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NASA NTRS2010

Replacement/Refurbishment of JSC/NASA POD Specimens

The NASA Special NDE certification process requires demonstration of NDE capability by test per NASA-STD-5009. This test is performed with fatigue cracked specimens containing very small cracks. The certification test results are usually based on binomial statistics and must meet a 90/95 Probability of Detection (POD). The assumption is that fatigue cracks are tightly closed, difficult to detect, and inspectors and processes passing such a test are well qualified for inspecting NASA fracture critical hardware. The JSC NDE laboratory has what may be the largest inventory that exists of such fatigue cracked NDE demonstration specimens. These specimens were produced by the hundreds in the late 1980s and early 1990s. None have been produced since that time and the condition and usability of the specimens are questionable.

Castner, Willard L.↗

NASA NTRS2017

Benchmark Shock Tube Experiments for Radiative Heating Relevant to Earth Re-Entry

Detailed spectrally and spatially resolved radiance has been measured in the Electric Arc Shock Tube (EAST) facility for conditions relevant to high speed entry into a variety of atmospheres, including Earth, Venus, Titan, Mars and the Outer Planets. The tests that measured radiation relevant for Earth re-entry are the focus of this work and are taken from campaigns 47, 50, 52 and 57. These tests covered conditions from 8 km/s to 15.5 km/s at initial pressures ranging from 0.05 Torr to 1 Torr, of which shots at 0.1 and 0.2 Torr are analyzed in this paper. These conditions cover a range of points of interest for potential fight missions, including return from Low Earth Orbit, the Moon and Mars. The large volume of testing available from EAST is useful for statistical analysis of radiation data, but is problematic for identifying representative experiments for performing detailed analysis. Therefore, the intent of this paper is to select a subset of benchmark test data that can be considered for further detailed study. These benchmark shots are intended to provide more accessible data sets for future code validation studies and facility-to-facility comparisons. The shots that have been selected as benchmark data are the ones in closest agreement to a line of best fit through all of the EAST results, whilst also showing the best experimental characteristics, such as test time and convergence to equilibrium. The EAST data are presented in different formats for analysis. These data include the spectral radiance at equilibrium, the spatial dependence of radiance over defined wavelength ranges and the mean non-equilibrium spectral radiance (so-called 'spectral non-equilibrium metric'). All the information needed to simulate each experimental trace, including free-stream conditions, shock time of arrival (i.e. x-t) relation, and the spectral and spatial resolution functions, are provided.

Shock Tube↗

DOE OSTI2018

Towards Malware Detection via CPU Power Consumption: Data Collection Design and Analytics

This paper presents an experimental design and data analytics approach aimed at power-based malware detection on general-purpose computers. Leveraging the fact that malware executions must consume power, we explore the postulate that malware can be accurately detected via power data analytics. Our experimental design and implementation allow for programmatic collection of CPU power profiles for fixed tasks during uninfected and infected states using five different rootkits. To characterize the power consumption profiles, we use both simple statistical and novel, sophisticated features. We test a one-class anomaly detection ensemble (that baselines non-infected power profiles) and several kernel-based SVM classifiers (that train on both uninfected and infected profiles) in detecting previously unseen malware and clean profiles. The anomaly detection system exhibits perfect detection when using all features and tasks, with smaller false detection rate than the supervised classifiers. The primary contribution is the proof of concept that baselining power of fixed tasks can provide accurate detection of rootkits. Moreover, our treatment presents engineering hurdles needed for experimentation and allows analysis of each statistical feature individually. This work appears to be the first step towards a viable power-based detection capability for general-purpose computers, and presents next steps toward this goal.

