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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS1979

Homogeneous alignment of nematic liquid crystals by ion beam etched surfaces

A wide range of ion beam etch parameters capable of producing uniform homogeneous alignment of nematic liquid crystals on SiO2 films are discussed. The alignment surfaces were generated by obliquely incident (angles of 5 to 25 deg) argon ions with energies in the range of 0.5 to 2.0 KeV, ion current densities of 0.1 to 0.6 mA sq cm and etch times of 1 to 9 min. A smaller range of ion beam parameters (2.0 KeV, 0.2 mA sq cm, 5 to 10 deg and 1 to 5 min.) were also investigated with ZrO2 films and found suitable for homogeneous alignment. Extinction ratios were very high (1000), twist angles were small ( or = 3 deg) and tilt-bias angles very small ( or = 1 deg). Preliminary scanning electron microscopy results indicate a parallel oriented surface structure on the ion beam etched surfaces which may determine alignment.

Wintucky, E. G.↗
NASA NTRS1994

Automatic commanding of the Mars Observer Camera

Mars Observer, launched in September 1992, was intended to be a 'survey-type' mission that acquired global coverage of Mars from a low, circular, near-polar orbit during an entire Martian year. As such, most of its instruments had fixed data rates, wide fields of view, and relatively low resolution, with fairly limited requirements for commanding. An exception is the Mars Observer Camera, or MOC. The MOC consists of a two-color Wide Angle (WA) system that can acquire both global images at low resolution (7.5 km/pixel) and regional images at commandable resolutions up to 250 m/pixel. Complementing the WA is the Narrow Angle (NA) system, that can acquire images at 8 resolutions from 12 m/pixel to 1.5 m/pixel, with a maximum crosstrack dimension of 3 km. The MOC also provides various forms of data compression (both lossless and lossy), and is designed to work at data rates from 700 bits per second (bps) to over 80k bps. Because of this flexibility, developing MOC command sequences is much more difficult than the routine mode-changing that characterizes other instrument operations. Although the MOC cannot be pointed (the spacecraft is fixed nadir-pointing and has no scan platform), the timing, downlink stream allocation, compression type and parameters, and image dimensions of each image must be commanded from the ground, subject to the constraints inherent in the MOC and the spacecraft. To minimize the need for a large operations staff, the entire command generation process has been automated within the MOC Ground Data System. Following the loss of the Mars Observer spacecraft in August 1993, NASA intends to launch a new spacecraft, Mars Global Surveyor (MGS), in late 1996. This spacecraft will carry the MOC flight spare (MOC 2). The MOC 2 operations plan will be largely identical to that developed for MOC, and all of the algorithms described here are applicable to it.

Caplinger, Michael↗
NASA NTRS2019

Radiometric Model and Inter-Comparison Results of the SGLI-VNR On-Board Calibration

The Second Generation Global Imager (SGLI) on Global Change Observation Mission– Climate (GCOM-C) satellite empowers surface and atmospheric measurements related to the carbon cycle and radiation budget, with two radiometers of Visible and Near Infrared Radiometer (SGLI-VNR) and Infrared Scanning Radiometer (SGLI-IRS) that perform a wide-band (380 nm–12 µm) optical observation not only with as wide as a 1150–1400 km field of view (FOV), but also with as high as 0.25–0.5 km resolution. Additionally, polarization and along-track slant view observations are quite characteristic of SGLI. It is important to calibrate radiometers to provide the sensor data records for more than 28 standard products and 23 research products including clouds, aerosols, ocean color, vegetation, snow and ice, and other applications. In this paper, the radiometric model and the first results of on-board calibrations on the SGLI-VNR, which include weekly solar and light-emitting diode (LED) calibration and monthly lunar calibration, will be described. Each calibration data was obtained with corrections, where beta angle correction and avoidance of reflection from multilayer insulation (MLI) were applied for solar calibration; LED temperature correction was performed for LED calibration; and the GIRO (GSICS (Global Space-based Inter-Calibration System) Implementation of the ROLO (RObotic Lunar Observatory) model) model was used for lunar calibration. Results show that the inter-comparison of the relative degradation amount between these three calibrations agreed to within 1% or less.

