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Commercial and government communication, radar, and information systems face the challenge of cost and mass reduction via the application of advanced packaging technology. A majority of both government and industry support has been focused on low frequency digital electronics.
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The testing and study of emerging materials—such as additively manufactured materials—demands for specimen designs that are cost effective and time saving. Here the design of a small-sized bending-fatigue test specimen for an ultrasonic fatigue testing system is reported in this paper. The design is optimized based on the finite element analysis and analytical-solution results to achieve the proper vibration shape and stress distribution. The proposed design is evaluated in the high- and very-high-cycle fatigue regimes under 20-kHz frequency. Both simulation and testing results confirm that the desirable vibration mode occurs and the specimen fails at the designated test (gauge) section, where the maximum stress exists. The stress–life (S–N) curve is obtained for Inconel alloy 718 and indicates an expected trend.
Additive Manufacturing (AM) has increasingly been used to fabricate parts in aerospace applications, which may require service lives beyond ten-million cycles due to the imposed high loading frequencies. Understanding the very high cycle fatigue (VHCF) behavior of these additive manufactured (AM) parts is an important step towards their design and qualification processes. This study focuses on the high cycle fatigue (HCF) and VHCF behaviors of both wrought and laser beam-powder bed fusion (LB-PBF) fabricated Inconel 718 in machined/polished surface condition, emphasizing on the influence of test frequency (i.e., cyclic strain rate). Uniaxial, fully-reversed force- and stress-controlled fatigue tests were conducted utilizing a servo-hydraulic and an ultrasonic test system operating at 5 Hz and 20 kHz, respectively, on wrought as well as LB-PBF vertically and diagonally built specimens. Fatigue cracks in the majority of the specimens were found to initiate from intra-granular slip bands near or at the surface, which gives rise to strong anisotropy in fatigue resistance in LB-PBF specimens due to the presence of columnar grains along the build directions. Longer fatigue lives were obtained at 20 kHz, which was ascribed to possibly lower-than-intended stresses applied in the ultrasonic tests. The corrected stress-life fatigue data at 20 kHz were found to converge to the one obtained from conventional testing at 5 Hz, implying no effect of cyclic strain rate on the fatigue behavior of Inconel 718 regardless of the fabrication process. The findings of this work confirm the use of ultrasonic fatigue testing to expedite generation of AM materials data to keep up with the current demand; however, the applied stress may need to be corrected.
A total of 38 quiet clean short haul experimental engine under the wing composite fan blades were manufactured for various component tests, process and tooling, checkout, and use in the QCSEE UTW engine. The component tests included frequency characterization, strain distribution, bench fatigue, platform static load, whirligig high cycle fatigue, whirligig low cycle fatigue, whirligig strain distribution, and whirligig over-speed. All tests were successfully completed. All blades planned for use in the engine were subjected to and passed a whirligig proof spin test.
To interface with other solids, many surfaces are engineered via methods such as plating, coating, and machining to produce a functional surface ensuring successful end products. In addition, subsurface properties such as hardness, residual stress, deformation, chemical composition, and microstructure are often linked to surface characteristics. Surface topography, therefore, contains the signatures of the surface and possibly links to volumetric properties, and as a result serves as a vital link between surface design, manufacturing, and performance. Hence, surface topography can be used to diagnose, monitor, and control fabrication methods. At the NASA Glenn Research Center, the measurement of surface topography is important in developing high-temperature structural materials and for profiling the surface changes of materials during microgravity combustion experiments. A prior study demonstrated that focused air-coupled ultrasound at 1 MHz could profile surfaces with a 25-m depth resolution and a 400-m lateral resolution over a 1.4-mm depth range. In this work, we address the question of whether higher frequency focused water-coupled ultrasound can improve on these specifications. To this end, we employed 10- and 25-MHz focused ultrasonic transducers in the water-coupled mode. The surface profile results seen in this investigation for 25-MHz water-coupled ultrasound, in comparison to those for 1-MHz air-coupled ultrasound, represent an 8 times improvement in depth resolution (3 vs. 25 m seen in practice), an improvement of at least 2 times in lateral resolution (180 vs. 400 m calculated and observed in practice), and an improvement in vertical depth range of 4 times (calculated).