Bridges, Robert↗

DOE OSTI2015

SU-E-J-232: Feasibility of MRI-Based Preplan On Low Dose Rate Prostate Brachytherapy

Purpose: To investigate the feasibility of using MRI-based preplan for low dose rate prostate brachytherapy. Methods: 12 patients who received transrectal ultrasound (TRUS) guided prostate brachytherapy with Pd-103 were retrospectively studied. Our care-standard of the TRUS-based preplan served as the control. One or more prostate T2-weighted wide and/or narrow-field of view MRIs obtained within the 3 months prior to the implant were imported into the MIM Symphony software v6.3 (MIM Software Inc., Cleveland, OH) for each patient. In total, 37 MRI preplans (10 different image sequences with average thickness of 4.8mm) were generated. The contoured prostate volume and the seed counts required to achieve adequate dosimetric coverage from TRUS and MRI preplans were compared for each patient. The effects of different MRI sequences and image thicknesses were also investigated statistically using Student’s t-test. Lastly, the nomogram from the MRI preplan and TRUS preplan from our historical treatment data were compared. Results: The average prostate volume contoured on the TRUS and MRI were 26.6cc (range: 12.6∼41.3cc), and 27.4 cc (range: 14.3∼50.0cc), respectively. Axial MRI thicknesses (range: 3.5∼8.1mm) did not significantly affect the contoured volume or the number of seeds required on the preplan (R2 = 0.0002 and 0.0012, respectively). Four of the MRI sequences (AX-T2, AX-T2-Whole-Pelvis, AX-T2-FSE, and AXIALT2- Hi-Res) showed statistically significant better prostate volume agreement with TRUS than the other seven sequences (P <0.01). Nomogram overlay between the MRI and TRUS preplans showed good agreement; indicating volumes contoured on MRI preplan scan reliably predict how many seeds are needed for implant. Conclusion: Although MRI does not allow for determination of the actual implant geometry, it can give reliable volumes for seed ordering purposes. Our future work will investigate if MRI is sufficient to reliably replace TRUS preplanning in patients where preplan TRUS may be technically challenging.

60 APPLIED LIFE SCIENCES↗

NASA NTRS1985

The Statistical Loop Analyzer (SLA)

The statistical loop analyzer (SLA) is designed to automatically measure the acquisition, tracking and frequency stability performance characteristics of symbol synchronizers, code synchronizers, carrier tracking loops, and coherent transponders. Automated phase lock and system level tests can also be made using the SLA. Standard baseband, carrier and spread spectrum modulation techniques can be accomodated. Through the SLA's phase error jitter and cycle slip measurements the acquisition and tracking thresholds of the unit under test are determined; any false phase and frequency lock events are statistically analyzed and reported in the SLA output in probabilistic terms. Automated signal drop out tests can be performed in order to trouble shoot algorithms and evaluate the reacquisition statistics of the unit under test. Cycle slip rates and cycle slip probabilities can be measured using the SLA. These measurements, combined with bit error probability measurements, are all that are needed to fully characterize the acquisition and tracking performance of a digital communication system.

Lindsey, W. C.↗

DOE OSTI2017

Cerebral Cortex Regions Selectively Vulnerable to Radiation Dose-Dependent Atrophy

Purpose and Objectives: Neurologic deficits after brain radiation therapy (RT) typically involve decline in higher-order cognitive functions such as attention and memory rather than sensory defects or paralysis. We sought to determine whether areas of the cortex critical to cognition are selectively vulnerable to radiation dose-dependent atrophy. Methods and Materials: We measured change in cortical thickness in 54 primary brain tumor patients who underwent fractionated, partial brain RT. The study patients underwent high-resolution, volumetric magnetic resonance imaging (T1-weighted; T2 fluid-attenuated inversion recovery, FLAIR) before RT and 1 year afterward. Semiautomated software was used to segment anatomic regions of the cerebral cortex for each patient. Cortical thickness was measured for each region before RT and 1 year afterward. Two higher-order cortical regions of interest (ROIs) were tested for association between radiation dose and cortical thinning: entorhinal (memory) and inferior parietal (attention/memory). For comparison, 2 primary cortex ROIs were also tested: pericalcarine (vision) and paracentral lobule (somatosensory/motor). Linear mixed-effects analyses were used to test all other cortical regions for significant radiation dose-dependent thickness change. Statistical significance was set at α = 0.05 using 2-tailed tests. Results: Cortical atrophy was significantly associated with radiation dose in the entorhinal (P=.01) and inferior parietal ROIs (P=.02). By contrast, no significant radiation dose-dependent effect was found in the primary cortex ROIs (pericalcarine and paracentral lobule). In the whole-cortex analysis, 9 regions showed significant radiation dose-dependent atrophy, including areas responsible for memory, attention, and executive function (P≤.002). Conclusions: Areas of cerebral cortex important for higher-order cognition may be most vulnerable to radiation-related atrophy. This is consistent with clinical observations that brain radiation patients experience deficits in domains of memory, executive function, and attention. Correlations of regional cortical atrophy with domain-specific cognitive functioning in prospective trials are warranted.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

