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NASA NTRS2004

Data Fusion in Wind Tunnel Testing; Combined Pressure Paint and Model Deformation Measurements (Invited)

As the benefit-to-cost ratio of advanced optical techniques for wind tunnel measurements such as Video Model Deformation (VMD), Pressure-Sensitive Paint (PSP), and others increases, these techniques are being used more and more often in large-scale production type facilities. Further benefits might be achieved if multiple optical techniques could be deployed in a wind tunnel test simultaneously. The present study discusses the problems and benefits of combining VMD and PSP systems. The desirable attributes of useful optical techniques for wind tunnels, including the ability to accommodate the myriad optical techniques available today, are discussed. The VMD and PSP techniques are briefly reviewed. Commonalties and differences between the two techniques are discussed. Recent wind tunnel experiences and problems when combining PSP and VMD are presented, as are suggestions for future developments in combined PSP and deformation measurements.

Bell, James H.↗

NASA NTRS2022

Local Scale (3-M) Soil Moisture Mapping Using SMAP and Planet Superdove

A capability for mapping meter-level resolution soil moisture with frequent temporal sampling over large regions is essential for quantifying local-scale environmental heterogeneity and eco-hydrologic behavior. However, available surface soil moisture (SSM) products generally involve much coarser grain sizes ranging from 30 m to several 10s of kilometers. Hence a new method is proposed to estimate 3-m resolution SSM using a combination of multi-sensor fusion, machine- learning (ML) and Cumulative Distribution Function (CDF) matching approaches. This method established favorable SSM correspondence between 3-m pixels and overlying 9-km grid cells from overlapping Planet SuperDove (PSD) observations and NASA Soil Moisture Active-Passive (SMAP) mission products. The resulting 3-m SSM predictions showed improved accuracy by reducing ab- solute bias and RMSE by ~0.01 cm3/cm3 over the original SMAP data in relation to in-situ soil moisture measurements for the Australian Yanco region, while preserving the high sampling frequency (1-3 day global revisit) and sensitivity to surface wetness (R 0.865) from SMAP. Heterogeneous soil moisture distributions varying with vegetation biomass gradients and irrigation regimes were generally captured within a selected study area. Further algorithm refinement and implementation for regional applications will allow for improvement in water resources management, precision agriculture, and disaster forecasts and responses.

soil moisture↗

NASA NTRS1972

Ion and laser microprobes applied to the measurement of corrosion produced hydrogen on a microscopic scale.

Use of an ion microprobe and a laser microprobe to measure concentrations of corrosion-produced hydrogen on a microscopic scale. Hydrogen concentrations of several thousand ppm were measured by both analytical techniques below corroded and fracture surfaces of hot salt stress corroded titanium alloy specimens. This extremely high concentration compares with only about 100 ppm hydrogen determined by standard vacuum fusion chemical analyses of bulk samples. Both the ion and laser microprobes were used to measure hydrogen concentration profiles in stepped intervals to substantial depths below the original corroded and fracture surfaces. For the ion microprobe, the area of local analysis was 22 microns in diameter and for the laser microprobe, the area of local analysis was about 300 microns in diameter. The segregation of hydrogen below fracture surfaces supports a previously proposed theory that corrosion-produced hydrogen is responsible for hot salt stress corrosion embrittlement and cracking of titanium alloys. These advanced analytical techniques suggest great potential for many areas of stress corrosion and hydrogen embrittlement research, quality control, and field inspection of corrosion problems. For example, it appears possible that a contour map of hydrogen distribution at notch roots and crack tips could be quantitatively determined. Such information would be useful in substantiating current theories of stress corrosion and hydrogen embrittlement.