Urabe, Tomoyuki↗
NASA NTRS1984

Sample size and scene identification (cloud) - Effect on albedo

Scan channels on the Nimbus 7 Earth Radiation Budget instrument sample radiances from underlying earth scenes at a number of incident and scattering angles. A sampling excess toward measurements at large satellite zenith angles is noted. Also, at large satellite zenith angles, the present scheme for scene selection causes many observations to be classified as cloud, resulting in higher flux averages. Thus the combined effect of sampling bias and scene identification errors is to overestimate the computed albedo. It is shown, using a process of successive thresholding, that observations with satellite zenith angles greater than 50-60 deg lead to incorrect cloud identification. Elimination of these observations has reduced the albedo from 32.2 to 28.8 percent. This reduction is very nearly the same and in the right direction as the discrepancy between the albedoes derived from the scanner and the wide-field-of-view channels.

Vemury, S. K.↗
NASA NTRS1982

Atmospheric effects on radiation reflected from soil and vegetation as measured by orbital sensors using various scanning directions

Ground-measured spectral reflectance data for Avondale loam and drought-stressed and unstressed wheat were converted into digital counts for spectral bands 5 and 7 of the Landsat Multispectral Scanner System (MSS). For dry loam, the differences between ratios of MSS bands 7-5 as determined from space and from ground level measurements were 2.3 percent for clear and 5.6 percent for turbid atmospheric conditions. By contrast, for wet loam the differences were 10.4 and 29.5 percent. It is found that atmospheric conditions may cause a delay of from 3 to 7 days in the discrimination between drought-stressed and unstressed wheat. For oblique angle observations the atmospheric modification of ground-measured reflectances increased with angle at a greater rate in the 0/180 deg azimuth than in the 90/270 deg azimuth. Implications of this result are discussed for oblique angle Systeme Probatoire d'Observation de la Terre (SPOT), Mapsat, future multispectral linear array system imagery, and wide-angle imagery collected from scanners in high-altitude aircraft.

Slater, P. N.↗
NASA NTRS2016

A Parametric Model of Shoulder Articulation for Virtual Assessment of Space Suit Fit

Shoulder injury is one of the most severe risks that have the potential to impair crewmembers' performance and health in long duration space flight. Overall, 64% of crewmembers experience shoulder pain after extra-vehicular training in a space suit, and 14% of symptomatic crewmembers require surgical repair (Williams & Johnson, 2003). Suboptimal suit fit, in particular at the shoulder region, has been identified as one of the predominant risk factors. However, traditional suit fit assessments and laser scans represent only a single person's data, and thus may not be generalized across wide variations of body shapes and poses. The aim of this work is to develop a software tool based on a statistical analysis of a large dataset of crewmember body shapes. This tool can accurately predict the skin deformation and shape variations for any body size and shoulder pose for a target population, from which the geometry can be exported and evaluated against suit models in commercial CAD software. A preliminary software tool was developed by statistically analyzing 150 body shapes matched with body dimension ranges specified in the Human-Systems Integration Requirements of NASA ("baseline model"). Further, the baseline model was incorporated with shoulder joint articulation ("articulation model"), using additional subjects scanned in a variety of shoulder poses across a pre-specified range of motion. Scan data was cleaned and aligned using body landmarks. The skin deformation patterns were dimensionally reduced and the co-variation with shoulder angles was analyzed. A software tool is currently in development and will be presented in the final proceeding. This tool would allow suit engineers to parametrically generate body shapes in strategically targeted anthropometry dimensions and shoulder poses. This would also enable virtual fit assessments, with which the contact volume and clearance between the suit and body surface can be predictively quantified at reduced time and cost.