NASA NTRSDate not supplied

Neuro-behavioral Consequences of Low Dose Radiation Social Isolation and Sex Differences in the Longevity MCAT Mouse Model

The physiological responses to spaceflight elicit wide-ranging consequences and resemble aspects of aging on Earth. Previous studies have shown that oxidative damage via reactive oxygen species (ROS), contributes to aging-related pathologies. Our study uses 1-year old C57BL/6NJ male and female mice (astronaut-relevant age) that underwent exposure to 0.5 gray of gamma radiation together with social isolation and were euthanized 12 weeks after. We used the longevity MCAT mouse model in which human catalase is overexpressed in the mitochondria, for ROS quenching. We aimed to determine whether in older mice quenching ROS, will mitigate the neuro-behavioral consequences of low dose ionizing radiation and/or social isolation and whether the outcomes will differ in males and females. We have performed five mission relevant behavioral tests which focused on performance, memory, physical stance, and stress. We have detected both sex and radiation effects; the older females look physically better are faster and perform better almost in all behavioral tests compared to their male counterparts. On the other hand, they are more sensitive to low dose radiation in many cases, in some cases this effect was indeed mitigated in the MCAT mice, pointing out to the importance of ROS in response to radiation stress and social isolation. We have measured plasma (7- and 90-days post radiation), cytokines, corticosterone and hippocampal cytokine and microglial activation at the end of the experiment. We saw significant changes in the plasma markers due to radiation, sex, and genotype in both short and long post radiation period and detected long term sex and radiation effects in the brain. Our focus is now on applying advanced statistical modeling to corelate the behavioral tests with our recent molecular findings to look for specific biomarkers that could predict behavioral deficits.

radiation↗

NASA NTRS2001

Robust Strategy for Rocket Engine Health Monitoring

Monitoring the health of rocket engine systems is essentially a two-phase process. The acquisition phase involves sensing physical conditions at selected locations, converting physical inputs to electrical signals, conditioning the signals as appropriate to establish scale or filter interference, and recording results in a form that is easy to interpret. The inference phase involves analysis of results from the acquisition phase, comparison of analysis results to established health measures, and assessment of health indications. A variety of analytical tools may be employed in the inference phase of health monitoring. These tools can be separated into three broad categories: statistical, rule based, and model based. Statistical methods can provide excellent comparative measures of engine operating health. They require well-characterized data from an ensemble of "typical" engines, or "golden" data from a specific test assumed to define the operating norm in order to establish reliable comparative measures. Statistical methods are generally suitable for real-time health monitoring because they do not deal with the physical complexities of engine operation. The utility of statistical methods in rocket engine health monitoring is hindered by practical limits on the quantity and quality of available data. This is due to the difficulty and high cost of data acquisition, the limited number of available test engines, and the problem of simulating flight conditions in ground test facilities. In addition, statistical methods incur a penalty for disregarding flow complexity and are therefore limited in their ability to define performance shift causality. Rule based methods infer the health state of the engine system based on comparison of individual measurements or combinations of measurements with defined health norms or rules. This does not mean that rule based methods are necessarily simple. Although binary yes-no health assessment can sometimes be established by relatively simple rules, the causality assignment needed for refined health monitoring often requires an exceptionally complex rule base involving complicated logical maps. Structuring the rule system to be clear and unambiguous can be difficult, and the expert input required to maintain a large logic network and associated rule base can be prohibitive.