Gray, H. R.↗

NASA NTRS2000

Demonstration of a Large-Scale Tank Assembly via Circumferential Friction Stir Welds

A collaborative effort between NASA/Marshall Space Flight Center and the Michoud Unit of Lockheed Martin Space Systems Company was undertaken to demonstrate assembly of a large-scale aluminum tank using circumferential friction stir welds. The hardware used to complete this demonstration was fabricated as a study of near-net- shape technologies. The tooling used to complete this demonstration was originally designed for assembly of a tank using fusion weld processes. This presentation describes the modifications and additions that were made to the existing fusion welding tools required to accommodate circumferential friction stir welding, as well as the process used to assemble the tank. The tooling modifications include design, fabrication and installation of several components. The most significant components include a friction stir weld unit with adjustable pin length capabilities, a continuous internal anvil for 'open' circumferential welds, a continuous closeout anvil, clamping systems, an external reaction system and the control system required to conduct the friction stir welds and integrate the operation of the tool. The demonstration was intended as a development task. The experience gained during each circumferential weld was applied to improve subsequent welds. Both constant and tapered thickness 14-foot diameter circumferential welds were successfully demonstrated.

Jones, Clyde S.↗

NASA NTRSDate not supplied

Thin-wall Internal Channel Geometry and Surface Enhancements for Heat Exchangers using Laser Powder Directed Energy Deposition

Additive Manufacturing (AM) has offered many new design and manufacturing opportunities for components across various industries. As AM evolves there is a need to better understand outputs of the process including geometric limitations, surface texture, and post-processing surface enhancements for specific application requirements. One possible application area of AM are components using thin-wall (~1 mm) microchannel heat exchangers for subsystems across aerospace and industrial applications. Laser Powder Bed Fusion (L-PBF) is a common process for complex internal channels but the build diameter is limited to approximately 600 mm. Laser Powder Directed Energy Deposition (LP-DED) is being evaluated to produce thin-wall microchannel heat exchangers at scales beyond the L-PBF process. Successful deployment of the LP-DED technology requires characterization of geometric features from the process and potential improvements to the surface using post-processing. Surface texture, inclusive of roughness and waviness, is one of the critical attributes of AM that effects the friction factor and pressure drop within a heat exchanger and lacks data for the LP-DED process. This presentation will provide an overview of the characterization work completed of the LP-DED process for thin-walls and small channel geometry representative of various high performance alloys including NASA HR-1 and GRCop-42. An overview of the experiments conducted with varying LP-DED parameters, evaluation of various internal channel geometry, geometric build features, and resulting surface texture will be provided along with a summary of conclusions from these experiments. This study presents characterization of 2.5 mm microchannels using LP-DED, mechanisms that cause the surface texture which include powder adherence and material droop, and angled walls have a significant impact on the thickness and surface texture. Results will also be presented on various surface enhancement processes that allow for tuning of the wetting surface for friction factor, heat transfer, or fatigue life performance requirements.

Additive Manufacturing↗

NASA NTRSDate not supplied

Parameter, Post-Processing Sensitivities, and Qualification Approach of Laser Powder Bed Fusion Hydrogen Resistant Alloy NASA HR-1

Metal additive manufacturing (AM) processes are being used to enable economical manufacturing of legacy alloys as well as advancing new alloys. Laser powder bed fusion (L-PBF) is a metal AM process that has high maturity and being used to produce a variety of parts for space applications including complex propulsion components. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique space applications such as high-pressure hydrogen environments. NASA HR-1 is a high strength Fe-Ni based superalloy designed to resist high pressure hydrogen environment embrittlement (HEE), oxidation, and corrosion that has been successfully adapted to laser powder directed energy deposition (LP-DED). Insights gained from the NASA HR-1 development for LP-DED have guided the development process for L-PBF. However, adapting NASA HR-1 to L-PBF posed new challenges due to the distinct differences between the additive manufacturing processes. During parameter development, sensitivities were observed in post-processing that necessitated additional optimization of heat treatments. Additionally, the variations in thickness and how it influenced the microstructural response during heat treatment was characterized. Understanding these sensitivities is important to qualification of the material in a L-PBF machine. This ensures that the microstructures and properties of the material maintain consistency in production. This presentation will cover parameter development along with post-processing challenges and solutions will be discussed in addition to key material properties as it pertains to application performance and qualification per NASA-STD-6030. Improvements made by developing a derivative alloy, NASA HR-2, will be highlighted through preliminary small scale parameter development, material characterization, and initial property testing.