Kim, K. Han↗
NASA NTRS2004

Materials Characterization at Utah State University: Facilities and Knowledge-base of Electronic Properties of Materials Applicable to Spacecraft Charging

In an effort to improve the reliability and versatility of spacecraft charging models designed to assist spacecraft designers in accommodating and mitigating the harmful effects of charging on spacecraft, the NASA Space Environments and Effects (SEE) Program has funded development of facilities at Utah State University for the measurement of the electronic properties of both conducting and insulating spacecraft materials. We present here an overview of our instrumentation and capabilities, which are particularly well suited to study electron emission as related to spacecraft charging. These measurements include electron-induced secondary and backscattered yields, spectra, and angular resolved measurements as a function of incident energy, species and angle, plus investigations of ion-induced electron yields, photoelectron yields, sample charging and dielectric breakdown. Extensive surface science characterization capabilities are also available to fully characterize the samples in situ. Our measurements for a wide array of conducting and insulating spacecraft materials have been incorporated into the SEE Charge Collector Knowledge-base as a Database of Electronic Properties of Materials Applicable to Spacecraft Charging. This Database provides an extensive compilation of electronic properties, together with parameterization of these properties in a format that can be easily used with existing spacecraft charging engineering tools and with next generation plasma, charging, and radiation models. Tabulated properties in the Database include: electron-induced secondary electron yield, backscattered yield and emitted electron spectra; He, Ar and Xe ion-induced electron yields and emitted electron spectra; photoyield and solar emittance spectra; and materials characterization including reflectivity, dielectric constant, resistivity, arcing, optical microscopy images, scanning electron micrographs, scanning tunneling microscopy images, and Auger electron spectra. Further details of the instrumentation used for insulator measurements and representative measurements of insulating spacecraft materials are provided in other Spacecraft Charging Conference presentations. The NASA Space Environments and Effects Program, the Air Force Office of Scientific Research, the Boeing Corporation, NASA Graduate Research Fellowships, and the NASA Rocky Mountain Space Grant Consortium have provided support.

Dennison, J. R.↗
NASA NTRS1992

The ALEXIS data processing package: An IDL based system

The Array of Low Energy X-ray Imaging Sensors (ALEXIS) experiment consists of a mini-satellite containing six wide angle EUV/ultrasoft x-ray telescopes. Its purpose is to map out the sky in three narrow (approximately 5 percent) bandpasses around 66, 71, and 93 eV. The 66 and 71 eV bandpasses are centered on intense Fe emission lines which are characteristic of million degree plasmas such as the one thought to produce the soft x-ray background. The 93 eV bandpass is not near any strong emission lines and is more sensitive to continuum sources. The mission will be launched on the Pegasus Air Launched Vehicle in the second half of 1992 into a 400-nautical-mile, high inclination orbit and will be controlled entirely from a small ground station located at Los Alamos. The project is a collaborative effort between Los Alamos National Laboratory, Sandia National Laboratory, and the University of California-Berkeley Space Sciences Laboratory. The six telescopes are arranged in three pairs. As the satellite spins twice a minute they scan the entire anti-solar hemisphere. Each f/1 telescope consists of a spherical, multilayer-coated mirror with a curved, microchannel plate detector located at the prime focus. The multilayer coatings determine the bandpasses of the telescopes. The field of view of each telescope is 30 degrees with a spatial resolution of 0.5 degree, limited by spherical aberration. The data processing requirements for ALEXIS are large. Each event is one of the six telescopes is telemetered to the ground with its time of arrival and position on the detector. This information must be folded with the aspect solution for the satellite to reconstruct the direction on the sky from which the photon came. Because of the way the six telescopes scan the sky, the effective exposure calculation is also very computationally intensive. ALEXIS may generate up to 100 megabytes of raw data per day, which are converted into a gigabyte per day of processed data. While the processing job for ALEXIS is sizable, the programming staff is small. To maximize programming efficiency, and to make the best use of tools available in the public domain, we chose IDL as our software development platform. IDL was used from the start of instrument development through flight. We use IDL as a top-level executive for the processing tasks (replacing Unix shell scripts), as a device independent graphics engine, as a database manager, and as a final data manipulator. IDL routines spawn special purpose C programs to perform detailed telemetry deconvolution and other specialized functions. We discuss the use of IDL and C within the processing and archiving strategy for the ALEXIS data anlaysis system as implemented on a SPARCstation platform. We also show results from our End-to-End software simulation capability as processed by our analysis codes.