Santi, L. Michael↗

DOE OSTI2015

Active helium target: Neutron scalar polarizability extraction via Compton scattering

Precise measurement of the neutron scalar polarizabilities has been a lasting challenge because of the lack of a free-neutron target. Led by the University of Glasgow and the Mount Allison University groups of the A2 collaboration in Mainz, Germany, preparations have begun to test a recent theoretical model with an active helium target with the hope of determining these elusive quantities with small statistical, systematic, and model-dependent errors. Apparatus testing and background-event simulations have been carried out, with the full experiment projected to run in 2015. Once determined, these values can be applied to help understand quantum chromodynamics in the nonperturbative region.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRS1984

Statistical analysis of Thematic Mapper Simulator data for the geobotanical discrimination of rock types in southwest Oregon

An evaluation of Thematic Mapper Simulator (TMS) data for the geobotanical discrimination of rock types based on vegetative cover characteristics is addressed in this research. A methodology for accomplishing this evaluation utilizing univariate and multivariate techniques is presented. TMS data acquired with a Daedalus DEI-1260 multispectral scanner were integrated with vegetation and geologic information for subsequent statistical analyses, which included a chi-square test, an analysis of variance, stepwise discriminant analysis, and Duncan's multiple range test. Results indicate that ultramafic rock types are spectrally separable from nonultramafics based on vegetative cover through the use of statistical analyses.

Morrissey, L. A.↗

NASA NTRS2023

Plug20 Test Report: Particle Image Velocimetry (PIV) Measurements

This report provides turbulent flow statistics made using particle image velocimetry (PIV) for several internally mixed exhaust systems with external plugs (Plug20 designs). The tests were conducted at the NASA Glenn Research Center’s Aero-Acoustic Propulsion Laboratory (AAPL) in May and June 2022. The corresponding acoustic data for the configurations and flows presented in this report can be found in an earlier Technical Memorandum, NASA/TM-20210010291, “Plug20 Test Report.” The Plug20 nozzle family was designed to represent commercial supersonic vehicles in the 2025 to 2035 timeframe with a bypass ratio around 4, having an internal mixer, with and without an external plug to improve nacelle boattail drag and shock. The flow conditions measured represent engine cycles for commercial supersonic aircraft at takeoff, having pressure ratios of 2.0 and heated fan and core streams, measured both with and without a flight stream surrounding the plume. A few unheated flow conditions were also tested to tie results to other baseline test results. The PIV measurements in both streamwise and cross-stream planes are described, along with brief analysis to visually catalog the contents and confirm their validity. In this analysis, the streamwise PIV is found to match benchmark datasets within its experimental error. However, the cross-stream turbulent quantities measured by two systems do not match each other or the streamwise measurements in amplitude—caution is required when using the cross-stream data. Data acquired and included in this report are (1) velocity statistics of the plumes in both a streamwise and several cross-stream planes, and (2) the hot nozzle geometry. Tabular forms of the data and computer-aided design (CAD) files of the hot geometry are presented as supplemental files described in Appendix A (TM-20230006779SUPPL1.zip) and Appendix B (TM-20230006779SUPPL2.zip).