Interest is increasing in the use of fiberoptics on liquid-fueled rocket engines in recognition of their immunity to lightning and EMI, light weight, high-frequency response, and the possibility offered by optical technologies to measure additional important engine parameters for which present measurement methods are impractical. This paper discusses the requirements to be placed on fiberoptics applied to liquid-fueled rocket engines; identifies manufacturers of fibers that appear to have promise for the harsh rocket engine applications; and summarizes information on the characteristics of these fibers obtained from the manufacturers, program testing, and the general literature.
The Geostationary Operational Environmental Satellite-R Series (GOES-R) is the first of the next generation geostationary weather satellites, scheduled for delivery in late 2015. GOES-R represents a quantum increase in Earth and solar weather observation capabilities, with 4 times the resolution, 5 times the observation rate, and 3 times the number of spectral bands for Earth observations. With the improved resolution, comes the instrument suite's increased sensitive to disturbances over a broad spectrum 0-512 Hz. Sources of disturbance include reaction wheels, thruster firings for station keeping and momentum management, gimbal motion, and internal instrument disturbances. To minimize the impact of these disturbances, the baseline design includes an Earth Pointed Platform (EPP), a stiff optical bench to which the two nadir pointed instruments are collocated together with the Guidance Navigation & Control (GN&C) star trackers and Inertial Measurement Units (IMUs). The EPP is passively isolated from the spacecraft bus with Honeywell D-Strut isolators providing attenuation for frequencies above approximately 5 Hz in all six degrees-of-freedom. A change in Reaction Wheel Assembly (RWA) vendors occurred very late in the program. To reduce the risk of RWA disturbances impacting performance, a secondary passive isolation system manufactured by Moog CSA Engineering was incorporated under each of the six 160 Nms RWAs, tuned to provide attenuation at frequencies above approximately 50 Hz. Integrated wheel and isolator testing was performed on a Kistler table at NASA Goddard Space Flight Center. High fidelity simulations were conducted to evaluate jitter performance for four topologies: 1) hard mounted no isolation, 2) EPP isolation only, 2) RWA isolation only, and 4) dual isolation. Simulation results demonstrate excellent performance relative to the pointing stability requirements, with dual isolated Line of Sight (LOS) jitter less than 1 micron rad.
Future NASA missions will depend on radiation-hardened, power-efficient processing systems-on-a-chip (SOCs) that consist of a range of processor cores custom tailored for space applications. Aries Design Automation, LLC, has developed a processing SOC that is optimized for software-defined radio (SDR) uses. The innovation implements the Institute of Electrical and Electronics Engineers (IEEE) RazorII voltage management technique, a microarchitectural mechanism that allows processor cores to self-monitor, self-analyze, and selfheal after timing errors, regardless of their cause (e.g., radiation; chip aging; variations in the voltage, frequency, temperature, or manufacturing process). This highly automated SOC can also execute legacy PowerPC 750 binary code instruction set architecture (ISA), which is used in the flight-control computers of many previous NASA space missions. In developing this innovation, Aries Design Automation has made significant contributions to the fields of formal verification of complex pipelined microprocessors and Boolean satisfiability (SAT) and has developed highly efficient electronic design automation tools that hold promise for future developments.
The amorphous tape wound core is manufactured with iron-based 2605-SA1 amorphous foil. The 2605-SA1 amorphous foil is provided by METGLAS, Inc. and the core is manufactured by MK Magnetics. The 2605-SA1 amorphous foil is made up of mainly Iron, with small percentages of Silicon and Boron. Applications include transformers, pulse power cores, motors, and high frequency inductors.