Bloch, J. J.↗
NASA NTRS2010

Multiple Velocity Profile Measurements in Hypersonic Flows using Sequentially-Imaged Fluorescence Tagging

Nitric-oxide planar laser-induced fluorescence (NO PLIF) was used to perform velocity measurements in hypersonic flows by generating multiple tagged lines which fluoresce as they convect downstream. For each laser pulse, a single interline, progressive scan intensified CCD camera was used to obtain separate images of the initial undelayed and delayed NO molecules that had been tagged by the laser. The CCD configuration allowed for sub-microsecond acquisition of both images, resulting in sub-microsecond temporal resolution as well as sub-mm spatial resolution (0.5-mm x 0.7-mm). Determination of axial velocity was made by application of a cross-correlation analysis of the horizontal shift of individual tagged lines. Quantification of systematic errors, the contribution of gating/exposure duration errors, and influence of collision rate on fluorescence to temporal uncertainty were made. Quantification of the spatial uncertainty depended upon the analysis technique and signal-to-noise of the acquired profiles. This investigation focused on two hypersonic flow experiments: (1) a reaction control system (RCS) jet on an Orion Crew Exploration Vehicle (CEV) wind tunnel model and (2) a 10-degree half-angle wedge containing a 2-mm tall, 4-mm wide cylindrical boundary layer trip. The experiments were performed at the NASA Langley Research Center's 31-inch Mach 10 wind tunnel.

Bathel, Brett F.↗
NASA NTRS2004

MODIS In-flight Calibration Methodologies

MODIS is a key instrument for the NASA's Earth Observing System (EOS) currently operating on the Terra spacecraft launched in December 1999 and Aqua spacecraft launched in May 2002. It is a cross-track scanning radiometer, making measurements over a wide field of view in 36 spectral bands with wavelengths from 0.41 to 14.5 micrometers and providing calibrated data products for science and research communities in their studies of the Earth s system of land, oceans, and atmosphere. A complete suite of on-board calibrators (OBC) have been designed for the instruments in-flight calibration and characterization, including a solar diffuser (SD) and solar diffuser stability monitor (SDSM) system for the radiometric calibration of the 20 reflective solar bands (RSB), a blackbody (BB) for the radiometric calibration of the 16 thermal emissive bands (TEB), and a spectro-radiometric calibration assembly (SRCA) for the spatial (all bands) and spectral (RSB only) characterization. This paper discusses MODIS in-flight Cali bration methodologies of using its on-board calibrators. Challenging issues and examples of tracking and correcting instrument on-orbit response changes are presented, including SD degradation (20% at 412nm, 12% at 466nm, and 7% at 530nm over four and a half years) and response versus scan angle changes (10%, 4%, and 1% differences between beginning of the scan and end of the scan at 412nm, 466nm, and 530nm) in the VIS spectral region. Current instrument performance and lessons learned are also provided.