Turbulence↗

DOE OSTI2016

Sci-Fri AM: Quality, Safety, and Professional Issues 05: QC Program Management and the Benefits of QATrack+

Purpose: Treatment unit uptime statistics are typically used to monitor radiation equipment performance. The Ottawa Hospital Cancer Centre has introduced the use of Quality Control (QC) test success as a quality indicator for equipment performance and overall health of the equipment QC program. Methods: Implemented in 2012, QATrack+ is used to record and monitor over 1100 routine machine QC tests each month for 20 treatment and imaging units ( http://qatrackplus.com/ ). Using an SQL (structured query language) script, automated queries of the QATrack+ database are used to generate program metrics such as the number of QC tests executed and the percentage of tests passing, at tolerance or at action. These metrics are compared against machine uptime statistics already reported within the program. Results: Program metrics for 2015 show good correlation between pass rate of QC tests and uptime for a given machine. For the nine conventional linacs, the QC test success rate was consistently greater than 97%. The corresponding uptimes for these units are better than 98%. Machines that consistently show higher failure or tolerance rates in the QC tests have lower uptimes. This points to either poor machine performance requiring corrective action or to problems with the QC program. Conclusions: QATrack+ significantly improves the organization of QC data but can also aid in overall equipment management. Complimenting machine uptime statistics with QC test metrics provides a more complete picture of overall machine performance and can be used to identify areas of improvement in the machine service and QC programs.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2018

The Coupled Location/Depth/Yield Problem for North Korea’s Declared Nuclear Tests

On 3 September 2017, the Democratic People's Republic of Korea (DPRK) conducted its sixth and largest declared nuclear test at the Pung'gye Ri test site. Recently, we have been using regional waveform envelopes to estimate the explosive yield and overburden of chemical and nuclear explosions by coupling explosion source models to propagation parameters. Like most yield determination methods, there can be tradeoffs between yield and depth, leading to uncertainties in both parameters. The relative locations are well-constrained by small timing differences in seismic-phase arrivals at stations that recorded multiple events, but there are potential uncertainties on the absolute locations. Depths are poorly constrained by the relative arrival times. In this study, we have performed a coupled location and yield analysis of the DPRK nuclear tests. We use correlation methods to get highly accurate travel times and relative locations using a Bayesian location method. Then, while keeping the relative locations of the six tests constant, we consider the consequences of shifts to the absolute locations on the resulting overburden for each event. Given that overburden, we determine the yield that minimizes the waveform misfit. We also test and compare a number of explosion source models. By considering the coupled location/depth/yield problem, we reduce uncertainties in the absolute locations, and yield and depth estimates of the events. Based on statistical analysis, we estimate that the 2017 test has a yield of 125 kilotons (equivalent TNT) with a 1 sigma uncertainty range of 103-150 ktons at about 600 m of overburden.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2021

Long-term Dynamical Stability in the Outer Solar System. I. The Regular and Chaotic Evolution of the 34 Largest Trans-Neptunian Objects

We carried out an extensive analysis of the stability of the outer solar system, making use of the frequency analysis technique over short-term integrations of nearly 100,000 test particles, as well as a statistical analysis of 200 1 Gyr long numerical simulations, which consider the mutual perturbations of the giant planets and the 34 largest trans-Neptunian objects (we have called all 34 objects “dwarf planets,” DPs, even if probably only the largest of them are true DPs). From the frequency analysis, we produced statistical diffusion maps for a wide region of the a–e phase-space plane; we also present the average diffusion time for orbits as a function of perihelion. We later turned our attention to the 34 DPs, making an individualized analysis for each of them and producing a first approximation of their future stability. From the 200 distinct realizations of the orbital evolution of the 34 DPs, we classified the sample into three categories, including 17 stable, 11 unstable, and 6 resonant objects; we also found that, statistically, two objects from the sample will leave the trans-Neptunian region within the next gigayear, most likely being ejected from the solar system, but with a nonnegligible probability of going inside the orbit of Neptune, either to collide with a giant planet or even falling to the inner solar system, where our simulations are no longer able to resolve their continuous evolution.

