter by 0.31 meter thick) of a 2 to 3 meter diameter mirror blank. The dimensional stability of this mirror was measured interferometrically before and after lightweighting, as a function of rough machining, etching, thermal environment, and support configuration. A special computer analysis program was used to plot the coefficients corresponding to aberrations with sixfold symmetry (caused by the mirror's self-weight deflection on a three point support). The objective was to enhance the test sensitivity. Results indicate that any such effects due to self-weight deflection are of the order of 0.015 lambda rms. The rms and peak-to-peak figure changes associated with each processing operation are summarized.

Slomba, A. F.↗

NASA NTRS1974

Laser holographic detection of tiny thin tapes beneath a thick opaque composite structure

Real-time laser holographic interferometry technique has been applied successfully in the detection of 1mm x 1mm x 0.025mm duct tapes hidden beneath a 150mm x 150mm x 16mm ceramic-epoxy-fiberglass sandwiched structure. The experimental results clearly demonstrate future applicability of this technique in the optical nondestructive detection of debonds and flaws in such composite structures.

Liu, H.-K.↗

NASA NTRS1999

Nondestructive Strain Measurement System Used to Determine Surface Strain on Fibers

Small-diameter structural fibers are being considered as reinforcements for high temperature ceramic matrix composite materials, and thus they require characterization. At the NASA Lewis Research Center, a nondestructive optical technique was used to determine surface strain on a structural fiber, in real time, as it was pulled in a tensile test machine. With this technique, interference or speckle patterns from the laser illuminated fiber test specimen are recorded. As the fiber is pulled, its speckle pattern shifts in proportion to the strain, translation, and rotation components of the sample deformation. Shifting speckle patterns are detected in real time by two linear charge-coupled discharge (CCD) camera arrays, and the images are processed by a hardware correlator. Surface strain is selectively detected on fibers with diameters on the order of 100 mm and can be resolved to 19 microstrain. This system was designed to be robust and compact and generally does not require surface preparation of the structural fibers. For strain detection, two laser beams are positioned incident on the structural fiber being tested, as shown in the photograph, where the test specimen is mounted in a tensile test machine via two coupons. As the fiber is pulled, the speckle pattern produced from each laser beam is detected by one of two CCD arrays located inside the tube on the right side of the photograph.

Tuma, Margaret L.↗

NASA NTRS1984

Methods for assessing the structural reliability of brittle materials

Failure from contact-induced surface flaws is considered along with controlled indentation flaws for construction of toughness and fatigue master maps, fatigue properties of ceramics with natural and controlled flaws, and a statistical analysis of size and stress state effects on the strength of an alumina ceramic. Attention is also given to dynamic and static fatigue of a machinable glass ceramic, the effect of multiregion crack growth on proof testing, and a fracture mechanics analysis of defect sizes. Other topics explored are related to the effect of temperature and humidity on delayed failure of optical glass fibers, subthreshold indentation flaws in the study of fatigue properties of ultrahigh-strength glass, the lifetime prediction for hot-pressed silicon nitride at high temperatures, static fatigue in high-performance ceramics, and requirements for flexure testing of brittle materials.

Freiman, S. W.↗

NASA NTRS1992

Mechanical properties of silicate glasses exposed to a low-Earth orbit

The effects of a 5.8 year exposure to low earth orbit environment upon the mechanical properties of commercial optical fused silica, low iron soda-lime-silica, Pyrex 7740, Vycor 7913, BK-7, and the glass ceramic Zerodur were examined. Mechanical testing employed the ASTM-F-394 piston on 3-ball method in a liquid nitrogen environment. Samples were exposed on the Long Duration Exposure Facility (LDEF) in two locations. Impacts were observed on all specimens except Vycor. Weibull analysis as well as a standard statistical evaluation were conducted. The Weibull analysis revealed no differences between control samples and the two exposed samples. We thus concluded that radiation components of the Earth orbital environment did not degrade the mechanical strength of the samples examined within the limits of experimental error. The upper bound of strength degradation for meteorite impacted samples based upon statistical analysis and observation was 50 percent.