In a continuing program of research and development, a system has been demonstrated that makes high-speed measurements of thermal infrared radiance from gas-turbine engine exhaust streams. When a gas-turbine engine is operated under conditions that minimize the emission of pollutants, there is a risk of crossing the boundary from stable to unstable combustion. Combustion instability can lead to engine damage and even catastrophic failure. Sensor systems of the type under development could provide valuable data during the development testing of gas-turbine engines or of engine components. A system of the type under development makes high-speed measurements of thermal infrared radiance from the engine exhaust stream. The sensors of this system can be mounted outside the engine, which eliminates the need for engine case penetrations typical with other engine dynamics monitors. This is an important advantage in that turbine-engine manufacturers consider such penetrations to be very undesirable. A prototype infrared sensor system has been built and demonstrated on a turbine engine. This system includes rugged and inexpensive near-infrared sensors and filters that select wavelengths of infrared radiation for high sensitivity. In experiments, low-frequency signatures were consistently observed in the detector outputs. Under some conditions, the signatures also included frequency components having one or two radiance cycles per engine revolution. Although it has yet to be verified, it is thought that the low-frequency signatures may be associated with bulk-mode combustion instabilities or flow instabilities in the compressor section of the engine, while the engine- revolution-related signatures may be indicative of mechanical problems in the engine. The system also demonstrated the ability to detect transient high-radiance events. These events indicate hot spots in the exhaust stream and were found to increase in frequency during engine acceleration.
Magnavox Government & Electronics Company originally used the NASTRAN program in the design stage of heavy aluminum fixtures for vibration testing. Program also used to compare the resonant frequencies of the circuitry to predict whether failures may occur because of high vibration levels. The company engineers can then make design alterations to improve the equipment's vibration resistance. Method allows Magnavox to insure reliability and reduce any possibility of vibration-caused failure in critical defense products they manufacture. Magnavox uses another COSMIC software package called GENOPTICS in the development of a Digital Optical Recorder, and also in research and development of other optical systems. This enables use of an optically recorded disc to store and retrieve digital data. It is reported that this program provides accurate results and that its use saved six man-months of time that would have been needed to develop a comparable software package.
The Geostationary Operational Environmental Satellite-R Series (GOES-R) is the first of the next generation geostationary weather satellites. GOES-R successfully launched on November19, 2016 and renamed GOES-16 upon entering geostationary orbit. Subsequently, GOES-16post-launch testing began. This paper presents the GOES-16 Satellite Dynamic Interaction Characterization results for the Earth Pointed Platform (EPP) stowed, referred to as the Reaction Wheel Assembly (RWA) Isolation Only configuration, and deployed, referred to as the Dual Isolation configuration. GOES-R represents a quantum increase in Earth and solar weather observation capabilities, with 4 times the resolution, 5 times the observation rate, and 3 times the number of spectral bands for Earth observations. With the improved resolution, comes the instrument suites increased sensitivity to disturbances over a broad spectrum 0-512Hz. Sources of disturbance include reaction wheels, thruster firings for station keeping and momentum management, gimbal motion, and internal instrument disturbances. To minimize the impact of these disturbances, the baseline design included an EPP, a stiff optical bench to which the two nadir pointed instruments are collocated together with the Guidance Navigation Control (GNC) star trackers and Inertial Measurement Units (IMUs). The EPP is passively isolated from the spacecraft bus with Honeywell D-Strut isolators providing attenuation for frequencies above 5 Hz in all six degrees-of-freedom. To reduce the risk of wheel disturbances impacting performance, a secondary passive isolation system manufactured by Moog CSA Engineering was incorporated under each of the six 160 Nms reaction wheels, tuned to provide attenuation at frequencies above 50 Hz. Integrated wheel and isolator testing was performed on a Kistler table at NASA Goddard Space Flight Center. Pre-launch Satellite Dynamic Interaction Characterization high-fidelity simulations and ground testing were conducted to evaluate jitter performance for two cases: 1) deployed EPP and reaction wheel (Dual Isolation) and 2) EPP hard mounted (RWA Isolation Only) to the spacecraft. A comparison of pre-launch to post-launch Satellite Dynamic Interaction Characterization results are also presented in this paper.
Here, this paper compares the calibration of different heat flux sensors in radiation- and convection-based sub- and supersonic operation. First, four heat flux sensors based on different principles: ALTP (Transverse Seebeck Effect), HFM-8E (differential-layer device), coaxial Thermocouple and a TG-2000 (circular-foil gage) are calibrated in a laser-based radiation setup. In a second step, all heat flux sensors are compared with a slug-calorimeter within a subsonic convection-dominated facility based on stagnation-point measurements of an impinging hot air jet. The obtained results indicate that a sensitivity transfer between a radiative calibrated sensor used in a mainly convective environment is not always possible and can lead to significant, systematic errors. Calibration in a subsonic shear flow with thermocouple readings demonstrate small divergence from the manufacturer provided sensitivity. Finally, supersonic testing with high frequency shock-boundary layer interactions highlight the need for ALTP rather than the conventional use of thermocouple arrays to resolve the high frequency phenomena associated with shock boundary layer interactions.