79 ASTRONOMY AND ASTROPHYSICS↗

NASA NTRS2016

High-Performance Reaction Wheel Optimization for Fine-Pointing Space Platforms: Minimizing Induced Vibration Effects on Jitter Performance plus Lessons Learned from Hubble Space Telescope for Current and Future Spacecraft Applications

The Hubble Space Telescope (HST) applies large-diameter optics (2.5-m primary mirror) for diffraction-limited resolution spanning an extended wavelength range (approx. 100-2500 nm). Its Pointing Control System (PCS) Reaction Wheel Assemblies (RWAs), in the Support Systems Module (SSM), acquired an unprecedented set of high-sensitivity Induced Vibration (IV) data for 5 flight-certified RWAs: dwelling at set rotation rates. Focused on 4 key ratios, force and moment harmonic values (in 3 local principal directions) are extracted in the RWA operating range (0-3000 RPM). The IV test data, obtained under ambient lab conditions, are investigated in detail, evaluated, compiled, and curve-fitted; variational trends, core causes, and unforeseen anomalies are addressed. In aggregate, these values constitute a statistically-valid basis to quantify ground test-to-test variations and facilitate extrapolations to on-orbit conditions. Accumulated knowledge of bearing-rotor vibrational sources, corresponding harmonic contributions, and salient elements of IV key variability factors are discussed. An evolved methodology is presented for absolute assessments and relative comparisons of macro-level IV signal magnitude due to micro-level construction-assembly geometric details/imperfections stemming from both electrical drive and primary bearing design parameters. Based upon studies of same-size/similar-design momentum wheels' IV changes, upper estimates due to transitions from ground tests to orbital conditions are derived. Recommended HST RWA choices are discussed relative to system optimization/tradeoffs of Line-Of-Sight (LOS) vector-pointing focal-plane error driven by higher IV transmissibilities through low-damped structural dynamics that stimulate optical elements. Unique analytical disturbance results for orbital HST accelerations are described applicable to microgravity efforts. Conclusions, lessons learned, historical context/insights, and perspectives on future applications are given; these previously unpublished data and findings represents a valuable resource for fine-pointing spacecraft or space-based platforms using RWAs, Control Moment Gyros (CMGs), Momentum Wheels, or other ball-bearing-based rotational units.

Hasha, Martin D.↗

NASA NTRS2017

Updated MISR Dark Water Research Aerosol Retrieval Algorithm - Part 1: Coupled 1.1 km Ocean Surface Chlorophyll a Retrievals with Empirical Calibration Corrections

As aerosol amount and type are key factors in the 'atmospheric correction' required for remote-sensing chlorophyll alpha concentration (Chl) retrievals, the Multi-angle Imaging SpectroRadiometer (MISR) can contribute to ocean color analysis despite a lack of spectral channels optimized for this application. Conversely, an improved ocean surface constraint should also improve MISR aerosol-type products, especially spectral single-scattering albedo (SSA) retrievals. We introduce a coupled, self-consistent retrieval of Chl together with aerosol over dark water. There are time-varying MISR radiometric calibration errors that significantly affect key spectral reflectance ratios used in the retrievals. Therefore, we also develop and apply new calibration corrections to the MISR top-of-atmosphere (TOA) reflectance data, based on comparisons with coincident MODIS (Moderate Resolution Imaging Spectroradiometer) observations and trend analysis of the MISR TOA bidirectional reflectance factors (BRFs) over three pseudo-invariant desert sites. We run the MISR research retrieval algorithm (RA) with the corrected MISR reflectances to generate MISR-retrieved Chl and compare the MISR Chl values to a set of 49 coincident SeaBASS (SeaWiFS Bio-optical Archive and Storage System) in situ observations. Where Chl(sub in situ) less than 1.5 mg m(exp -3), the results from our Chl model are expected to be of highest quality, due to algorithmic assumption validity. Comparing MISR RA Chl to the 49 coincident SeaBASS observations, we report a correlation coefficient (r) of 0.86, a root-mean-square error (RMSE) of 0.25, and a median absolute error (MAE) of 0.10. Statistically, a two-sample Kolmogorov- Smirnov test indicates that it is not possible to distinguish between MISR Chl and available SeaBASS in situ Chl values (p greater than 0.1). We also compare MODIS-Terra and MISR RA Chl statistically, over much broader regions. With about 1.5 million MISR-MODIS collocations having MODIS Chl less than 1.5 mg m(exp -3), MISR and MODIS show very good agreement: r = 0.96, MAE = 0.09, and RMSE = 0.15. The new dark water aerosol/Chl RA can retrieve Chl in low-Chl, case I waters, independent of other imagers such as MODIS, via a largely physical algorithm, compared to the commonly applied statistical ones. At a minimum, MISR's multi-angle data should help reduce uncertainties in the MODIS-Terra ocean color retrieval where coincident measurements are made, while also allowing for a more robust retrieval of particle properties such as spectral single-scattering albedo.