Xiong, X.↗
NASA NTRS2013

Forward-Looking IED Detector Ground Penetrating Radar

There have been many developments of mine or metal detectors based on ground penetrating radar techniques, usually in hand-held or rover-mounted devices. In most mine or metal detector applications, conditions are in a stationary mode and detection speed is not an important factor. A novel, forward-looking, stepped-frequency ground penetrating radar (GPR) has been developed with a capability to detect improvised explosive devices (IEDs) at vehicular speeds of 15 to 20 mph (24 to 32 km/h), 10 to 20 m ahead of the vehicle, to ensure adequate time for response. The GPR system employs two horn antennas (1.7 to 2.6 GHz, 20 dBi) as transmit and receive. The detector system features a user-friendly instantaneous display on a laptop PC and is a low-power-consumption (3 W) compact system with minimal impact on vehicle operations. In practice, the whole GPR system and a laptop PC can be powered by plugging into a cigarette lighter of a vehicle. The stepped-frequency continuous-wave (CW) radar scans frequency from 1.7 to 2.6 GHz in 1,000 steps of 0.9 MHz, with the full frequency scan in 60 ms. The GPR uses a bi-static configuration with one horn antenna used as a transmitter and the other used as a receiver so that isolation between transmitter and receiver is improved. Since the horn antennas (20 dBi) are mounted on the roof of a vehicle at a shallow inclination angle (15 to 25 with respect to horizontal), there is a first-order reduction in ground reflection so that a significant amount of the total reflected power received by the GPR comes from the scattering of RF energy off of buried objects. The stepped-frequency technique works by transmitting a tone at a particular frequency, while the received signal is mixed with the transmitted tone. As a result, the output of the mixer produces a signal that indicates the strength of the received signal and the extent to which it is in phase or out of phase with the transmitted tone. By taking measurements of the phase relationship between the transmitted and received signals over a wide frequency range, an interference pattern is produced showing all target reflections. When a Fourier transform is performed on this pattern, the result is a time-domain representation of targets. Among the advantages of this technique over impulse radar is the ability to transmit and receive much more total energy, and to use non-damped, highly focused horn antennas. The novelty of the IED detector GPR has been achieved by miniaturization of GPR electronics (single electronics board, 10x5x2 cm), low power consumption (3 W), faster signal processing capability, and minimal impact on vehicle operations.

Kim, Soon Sam↗
NASA NTRS2010

Multiple Velocity Profile Measurements in Hypersonic Flows Using Sequentially-Imaged Fluorescence Tagging

Nitric-oxide planar laser-induced fluorescence (NO PLIF) was used to perform velocity measurements in hypersonic flows by generating multiple tagged lines which fluoresce as they convect downstream. For each laser pulse, a single interline, progressive scan intensified CCD (charge-coupled device) camera was used to obtain two sequential images of the NO molecules that had been tagged by the laser. The CCD configuration allowed for sub-microsecond acquisition of both images, resulting in sub-microsecond temporal resolution as well as sub-mm spatial resolution (0.5-mm horizontal, 0.7-mm vertical). Determination of axial velocity was made by application of a cross-correlation analysis of the horizontal shift of individual tagged lines. A numerical study of measured velocity error due to a uniform and linearly-varying collisional rate distribution was performed. Quantification of systematic errors, the contribution of gating/exposure duration errors, and the influence of collision rate on temporal uncertainty were made. Quantification of the spatial uncertainty depended upon the signal-to-noise ratio of the acquired profiles. This velocity measurement technique has been demonstrated for two hypersonic flow experiments: (1) a reaction control system (RCS) jet on an Orion Crew Exploration Vehicle (CEV) wind tunnel model and (2) a 10-degree half-angle wedge containing a 2-mm tall, 4-mm wide cylindrical boundary layer trip. The experiments were performed at the NASA Langley Research Center's 31-Inch Mach 10 Air Tunnel.