NASA HR-1↗

NASA NTRS2002

Expression and affinity purification of recombinant proteins from plants

With recent advances in plant biotechnology, transgenic plants have been targeted as an inexpensive means for the mass production of proteins for biopharmaceutical and industrial uses. However, the current plant purification techniques lack a generally applicable, economic, large-scale strategy. In this study, we demonstrate the purification of a model protein, beta-glucuronidase (GUS), by employing the protein calmodulin (CaM) as an affinity tag. In the proposed system, CaM is fused to GUS. In the presence of calcium, the calmodulin fusion protein binds specifically to a phenothiazine-modified surface of an affinity column. When calcium is removed with a complexing agent, e.g., EDTA, calmodulin undergoes a conformational change allowing the dissociation of the calmodulin-phenothiazine complex and, therefore, permitting the elution of the GUS-CaM fusion protein. The advantages of this approach are the fast, efficient, and economical isolation of the target protein under mild elution conditions, thus preserving the activity of the target protein. Two types of transformation methods were used in this study, namely, the Agrobacterium-mediated system and the viral-vector-mediated transformation system. Copyright 2002 Elsevier Science (USA).

Non-NASA Center↗

NASA NTRS1980

Active heat exchange system development for latent heat thermal energy storage

Alternative mechanizations of active heat exchange concepts were analyzed for use with heat of fusion Phase Change Materials (PCM's) in the temperature range of 250 C to 350 C for solar and conventional power plant applications. Over 24 heat exchange concepts were reviewed, and eight were selected for detailed assessment. Two candidates were chosen for small-scale experimentation: a coated tube and shell that exchanger, and a direct contact reflux boiler. A dilute eutectic mixture of sodium nitrate and sodium hydroxide was selected as the PCM from over fifty inorganic salt mixtures investigated. Preliminary experiments with various tube coatings indicated that a nickel or chrome plating of Teflon or Ryton coating had promise of being successful. An electroless nickel plating was selected for further testing. A series of tests with nickel-plated heat transfer tubes showed that the solidifying sodium nitrate adhered to the tubes and the experiment failed to meet the required discharge heat transfer rate of 10 kW(t). Testing of the reflux boiler is under way.

Lefrois, R. T.↗

NASA NTRS2000

Structure of Protoplanetary Environments

Our research focused on the structure and composition of the disks in the T Tau and Haro 6-10 multiple star systems and on the nature of the 'infrared companions' that these systems contain. This work has resulted in two papers, one on T Tau, presently under review at the Astrophysical Journal, and the other, on Haro 6-10, about to be submitted to Astronomy and Astrophysics. In the paper 'Evidence for Extinction and Accretion Variability in T Tau S' by Tracy L. Beck, L. Prato, and M. Simon, we present angularly resolved spectra of T Tau N (the visible star) and T Tau S (the infrared companion, IRC) in the three micrometer water ice-feature and the K-band. Most of the water ice absorption lies along the line of sight to T Tau S, confirming it is seen through stronger obscuration. A decrease in the ice-band absorption toward T Tau S between 12/98 and 1/00, significant, at the two-sigma level, was associated with an increase in its near IR flux. Bracket gamma emission is detected in T Tau N and S, and H2 (2.12 micrometer) emission only toward T Tau S, consistent with previous studies of IRCs. Our results suggest that the near IR variability of T Tau S is probably caused by both variations in accretion rate and extinction. Our paper on Haro 6-10, 'The Near IR and Ice Band Variability of Haro, 6-10' by Ch. Leinert, T.L. Beck, S. Ligori, M. Simon, J. Woitas, and R.R. Howell, represents a fusion of originally independent efforts at the Max Planck Institut fur Astronomie (Heidelberg) and Stony Brook. Our combined observations demonstrate that both Haro 6-10 S (the visible star) and Haro 6-10 N (the IRC) vary significantly in near IR flux on time scales as short as a month. The substantial decrease of Haro 6-10 S in the last four years carries the photometric signature of increased extinction. However, a comparable K-band flux increase of the IRC is associated with a dimming at H so cannot be explained by lower extinction. Absorption in the 3.1 micrometer ice band was always greater toward the IRC during our observations indicating a large amount of obscuring material. We detect variable extinction in the ice-band toward Haro 6-10 S and the IRC, significant at the 3.5-sigma and 2.0-sigma levels, respectively.

