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Ceramic cloth and thread tested quickly at temperatures up to 1,250 degree C. Tensile strengths of ceramic cloths and threads measured conveniently in new furnace at specified temperatures up to 1,250 degree C, using ordinary mechanical tester. Samples heated along part of their lengths in furnace slots. Interchangeable furnace chambers and matching heating elements sized to match size of tested ceramic material.
High Output Paraffin (HOP) thermal actuators were developed to provide an alternative to conventional aerospace actuators: HOP actuators directly convert temperature changes to useful mechanical work. When fabricated with internal resistance heating elements, they provide an electric linear motor. For applications in which slower response times are acceptable or preferred, HOP actuators have distinct advantages over conventional approaches.
A simple breadboard power controller was designed and demonstrated for a new liquid-fed water resistojet. The 1-piece laboratory model thruster has an integrated vaporizer/superheater using a single heating element. Heater temperature was maintained at or near a preset reference value with the closed loop controller providing pulse width modulated (PWM) dc power into the thruster heater. A combined thruster, temperature readout, PWM transfer function was experimentally determined. This transfer function was used to design a proportional plus integral controller that demonstrated zero steady state error, conservative stability margins and adequate transient response to step changes in propellant flow rate, input voltage and temperature reference. Initial turn-on temperature overshoot from room temperature to a 650 C setpoint was 80 C. In addition, EMI was alleviated by reducing heater dI/dt and dV/dt using a simple diode-inductor-capacitor network. Based on limited initial tests, thruster preheat with no propellant flow was necessary to achieve stable system operation during startup. Breadboard power efficiency was 99 percent at 1 kW, and component mass was 0.4 kg excluding the power loss and mass of an input filter required for spacecraft integration.
An account is given of the design features and operating characteristics of a method for the joining of composite parts, at a rate of 2 to 6 inches/min, in which the heating process responsible for adhesive flow at 800 F is focused upon the overlapped seam. The heating element is a self-tuning solid state power oscillator whose ferrite's toroid geometry generates a uniform, concentrated magnetic flux in the component to be bonded. Specimens cut from graphite/epoxy panels bonded with epoxy-phenolic adhesive by this process have exhibited average lap-shear strengths of the order of 3400 lbs/sq in.
A vacuum heat treatment facility, with hot zone dimensions of 12 x 19 x 19 cm, has been designed and constructed at a cost substantially below that of a commercial unit. The design incorporates efficient water cooling and a resistive heating element. A vacuum pressure of 1.5 x 10 to the -8th torr at room temperature has been obtained after baking. The temperature limit is approximately 1900 C. This limit results from the choice of niobium as the hot zone material.
The microstructural characteristics of the Ni-based superalloy MAR-M246(Hf) which is used in manufacturing the components of the Space Shuttle's main engine have been studied. These superalloys need optimal heat treatment to get the best results. To find the optimum heat treatment the technique of differential thermal analysis and the optical photomicrographs are being planned to be utilized. In the first phase, the existing experimental equipment like cutting, grinding/polishing machines and metallurgical microscope have been set up to cut/polish and take the photomicrographs. In the beginning of this year an order was placed for the Leitz Mettalux-3 microscope with a hot stage for in-situ observation of the superalloy samples. The hot stage was tested for the first time, alloying the thermocouple with the Tantulum heating element and has not been installed finally by the supplier. A Perkin Elmer Differential Thermal Analyzer (DTA 1700) was procured in the first year of the project. Samples of MAR-M246(Hf), MAR-M247, Waspaloy, Udimet-41, CMSX-2 and CMSX-3 (polycrystalline and single crystals) have been studied using differential thermal analyzer.
Analytical, numerical and experimental studies were performed on two classes of high temperature materials processing furnaces. The research concentrates on a commercially available high temperature furnace using zirconia as the heating element and an arc furnace based on a ST International tube welder. The zirconia furnace was delivered and work is progressing on schedule. The work on the arc furnace was initially stalled due to the unavailability of the NASA prototype, which is actively being tested aboard the KC-135 experimental aircraft. A proposal was written and funded to purchase an additional arc welder to alleviate this problem. The ST International weld head and power supply were received and testing will begin in early November. The first 6 months of the grant are covered.