Limbacher, James A.↗

NASA NTRS1998

Neutral Networks for Subpixel Classification of Multispectral Images

In this work, the implementation and use of AVHRR (Advanced Very High Resolution Radiometer) images for subpixel analysis is studied. The work consists of two parts, the first is making training data, the second is using the training data to design a neural net subpixel analyzer. Most work on subpixel analysis has been done with images with more spectral bands. AVHRR images were chosen because of their easy acquisition, and because the five spectral bands allow investigation into the development of training data. The first step in subpixel analysis is the development of training data. This consists of image to be classified, and the classification of each pixel. In order to do the classification, a high spatial resolution image is typically needed in order to manually create a classified image. It is difficult to have both the image of interest, and a high spatial resolution image of the same area taken at the same time. Thus it was studied whether a subsampled image taken from the image of interest could serve as the training data. Statistical work has been done showing the unusefulness of this approach. In the second part of the analysis, a feedforward neural net was trained and used to classify the AVHRR images. Results of these tests, comparing the neural net with typical statistical based schemes are shown.

Figueroa, Ricardo R.↗

NASA NTRS1997

Development of Statistical Process Control Methodology for an Environmentally Compliant Surface Cleaning Process in a Bonding Laboratory

Bonding labs at both MSFC and the northern Utah production plant prepare bond test specimens which simulate or witness the production of NASA's Reusable Solid Rocket Motor (RSRM). The current process for preparing the bonding surfaces employs 1,1,1-trichloroethane vapor degreasing, which simulates the current RSRM process. Government regulations (e.g., the 1990 Amendments to the Clean Air Act) have mandated a production phase-out of a number of ozone depleting compounds (ODC) including 1,1,1-trichloroethane. In order to comply with these regulations, the RSRM Program is qualifying a spray-in-air (SIA) precision cleaning process using Brulin 1990, an aqueous blend of surfactants. Accordingly, surface preparation prior to bonding process simulation test specimens must reflect the new production cleaning process. The Bonding Lab Statistical Process Control (SPC) program monitors the progress of the lab and its capabilities, as well as certifies the bonding technicians, by periodically preparing D6AC steel tensile adhesion panels with EA-91 3NA epoxy adhesive using a standardized process. SPC methods are then used to ensure the process is statistically in control, thus producing reliable data for bonding studies, and identify any problems which might develop. Since the specimen cleaning process is being changed, new SPC limits must be established. This report summarizes side-by-side testing of D6AC steel tensile adhesion witness panels and tapered double cantilevered beams (TDCBs) using both the current baseline vapor degreasing process and a lab-scale spray-in-air process. A Proceco 26 inches Typhoon dishwasher cleaned both tensile adhesion witness panels and TDCBs in a process which simulates the new production process. The tests were performed six times during 1995, subsequent statistical analysis of the data established new upper control limits (UCL) and lower control limits (LCL). The data also demonstrated that the new process was equivalent to the vapor degreasing process.

Hutchens, Dale E.↗