Simon, Michal↗

NASA NTRS1972

Development of dispersion-strengthened Ni-Cr-ThOz alloys for the space shuttle thermal protection system

Manufacturing processes were developed for TD-NiCr providing small sheet (45 x 90 cm), and larger sheet (60 x 150 cm) and foil. The alternate alloy, DS-NiCr, was produced by pack-chromizing Ni-ThO2 sheet. Formability criteria are being established for basic sheet forming processes, which are brake forming, corrugation forming, joggling, dimpling, and beading. Resistance spot welding (fusion and solid state), resistance seam welding, solid state diffusion welding, and brazing are included in the joining programs. Major emphasis is centered on an Al-modified Ni-Cr-ThO2 alloy development. These alloys, containing 3 to 5% Al, form the protective Al2O3 scale. This enhances oxidation resistance under reentry conditions. Both TD-NiCrAl and DS-NiCrAl alloys are included. A tentative composition of Ni-16Cr-3.5Al-2ThO2 was selected based on oxidation resistance and fabricability.

Blankenship, C. P.↗

NASA NTRS1991

Inverse energy cascades in three-dimensional turbulence

Fully three-dimensional magnetohydrodynamic (MHD) turbulence at large kinetic and low magnetic Reynolds numbers is considered in the presence of a strong uniform magnetic field. It is shown by numerical simulation of a model of MHD that the energy inverse cascades to longer length scales when the interaction parameter is large. While the steady-state dynamics of the driven problem is three-dimensional in character, the behavior has resemblance to two-dimensional hydrodynamics. These results have implications in turbulence theory, MHD power generator, planetary dynamos, and fusion reactor blanket design.

Hossain, Murshed↗

NASA NTRS2001

Friction Stir Welding Development at NASA, Marshall Space Flight Center

Friction stir welding (FSW) is a solid state process that pan be used to join materials without melting. The process was invented by The Welding Institute (TWI), Cambridge, England. Friction stir welding exhibits several advantages over fusion welding in that it produces welds with fewer defects and higher joint efficiency and is capable of joining alloys that are generally considered non-weldable with a fusion weld process. In 1994, NASA-Marshall began collaborating with TWI to transform FSW from a laboratory curiosity to a viable metal joining process suitable for manufacturing hardware. While teamed with TWI, NASA-Marshall began its own FSW research and development effort to investigate possible aerospace applications for the FSW process. The work involved nearly all aspects of FSW development, including process modeling, scale-up issues, applications to advanced materials and development of tooling to use FSW on components of the Space Shuttle with particular emphasis on aluminum tanks. The friction stir welding process involves spinning a pin-tool at an appropriate speed, plunging it into the base metal pieces to be joined, and then translating it along the joint of the work pieces. In aluminum alloys the rotating speed typically ranges from 200 to 400 revolutions per minute and the translation speed is approximately two to five inches per minute. The pin-tool is inserted at a small lead angle from the axis normal to the work piece and requires significant loading along the axis of the tool. An anvil or reaction structure is required behind the welded material to react the load along the axis of the pin tool. The process requires no external heat input, filler material, protective shielding gas or inert atmosphere typical of fusion weld processes. The FSW solid-state weld process has resulted in aluminum welds with significantly higher strengths, higher joint efficiencies and fewer defects than fusion welds used to join similar alloys.