Wiedlocher, David E.↗

NASA NTRS1995

Real time acousto-ultrasonic NDE technique for monitoring damage in ceramic composites under dynamic loads

Research effort was directed towards developing a near real-time, acousto-ultrasonic (AU), nondestructive evaluation (NDE) tool to study the failure mechanisms of ceramic composites. Progression of damage is monitored in real-time by observing the changes in the received AU signal during the actual test. During the real-time AU test, the AU signals are generated and received by the AU transducers attached to the specimen while it is being subjected to increasing quasi-static loads or cyclic loads (10 Hz, R = 1.0). The received AU signals for 64 successive pulses were gated in the time domain (T = 40.96 micro sec) and then averaged every second over ten load cycles and stored in a computer file during fatigue tests. These averaged gated signals are representative of the damage state of the specimen at that point of its fatigue life. This is also the first major attempt in the development and application of real-time AU for continuously monitoring damage accumulation during fatigue without interrupting the test. The present work has verified the capability of the AU technique to assess the damage state in silicon carbide/calcium aluminosilicate (SiC/CAS) and silicon carbide/ magnesium aluminosilicate (SiC/MAS) ceramic composites. Continuous monitoring of damage initiation and progression under quasi-static ramp loading in tension to failure of unidirectional and cross-ply SiC/CAS and quasi-isotropic SiC/MAS ceramic composite specimens at room temperature was accomplished using near real-time AU parameters. The AU technique was shown to be able to detect the stress levels for the onset and saturation of matrix cracks, respectively. The critical cracking stress level is used as a design stress for brittle matrix composites operating at elevated temperatures. The AU technique has found that the critical cracking stress level is 10-15% below the level presently obtained for design purposes from analytical models. An acousto-ultrasonic stress-strain response (AUSSR) model for unidirectional and cross-ply ceramic composites was formulated. The AUSSR model predicts the strain response to increasing stress levels using real-time AU data and classical laminated plate theory. The Weibull parameters of the AUSSR model are used to calculate the design stress for thermo-structural applications. Real-time AU together with the AUSSR model was used to study the failure mechanisms of SiC/CAS ceramic composites under static and fatigue loading. An S-N curve was generated for a cross-ply SiC/CAS ceramic composite material. The AU results are corroborated and complemented by other NDE techniques, namely, in-situ optical microscope video recordings and edge replication.

Tiwari, Anil↗

NASA NTRS2000

Rapid Model Fabrication and Testing for Aerospace Vehicles

Advanced methods for rapid fabrication and instrumentation of hypersonic wind tunnel models are being developed and evaluated at NASA Langley Research Center. Rapid aeroheating model fabrication and measurement techniques using investment casting of ceramic test models and thermographic phosphors are reviewed. More accurate model casting techniques for fabrication of benchmark metal and ceramic test models are being developed using a combination of rapid prototype patterns and investment casting. White light optical scanning is used for coordinate measurements to evaluate the fabrication process and verify model accuracy to +/- 0.002 inches. Higher-temperature (<210C) luminescent coatings are also being developed for simultaneous pressure and temperature mapping, providing global pressure as well as global aeroheating measurements. Together these techniques will provide a more rapid and complete experimental aerodynamic and aerothermodynamic database for future aerospace vehicles.

Buck, Gregory M.↗

NASA NTRS2003

Multiwavelength Pyrometer Developed for Use at Elevated Temperatures in Aerospace Applications

Researchers at the NASA Glenn Research Center have developed a unique multiwavelength pyrometer for aerospace applications. It has been shown to be a useful and versatile instrument for measuring the surface temperatures of ceramic zirconia thermal barrier coatings (TBCs) and alumina, even when their emissivity is unknown. The introduction of fiber optics into the pyrometer has greatly increased the ease of using this instrument. Direct comparison of measurements obtained using the pyrometer and thin film thermocouples on a sample provided independent verification of pyrometry temperature measurement. Application of the pyrometer has also included simultaneous surface and bulk temperature measurement in a transparent material, the measurement of combustion gas temperatures in the flames of an atmospheric burner, the measurement of the temperature distribution appearing on a large surface from the recording of just a single radiation spectrum emitted from this nonuniform temperature surface, and the measurement of some optical properties for special aeronautical materials-such as nanostructured layers. The multiwavelength pyrometer temperature is obtained from a radiation spectrum recorded over a broad wavelength region by transforming it into a straight line segment(s) in part or all of the spectral region. The intercept of the line segment(s) with the vertical axis at zero wavelength gives the inverse of the temperature. In a two-color pyrometer, the two data points are also amenable to this analysis to determine the unknown temperature. Implicit in a two-color pyrometer is the assumption of wavelength-independent emissivity. Its two (and minimum) pieces of data are sufficient to determine this straight line. However, a multiwavelength pyrometer not only has improved accuracy but also confirms that the wavelength-independent emissivity assumption is valid when a multitude of data points are shown to lie on a simple straight line.