Bathel, Brett F.↗
NASA NTRS1996

Silicone Contamination Camera for Developed for Shuttle Payloads

On many shuttle missions, silicone contamination from unknown sources from within or external to the shuttle payload bay has been a chronic problem plaguing experiment payloads. There is currently a wide range of silicone usage on the shuttle. Silicones are used to coat the shuttle tiles to enhance their ability to shed rain, and over 100 kg of RTV 560 silicone is used to seal white tiles to the shuttle surfaces. Silicones are also used in electronic components, potting compounds, and thermal control blankets. Efforts to date to identify and eliminate the sources of silicone contamination have not been highly successful and have created much controversy. To identify the sources of silicone contamination on the space shuttle, the NASA Lewis Research Center developed a contamination camera. This specially designed pinhole camera utilizes low-Earth-orbit atomic oxygen to develop a picture that identifies sources of silicone contamination on shuttle-launched payloads. The volatile silicone species travel through the aperture of the pinhole camera, and since volatile silicone species lose their hydrocarbon functionalities under atomic oxygen attack, the silicone adheres to the substrate as SiO_x. This glassy deposit should be spatially arranged in the image of the sources of silicone contamination. To view the contamination image, one can use ultrasensitive thickness measurement techniques, such as scanning variable-angle ellipsometry, to map the surface topography of the camera's substrate. The demonstration of a functional contamination camera would resolve the controversial debate concerning the amount and location of contamination sources, would allow corrective actions to be taken, and would demonstrate a useful tool for contamination documentation on future shuttle payloads, with near negligible effect on cost and weight.

Source record↗
NASA NTRS2017

Detached Melt and Vapor Growth of InI in SUBSA Furnace

Indium iodide (InI) is a promising wide energy band gap nuclear detector material. It is ideal for space experiments because it is non-toxic and has a relatively low melting point of only 351 degrees Centigrade. However, it has been established that melt-grown crystals contain a large amount of second phase inclusions/precipitates. The typical size of inclusions are 1 to 27 microns in diameter, while the volume fraction of all sizes is 300 to 600 parts per million. The SEM-EDS (Scanning Electron Microscopy / Energy Dispersive X-Ray Spectroscopy) analysis of the inclusions has revealed that they all contain oxygen and some contain carbon. At present, under sponsorship of NASA and CASIS (Center for the Advancement of Science in Space), we are conducting ground-based experiments with InI in preparation for the flight experiments to be conducted in the SUBSA (Solidification Using a Baffle in Sealed Ampoules) furnace in the Microgravity Science Glovebox at the International Space Station, planned for the summer/fall of 2017. Earth-based experiments include melt and vapor growth conducted in the SUBSA ground unit, measurements of the volumetric expansion coefficient of the melt, and measurements of the wetting angle of molten InI. Finite element modeling has been conducted to optimize the design of the flight ampoules. Alloying with Tl and Ga has given promising results.

Ostrogorsky, A. G.↗
NASA NTRS1992

Seawifs Technical Report Series. Volume 2: Analysis of Orbit Selection for Seawifs: Ascending Versus Descending Node

Due to range safety considerations, the Sea-viewing Wide Field-of-view Sensor (SeaWiFS) ocean color instrument may be required to be launched into a near-noon descending node, as opposed to the ascending node used by the predecessor sensor, the Coastal Zone Color Scanner (CZCS). The relative importance of ascending versus descending near-noon orbits was assessed here to determine if descending node will meet the scientific requirements of SeaWiFS. Analyses focused on ground coverage, local times of coverage, solar and viewing geometries (zenith and azimuth angles), and sun glint. Differences were found in the areas covered by individual orbits, but were not important when taken over a 16 day repeat time. Local time of coverage was also different: for ascending node orbits the Northern Hemisphere was observed in the morning and the Southern Hemisphere in the afternoon, while for descending node orbits the Northern Hemisphere was observed in the afternoon and the Southern in the morning. There were substantial differences in solar azimuth and spacecraft azimuth angles both at equinox and at the Northern Hemisphere summer solstice. Negligible differences in solar and spacecraft zenith angles, relative azimuth angles, and sun glint were obtained at the equinox. However, large differences were found in solar zenith angles, relative azimuths, and sun glint for the solstice. These differences appeared to compensate across the scan, however, an increase in sun glint in descending node over that in ascending node on the western part of the scan was compensated by a decrease on the eastern part of the scan. Thus, no advantage or disadvantage could be conferred upon either ascending node or descending node for noon orbits. Analyses were also performed for ascending and descending node orbits that deviated from a noon equator crossing time. For ascending node, afternoon orbits produced the lowest mean solar zenith angles in the Northern Hemisphere, and morning orbits produced the lowest angles for the Southern Hemisphere. For descending node, morning orbits produced the lowest mean solar zenith angles for the Northern Hemisphere; afternoon orbits produced the lowest angles for the Southern Hemisphere.