McGill, Preston↗

NASA NTRSDate not supplied

Bridging the Last Mile with Open-Source Advancements: Empowering Communities through Fusion of Aerosol Optical Depth (AOD) Products from Multi-Satellite Sensors

Aerosol Optical Depth (AOD) is a crucial parameter for understanding atmospheric aerosol distribution and their impact on climate and air quality. With the growing number of Earth observation satellites, there is an abundance of AOD products derived from various sensors onboard both geostationary and low-orbit satellites. The availability of multiple datasets provides an opportunity to harness the strengths of each sensor and create comprehensive and accurate AOD datasets for climate and air quality studies at different temporal and spatial scales. Our NASA aerosol MEaSURES project has made significant strides in recent years by undertaking the ambitious task of developing an open-source package tailored for fusing AOD products from different sources. The package is based on OOP (Object-Oriented Programming) design and is implemented in Python modules. Generic interfaces enable easy inclusion of large and heterogeneous data. The package may be utilized to produce harmonized AOD datasets with enhanced spatial and temporal coverage. The latest version of the package is able to process and integrate the dark-target AOD data from six different sensors: AHI Himawari-8, ABI GOES-West, ABI GOES-East, MODIS AQUA, MODIS TERRA, and VIIRS SNPP. Rigorous validation and intercomparison studies have been performed to assess the accuracy and reliability of the fused AOD product against ground-based measurements and reference datasets. The open-source nature of the developed package ensures transparency, reproducibility, and community engagement. The research community and stakeholders can access, contribute to, and further improve the fusion methodology, making it adaptable to other studies, or expanding it to include new satellite data as they become available. In this poster presentation, we will introduce the accomplishments and challenges faced during the development of the open-source package for AOD data fusion, and demonstrate the advantages of combining AOD products from the six aforementioned satellite sensors. The presentation aims to foster discussions, collaborations, and future directions in integrating Earth observation and remote sensing data, which may contribute to a better understanding of atmospheric aerosols and their impacts on our environment.

Zhaohui Zhang↗

NASA NTRSDate not supplied

Large Scale and Multi-Alloy Rocket Engine Component Development using Various Metal Additive Manufacturing Techniques

The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing (AM) for use in liquid rocket engine component design, development, and testing since 2010. These AM techniques have been demonstrated to significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The focus at the NASA MSFC for these metal additive manufacturing techniques include laser powder-bed fusion (L-PBF), blown powder directed energy deposition (DED), arc-based deposition, and Laser Wire Direct Closeout (LWDC). A variety of components have been evaluated and tested including thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. To support these component applications in harsh environments, NASA has advanced a variety of “standard” additive manufacturing alloys such as those in the superalloy-family and also evolved new alloys including GRCop-84, GRCop-42, NASA HR-1, and JBK-75. The purpose of this presentation is to discuss the various component programs at the NASA MSFC using AM to develop, fabricate, and test combustion devices hardware and the evolution of the new additive alloys. One of these projects that will be highlighted is Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), which includes new process development for large scale AM components, multi-metallic AM components, including unique component designs using additive manufacturing. Additional information will be provided on the development of other components, hot-fire testing, post-processing of AM techniques including surface enhancements (polishing) techniques, material and process characterization, future development programs, and dissemination of data to industry partners.

Additive Manufacturing↗

NASA NTRS2004

Magnetohydrodynamic Instabilities in a Simple Gasdynamic Mirror Propulsion System

The gasdynamic mirror has been proposed as a concept which could form the basis of a highly efficient fusion rocket engine. Gasdynamic mirrors differ from most other mirror type plasma confinement schemes in that they have much larger aspect ratios and operate at somewhat higher plasma densities. To evaluate whether a gasdynamic mirror could indeed confine plasmas in a stable manner for long periods of time, a small scale experimental gasdynamic mirror was built and tested. The objective of this experiment was to determine ranges of mirror ratios and plasma densities over which gasdynamic mirror could maintain stable plasmas. Theoretical analyses indicated that plasma magnetohydrodynamic instabilities were likely to occur during subsonic to supersonic flow transitions in the mirror throat region of the gasdynamic mirror. The experimental evidence based upon data derived from the Langmuir probe measurements seems to confirm this analysis. The assumption that a gasdynamic mirror using a simple mirror geometry could be used as a propulsion system, therefore, appears questionable. Modifications to the simple mirror concept are presented which could mitigate these MHD instabilities.