Ng, Daniel L.↗

NASA NTRS2013

Cobra Fiber-Optic Positioner Upgrade

A prime focus spectrometer (PFS), along with corrective optics, will mount in place of the secondary mirror of the Subaru telescope on Mauna Kea, Hawaii. This will allow simultaneous observations of cosmologic targets. It will enable large-scale galactic archeology and dark energy surveys to help unlock the secrets of the universe. To perform these cosmologic surveys, an array of 2,400 optical fibers needs to be independently positioned within the 498-mm-diameter focal plane of the PFS instrument to collect light from galaxies and stars for spectrographic analyses. To allow for independent re-positioning of the fibers, a very small positioner (7.7 mm in diameter) is required. One hundred percent coverage of the focal plane is also required, so these small actuators need to cover a patrol region of 9.5 mm in diameter. To optimize the amount of light that can be collected, the fibers need to be placed within 5 micrometers of their intended target (either a star or galaxy). The Cobra Fiber Positioner was designed to meet the size and accuracy requirements stated above. Cobra is a two-degrees-of-freedom mechanism that can position an optical fiber in the focal plane of the PFS instrument to a precision of 5 micrometers. It is a theta-phi style positioner containing two rotary piezo tube motors with one offset from the other, which enables the optic fibers to be placed anywhere in a small circular patrol region. The patrol region of the actuator is such that the array of 2,400 positioners allows for full coverage of the instrument focal plane by overlapping the patrol areas. A second-generation Cobra positioner was designed based on lessons learned from the original prototype built in 2009. Improvements were made to the precision of the ceramic motor parts, and hard stops were redesigned to minimize friction and prevent jamming. These changes resulted in reducing the number of move iterations required to position the optical fiber within 5 micrometers of its target. At the time of this reporting, there are still many tests to be performed that will validate system level performance, but on an individual level, the Cobra positioner demonstrates excellent performance and will enable the PFS instrument to make unprecedented measurements of the universe. What is unique about the upgrades made to the Cobra positioner is the improved performance due to the design changes in the hard stops and the ceramic end caps of the motors. Other changes were made to reduce the unit cost of a Cobra positioner without affecting the performance, since thousands of these devices will have to be built for the PFS instrument.

Fisher, Charles D.↗

NASA NTRS2009

Light-Driven Polymeric Bimorph Actuators

Light-driven polymeric bimorph actuators are being developed as alternatives to prior electrically and optically driven actuators in advanced, highly miniaturized devices and systems exemplified by microelectromechanical systems (MEMS), micro-electro-optical-mechanical systems (MEOMS), and sensor and actuator arrays in smart structures. These light-driven polymeric bimorph actuators are intended to satisfy a need for actuators that (1) in comparison with the prior actuators, are simpler and less power-hungry; (2) can be driven by low-power visible or mid-infrared light delivered through conventional optic fibers; and (3) are suitable for integration with optical sensors and multiple actuators of the same or different type. The immediate predecessors of the present light-driven polymeric bimorph actuators are bimorph actuators that exploit a photorestrictive effect in lead lanthanum zirconate titanate (PLZT) ceramics. The disadvantages of the PLZT-based actuators are that (1) it is difficult to shape the PLZT ceramics, which are hard and brittle; (2) for actuation, it is necessary to use ultraviolet light (wavelengths < 380 nm), which must be generated by use of high-power, high-pressure arc lamps or lasers; (3) it is difficult to deliver sufficient ultraviolet light through conventional optical fibers because of significant losses in the fibers; (4) the response times of the PLZT actuators are of the order of several seconds unacceptably long for typical applications; and (5) the maximum mechanical displacements of the PLZT-based actuators are limited to those characterized by low strains beyond which PLZT ceramics disintegrate because of their brittleness. The basic element of a light-driven bimorph actuator of the present developmental type is a cantilever beam comprising two layers, at least one of which is a polymer that exhibits a photomechanical effect (see figure). The dominant mechanism of the photomechanical effect is a photothermal one: absorption of light energy causes heating, which, in turn, causes thermal expansion.

Adamovsky, Gregory↗