Hooker, Stanford B.↗
NASA NTRS2023

Aqua MODIS: 20 Years of On-orbit Calibration and Performance

Since its launch in May 2002, Aqua MODIS has successfully operated for more than 20 years and has continuously generated a wide range of data products that have enabled and supported the remote sensing community and users worldwide for their studies of the Earth’s system by monitoring changes in its key environmental parameters. Although Aqua MODIS, designed with a lifetime requirement of 6 years, is currently operated in its extended mission phase, it continues to make high quality global observations of the Earth’s surface via its 36 spectral bands that cover wavelengths from visible to long-wave infrared. To date, all instrument on-board calibrators (OBC) remain capable of performing their design functions, providing various calibration data sets to help monitor on-orbit changes in sensor responses and performance characteristics. In addition to the OBC, regularly scheduled lunar observations and select Earth-view targets are used extensively to support sensor on-orbit calibration, especially for the calibration of the visible channels (or bands). In this paper, we provide an overview of Aqua MODIS on-orbit calibration activities and methodologies for both reflective solar bands (RSB) and thermal emissive bands (TEB), illustrate its on-orbit performance over the past 20 years using examples derived from OBC measurements, lunar observations, and Earth-view response trends, and describe various calibration improvements made over its entire mission. We focus on key issues identified since launch, such as solar diffuser degradation, electronic crosstalk, and on-orbit changes in sensor response versus scan-angle, along with approaches and strategies developed to mitigate their impact on sensor calibration quality. Also discussed in this paper are some of the key calibration enhancements incorporated recently in the Collection 6.1 and the upcoming Collection 7 Level-1B algorithms.

Polarization↗
NASA NTRS2000

Laser Brazing of High Temperature Braze Alloy

The Space Shuttle Main Engine (SSME) consists of 1080 conical tubes, which are furnace brazed themselves, manifolds, and surrounding structural jacket making almost four miles of braze joints. Subsequent furnace braze cycles are performed due to localized braze voids between the coolant tubes. SSME nozzle experiences extremely high heat flux (180 mW/sq m) during hot fire. Braze voids between coolant tubes may result in hot combustion gas escape causing jacket bulges. The nozzle can be disqualified for flight or result in mission failure if the braze voids exceed the limits. Localized braze processes were considered to eliminate braze voids, however, damage to the parent materials often prohibited use of such process. Being the only manned flight reusable rocket engine, it has stringent requirement on the braze process. Poor braze quality or damage to the parent materials limits the nozzle service life. The objective of this study was to develop a laser brazing process to provide quality, localized braze joints without adverse affect on the parent materials. Gold (Au-Cu-Ni-Pd-Mn) based high temperature braze alloys were used in both powder and wire form. Thin section iron base superalloy A286 tube was used as substrate materials. Different Laser Systems including CO2 (10.6 micrometers, 1kW), ND:YAG (1.06 micrometers, 4kW). and direct diode laser (808nm. 150W) were investigated for brazing process. The laser process variables including wavelength. laser power, travel speed and angle of inclination were optimized according to bead geometry and braze alloy wetting at minimum heat input level, The properties of laser brazing were compared to that of furnace brazing. Microhardness profiles were used for braze joint property comparison between laser and furnace brazing. The cooling rate of laser brazing was compared to furnace brazing based on secondary dendritic arm spacing, Both optical and Scanning Electron Microscope (SEM) were used to evaluate the microstructures of the braze materials and tube substrate. Metallography of the laser braze joint was compared to the furnace braze. SEM Energy Disperse X-Ray Spectra (EDX) and back scattered imaging were used to analyze braze alloy segregation. Although all of the laser systems, CO2, ND:YAG, and direct diode laser produced good braze joint, the direct diode laser was selected for its system simplicity, compactness and portability. Excellent laser and braze alloy coupling is observed with powder alloy compared to braze alloy wire. Good wetting is found with different gold based braze alloys. The laser brazing process can be optimized so that the adverse affect on the parent materials can be eliminated. Metallography of the laser braze joint has shown that quality braze joint was produced with laser brazing process. Penetration of the laser braze to the substrate is at neglectable level. Zero penetration is observed. Microstructure examinations shown that no observable changes of the microstructure (grain structure and precipitation) in the HAZ area between laser braze and furnace braze. Wide gaps can be laser brazed with single pass for up to 0.024 inches. Finer dendritic structure is observed in laser brazing compared with equiaxial and coarser grain of the furnace brazing microstructure. Greater segregation is also found in the furnace braze. Higher hardness of the laser braze joint comparing to furnace braze is observed due to the fast cooling rate and Finer microstructure in the laser brazing. Laser braze joint properties meet or exceed the furnace joint properties. Direct diode laser for thin section tube brazing with high temperature braze alloys have been successfully demonstrated. The laser's high energy density and precise control has shown significant advantages in reducing process heat input to the substrates and provide high quality braze joints comparing to other localized braze process such as torch, TIG, and MPTA processes. Significant cost savings can be realized particularly with localized braze comparing to a full furnace braze cycle.