An IR pyrometric technique for measuring the surface temperatures of metal specimens in an ultrahigh-vacuum analytic chamber is described and demonstrated. The experimental setup comprises a commercial IR microscope with a long-working-distance right-angle objective (focal spot diameter 1 mm at 53 cm), a metal-coated glass vacuum chamber with a Ta-mesh-covered quartz viewport, an Mo specimen stub with an internal heating element, and a Ta disk test specimen with a flat side coated with a high-emissivity graphite film. The results of an initial calibration test are presented graphically and briefly characterized. The measurement error at 450 C is found to be less than 10 C.
A simple breadboard power controller was designed and demonstrated for a new liquid-fed water resistojet. The 1-piece laboratory model thruster has an integrated vaporizer/superheater using a single heating element. Heater temperature was maintained at or near a preset reference value with the closed loop controller providing pulse width modulated (PWM) dc power into the thruster heater. A combined thruster, temperature readout, PWM transfer function was experimentally determined. This transfer function was used to design a proportional plus integral controller that demonstrated zero steady state error, conservative stability margins and adequate transient response to step changes in propellant flow rate, input voltage and temperature reference. Initial turn-on temperature overshoot from room temperature to a 650 C setpoint was 80 C. In addition, EMI was alleviated by reducing heater dI/dt and dV/dt using a simple diode-inductor-capacitor network. Based on limited initial tests, thruster preheat with no propellant flow was necessary to achieve stable system operation during startup. Breadboard power efficiency was 99 percent at 1 kW, and component mass was 0.4 kg excluding the power loss and mass of an input filter required for spacecraft integration.
The nuclear light bulb engine is a closed cycle concept. The nuclear light bulb concept provides containment by keeping the nuclear fuel fluid mechanically suspended in a cylindrical geometry. Thermal heat passes through an internally cooled, fused-silica, transparent wall and heats hydrogen propellant. The seeded hydrogen propellant absorbs radiant energy and is expanded through a nozzle. Internal moderation was used in the configuration which resulted in a reduced critical density requirement. This result was supported by criticality experiments. A reference engine was designed that had seven cells and was sized to fit in what was then predicted to be the shuttle bay mass and volume limitations. There were studies done of nozzle throat cooling schemes to remove the radiant heat. Elements of the nuclear light bulb program included closed loop critical assembly tests done at Los Alamos with UF6 confined by argon buffer gas. It was shown that the fuel region could be seeded with constituents that would block UV radiation from the uranium plasma. A combination of calculations and experiments showed that internal moderation produced a critical mass reduction. Other aspects of the research are presented.
A computer simulation for 'running wet' and evaporative aircraft anti-icing systems is developed. The model is based on the analysis of the liquid water film which forms in the regions of direct impingement and, then, breaks up near the impingement limits into rivulets. The wetness factor distribution resulting from the film breakup and the rivulet configuration on the surface are predicted using a stability analysis theory and the laws of mass energy conservation. The solid structure is modeled as a multiple layer wall. The anti-icing system modeled is of the thermal type utilizing hot air and/or electrical heating elements embedded within the wall layers. Experimental observations revealing some of the basic physics of the water flow on the surface are presented. Detailed qualitative documentation of the tests are given. Several numerical examples are considered, and the effect of some of the involved parameters on the system performance are investigated.
A numerical simulation for 'running wet' aircraft anti-icing systems is developed. The model includes breakup of the water film, which exists in regions of direct impingement, into individual rivulets. The wetness factor distribution resulting from the film breakup and the rivulet configuration on the surface are predicted in the numerical solution procedure. The solid wall is modeled as a multilayer structure and the anti-icing system used is of the thermal type utilizing hot air and/or electrical heating elements embedded with the layers. Details of the calculation procedure and the methods used are presented.
Two-zone vertical directional-solidification furnace designed and built to grow crystals from stoichiometric and nonstoichiometric melts and from solutions. Includes conventional wire heater in lower zone, tubular silicon carbide heating element in upper zone, and thermal baffle between zones. Temperature gradients up to 125 degrees centigrade per centimeter achieved in the crystal-growth region. Sharper gradient enables both faster growth and better separation between solid and liquid. Furnace used in laboratory or industrial setting for growth of crystals from congruently melting materials as well as for growth of compounds formed by peritectic reactions.