This report presents an enhanced performance evaluation of emergency diesel generators (EDGs) at U.S. commercial nuclear power plants. This report evaluates component performance over time using (1) Institute of Nuclear Power Operations (INPO) Consolidated Events Database (ICES) data from 1998 through 2018 and (2) maintenance unavailability (UA) performance data from Mitigating Systems Performance Index (MSPI) Basis Document data from 2002 through 2018. The objective is to show estimates of current failure probabilities and rates related to EDGs, trend these data on an annual basis, determine if the current data are consistent with the probability distributions currently recommended for use in NRC probabilistic risk assessments, show how the reliability data differ for different EDG manufacturers and for EDGs with different ratings; and summarize the subcomponents, causes, detection methods, and recovery associated with each EDG failure mode. Engineering analyses were performed with respect to time period and failure mode without regard to the actual number of EDGs at each plant. The factors analyzed are: sub-component, failure cause, detection method, recovery, manufacturer, and EDG rating. A statistically significant increasing trend was identified in the frequency of FTLR demands for emergency power system (EPS) and high pressure core spray (HPCS) EDGs and a statistically significant decreasing trend was identified in the frequency of run > 1H hours for EPS and HPCS EDGs.
Cooling of the fusion blanket first wall remains a significant challenge given the adverse conditions of heat and particle flux encountered near the plasma. Helium emerges as an attractive cooling candidate because of its chemical and neutronic inertness and separability from hydrogenic species (e.g. tritium). Because of the low thermal mass of helium, optimization of these coolant channels is warranted to provide high heat transfer performance at low pumping costs. Increasingly, computational fluid dynamics (CFD) simulations are employed to model and optimize these flow channels, and accompanying experimental data are needed to validate the predictions of these models. To provide the aforementioned experimental data, a high-pressure helium flow visualization upgrade has been designed for the Helium Flow Loop Experiment facility. This apparatus was built to American Society of Mechanical Engineers boiler and pressure vessel standards to withstand operating pressure of 4 MPa and mated to high-pressure glass windows. Seedless flow visualization is performed via high-speed background oriented schlieren (BOS), with image correlation used for time-resolved two-dimensional velocimetry at frequencies in excess of 60 kHz. Rectangular flow channel test articles are additively manufactured via laser powder bed fusion and installed into this visualization apparatus, with one-sided heating supplied by resistive heaters. In conclusion, the chosen test geometries were informed by prior CFD simulations, and the helium flow structures observed via BOS (detachment, recirculation, etc.) will be used for the validation of these accompanying models, in support of the design and optimization of blanket cooling channel configurations.
Lithium niobate (LN), first synthesized 70 years ago, has been widely used in diverse applications ranging from communications to quantum optics. These high-volume commercial applications have provided the economic means to establish a mature manufacturing and processing industry for high-quality LN crystals and wafers. Breakthrough science demonstrations to commercial products have been achieved owing to the ability of LN to generate and manipulate electromagnetic waves across a broad spectrum, from microwave to ultraviolet frequencies. Here, we provide a high-level Review of the history of LN as an optical material, its different photonic platforms, engineering concepts, spectral coverage, and essential applications before providing an outlook for the future of LN.
ORNL worked with PrintSpace 3D to demonstrate cost effective electromagnetic induction melting of aluminum alloys on their desktop Altair 3D printer. An electromagnetic coil design and susceptor have been optimized and paired with a high frequency power supply to melt Al-Ce alloys. The manufacturing feasibility of Al-Ce wire was also proven to be successful and precise process control of electro-magnetic heating was demonstrated. The system was found to have inherent safety benefits, requiring no powder handling and with very localized heating. Further research will demonstrate the ability to use DMW technology to print high temperature engine components for the transportation industry.