Gao, Y. P.↗
NASA NTRS2009

An Overview of MODIS Calibration and Characterization and Lessons Learned

The Moderate Resolution Imaging Spectroradiometer (MODIS) is a key instrument for NASA's EOS missions. Two nearly identical copies have flown on the Terra and Aqua spacecraft for more than 9 years and 6 years since their launch in December 1999 and May 2002, respectively. MODIS observations and associated data products have been widely used by the science community and users worldwide for studies of Earth's system of land, oceans, and atmosphere. MODIS was developed based on the desire of the science community to extend and enhance heritage sensors' data records. It was designed with enhancements made over its heritage sensors in terms of its spectral, spatial, and radiometric characteristics. It is a cross-track scanning radiometer, that uses a two-sided scan mirror, collecting data in 36 spectral bands covering spectral regions of visible (VIS), near-infrared (NIR), short-wave infrared (SWIR), mid-wave infrared (MWIR), and long-wave infrared (LWIR). The VIS, NIR, and SWIR bands (bands 1-19 and 26), which make measurements of daytime surface reflected radiances, are referred to as the reflective solar bands (RSB). The MWIR and LWIR bands (20-25 and 27-36), which measure both the daytime and nighttime scene emissive radiances, are thus referred to as the thermal emissive bands (TEB). In this paper, we provide an overview of MODIS instrument calibration and characterization methodologies, activities, and results from pre-launch to post launch, with emphasis on the lessons learned from its design to on-orbit operation. Currently, both instruments are operated normally and all the on-orbit calibration activities are performed on a regular basis with some at slightly reduced frequencies. The TEB responses have been extremely stable with less than 0.3% change per year. For the RSB, the changes are wavelength and scan angle dependent with the largest changes in the VIS spectral bands. As both Terra and Aqua MODIS continue to operate beyond their prime missions, constant effort is still needed to maintain instrument and calibration and data product quality. This paper shows that the lessons from Terra MODIS design, test, and operation, have greatly benefitted Aqua MODIS. Because of this, Aqua MODIS overall performance is better than Terra MODIS. It is not surprising that lessons from MODIS calibration and characterization, from methodologies to on-orbit implementation, have also provided valuable information for the design and development of future earth observing missions/sensors, such as VHRS on the NPP and NPOESS, ABI on GOES-R, OLI on LDCM, and the reflective solar sensor on CLARREO.

Xiong, Xiaxiong↗