Emrich, William J., Jr.↗

NASA NTRS1985

An experimental investigation of agglutinate melting mechanisms - Shocked mixtures of sodium and potassium feldspars

The results of an experiment designed to test the validity of the model for agglutinate formation involving fusion of the finest fraction or F3 are reported. Impact glasses were formed from various mixes of orthoclase and albite powders, which were used as analogs for soils with chemically constrasting coarse and fine fractions. The results showed that the single most important factor displacing the composition of a small-scale impact melt from the bulk composition of the source regolith is the fractionated composition of the finest soil fraction. Volatile loss and the amount of melting, which in turn are determined by the degree of shock, are also important. As predicted by the model, the lower pressure melts are the most fractionated, and higher pressure is accompanied by increased melting causing glass compositions to approach the bulk. In general, the systematics predicted by the model are observed; the model appears to be valid.

Simon, S. B.↗

NASA NTRS2018

Quantifying Methane Leak Emissions by Fused Airborne Imaging Spectroscopy with in Situ Surface Mobile and Airborne Observations of a California Producing Oil Field

Methane (CH4) emission budgets remain uncertain and are projected to grow as oil and gas production from short-lived wells increases and their subsequent transport through aging gas distribution networks. Orders-of-magnitude variations in temporal, spatial, and emission scales present a key challenge to leak detection and quantification. Also, the probability distributions for large and stochastic, leaky systems such as geological reservoirs (by natural migration-seeps) and petroleum production from those reservoirs remain largely unknown, needed to address current approach limitations. The scale of many petroleum systems favors remote sensing, but the sensitivity of such systems often precludes detection of weak emissions. Consequently, an accurate evaluation requires that the relative contribution from the emission "tails" of small leaks also be quantified, which is best carried out using high-sensitivity in situ methods. Fusion of remote sensing and in situ approaches leverages complementary capabilities to address these limitations. We show results from mobile surface (AMOG) and airborne in situ (AJAX) and thermal-infrared (TIR) hyperspectral imaging spectroscopy (Mako) data applied to a producing oil field in the California Central Valley near Bakersfield. AMOG is an automobile-based mobile lab that measures 13 trace gases, aerosol size distributions and vertical profiles, 3D winds and other meteorology, and atmospheric column measurements by solar spectroscopy at highway speeds. AJAX measures 5 trace gases and 3D winds at ~140 m/s. Mako is a broad-area TIR imaging spectrometer that can discriminate multiple gases present in each pixel acquired. In situ-derived, total field emissions were 31±16 Gg/yr CH4. This was compared with Mako-derived emissions from all plumes identified across the study site. We found that super-emitters were not the dominant emissions mode and the spatial pattern of plume locations from production infrastructure was correlated to geological structures.

Leifer, Ira↗

NASA NTRS2016

Design, Development and Hotfire Testing of Monolithic Copper and Bimetallic Additively Manufactured Combustion Chambers

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM) otherwise commonly referred to as additive manufacturing. The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for the GRCop-84 copper-alloy commensurate with powder bed additive manufacturing, evaluate bimetallic deposition and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. As a direct spin off of this program, NASA is working with industry partners to further develop the printing process for the GRCop-84 material in addition to the C-18150 (CuCrZr) material. To advance the process further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic additively manufactured chambers. A 1.2k sized thrust-chamber was designed and developed to compare the printing process of the GRCop-84 and C-18150 SLM materials. A series of similar MCC liners also completed development with an Inconel 625 jacket bonded to the GRcop-84 liner evaluating direct metal deposition (DMD) laser and arc-based techniques. This paper describes the design, development, manufacturing and testing of these combustion chambers and associated lessons learned throughout the design and development process.

Gradl, Paul↗