A prototype dual-axis electrolytic tilt sensor package for angular position measurements was built and evaluated in a laboratory environment. The objective was to investigate the use of this package for making wind tunnel wall attitude measurements for the National Transonic Facility (NTF) at NASA Langley Research Center (LaRC). The instrumentation may replace an existing, more costly, and less rugged servo accelerometer package (angle-of-attack package) currently in use. The dual-axis electrolytic tilt sensor package contains two commercial electrolytic tilt sensors thermally insulated with NTF foam, all housed within a stainless steel package. The package is actively heated and maintained at 160 F using foil heating elements. The laboratory evaluation consisted of a series of tests to characterize the linearity, repeatability, cross-axis interaction, lead wire effect, step response, thermal time constant, and rectification errors. Tests revealed that the total RMS errors for the x-axis sensor is 0.084 degree, and 0.182 degree for the y-axis sensor. The RMS errors are greater than the 0.01 degree specification required for NTF wall attitude measurements. It is therefore not a viable replacement for the angle-of-attack package in the NTF application. However, with some physical modifications, it can be used as an inexpensive 5-degree range dual-axis inclinometer with overall accuracy approaching 0.01 degree under less harsh environments. Also, the data obtained from the tests can be valuable for wind tunnel applications of most types of electrolytic tilt sensors.
Computational methods are described for simulating the formation and the material behavior of ice in prevailing transient environments. The methodology developed at the NASA Lewis Research Center was adopted. A three dimensional finite-element heat transfer analyzer was used to predict the thickness of ice formed under prevailing environmental conditions. A multi-factor interaction model for simulating the material behavior of time-variant ice layers is presented. The model, used in conjunction with laminated composite mechanics, updates the material properties of an ice block as its thickness increases with time. A sample case of ice formation in a body of water was used to demonstrate the methodology. The results showed that the formation and the material behavior of ice can be computationally simulated using the available composites technology.
Under the sponsorship of the BMDO Russian Hall Electric Thruster Technology program two xenon hollow cathodes, a flight unit and a flight spare were fabricated, acceptance tested and delivered to the Naval Research Laboratory for use on the Electric Propulsion Demonstration Module. These hollow cathodes, based on the International Space Station plasma contactor design, were fabricated at the NASA Lewis Research Center for use with a D-55 anode layer thruster in the first on-orbit operational application of this technology. The 2.2 Ampere nominal emission current of this device was obtained with a xenon flow rate of 0.6 mg/s. Ignition of the cathode discharge was accomplished through preheating the active electron emitter with a resistive heating element before application of a 650 volt ignition pulse between the emitter and an external starting electrode. The successful acceptance testing of the Electric Propulsion Demonstration Module utilizing these cathodes demonstrated the suitability of cathodes based on barium impregnated inserts in an enclosed keeper configuration for use with Hall thruster propulsion systems.
In cooperation with Raichle Molitor USA Inc. and the international Raichle organization, Comfort Products developed the Raichle Flexon concept in ski boots. The Flexon concept is an adaptation of the accordion-like corrugations of extravehicular space suit joints, which allows ski boots to flex without significant distortion. The design provides immediate transmission of power and therefore precision skiing. Comfort Products also applied heating element circuitry from Apollo astronaut's clothing to foot-warming devices in their boots in the 1970s.
Deep space probes and planetary exploration missions require electrical power management and control systems that are capable of efficient and reliable operation in very cold temperature environments. Typically, in deep space probes, heating elements are used to keep the spacecraft electronics near room temperature. The utilization of power electronics designed for and operated at low temperature will contribute to increasing efficiency and improving reliability of space power systems. At NASA Glenn Research Center, commercial-off-the-shelf devices as well as developed components are being investigated for potential use at low temperatures. These devices include semiconductor switching devices, magnetics, and capacitors. Integrated circuits such as digital-to-analog and analog-to-digital converters, DC/DC converters, operational amplifiers, and oscillators are also being evaluated. In this paper, results will be presented for selected analog-to-digital converters, oscillators, DC/DC converters, and pulse width modulation (PWM) controllers.