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NASA NTRS2003

Microelectromechanical Systems (MEMS) Broadband Light Source Developed

A miniature, low-power broadband light source has been developed for aerospace applications, including calibrating spectrometers and powering miniature optical sensors. The initial motivation for this research was based on flight tests of a Fabry-Perot fiberoptic temperature sensor system used to detect aircraft engine exhaust gas temperature. Although the feasibility of the sensor system was proven, the commercial light source optically powering the device was identified as a critical component requiring improvement. Problems with the light source included a long stabilization time (approximately 1 hr), a large amount of heat generation, and a large input electrical power (6.5 W). Thus, we developed a new light source to enable the use of broadband optical sensors in aerospace applications. Semiconductor chip-based light sources, such as lasers and light-emitting diodes, have a relatively narrow range of emission wavelengths in comparison to incandescent sources. Incandescent light sources emit broadband radiation from visible to infrared wavelengths; the intensity at each wavelength is determined by the filament temperature and the materials chosen for the filament and the lamp window. However, present commercial incandescent light sources are large in size and inefficient, requiring several watts of electrical power to obtain the desired optical power, and they emit a large percentage of the input power as heat that must be dissipated. The miniature light source, developed jointly by the NASA Glenn Research Center, the Jet Propulsion Laboratory, and the Lighting Innovations Institute, requires one-fifth the electrical input power of some commercial light sources, while providing similar output light power that is easily coupled to an optical fiber. Furthermore, it is small, rugged, and lightweight. Microfabrication technology was used to reduce the size, weight, power consumption, and potential cost-parameters critical to future aerospace applications. This chip-based light source has the potential for monolithic fabrication with on-chip drive electronics. Other uses for these light sources are in systems for vehicle navigation, remote sensing applications such as monitoring bridges for stress, calibration sources for spectrometers, light sources for space sensors, display lighting, addressable arrays, and industrial plant monitoring. Two methods for filament fabrication are being developed: wet-chemical etching and laser ablation. Both yield a 25-mm-thick tungsten spiral filament. The proof-of-concept filament shown was fabricated with the wet etch method. Then it was tested by heating it in a vacuum chamber using about 1.25 W of electrical power; it generated bright, blackbody radiation at approximately 2650 K. The filament was packaged in Glenn's clean-room facilities. This design uses three chips vacuum-sealed with glass tape. The bottom chip consists of a reflective film deposited on silicon, the middle chip contains a tungsten filament bonded to silicon, and the top layer is a transparent window. Lifetime testing on the package will begin shortly. The emitted optical power is expected to be approximately 1.0 W with the spectral peak at 1.1 mm.

Tuma, Margaret L.↗

NASA NTRS1988

The role of fiberoptics in remote temperature measurement

The use of optical fibers in conjunction with infrared detectors and signal processing electronics represents the latest advance in the field of non-contact temperature measurement and control. The operating principles and design of fiber-optic radiometric systems are discussed and the advantages and disadvantages of using optical fibers are addressed. Signal processing requirements and various infrared detector types are also described. Several areas in which infrared fiber-optic instrumentation is used for temperature monitoring and control are discussed.

Vanzetti, Riccardo↗

NASA NTRS1992

The Development of a Fiber Optic Raman Temperature Measurement System for Rocket Flows

A fiberoptic Raman diagnostic system for H2/O2 rocket flows is currently under development. This system is designed for measurement of temperature and major species concentration in the combustion chamber and part of the nozzle of a 100 Newton thrust rocket currently undergoing testing. This paper describes a measurement system based on the spontaneous Raman scattering phenomenon. An analysis of the principles behind the technique is given. Software is developed to measure temperature and major species concentrations by comparing theoretical Raman scattering spectra with experimentally obtained spectra. Equipment selection and experimental approach are summarized. This experimental program is part of a program, which is in progress, to evaluate Navier-Stokes based analyses for this class of rocket.

Degroot, Wim A.↗

NASA NTRS1992

Fiberoptic characteristics for extreme operating environments

Fiberoptics could offer several major benefits for cryogenic liquid-fueled rocket engines, including lightning immunity, weight reduction, and the possibility of implementing a number of new measurements for engine condition monitoring. The technical feasibility of using fiberoptics in the severe environments posed by cryogenic liquid-fueled rocket engines was determined. The issues of importance and subsequent requirements for this use of fiberoptics were compiled. These included temperature ranges, moisture embrittlement succeptability, and the ability to withstand extreme shock and vibration levels. Different types of optical fibers were evaluated and several types of optical fibers' ability to withstand use in cryogenic liquid-fueled rocket engines was demonstrated through environmental testing of samples. This testing included: cold-bend testing, moisture embrittlement testing, temperature cycling, temperature extremes testing, vibration testing, and shock testing. Three of five fiber samples withstood the tests to a level proving feasibility, and two of these remained intact in all six of the tests. A fiberoptic bundle was also tested, and completed testing without breakage. Preliminary cabling and harnessing for fiber protection was also demonstrated. According to cable manufacturers, the successful -300 F cold bend, vibration, and shock tests are the first instance of any major fiberoptic cable testing below roughly -55 F. This program has demonstrated the basic technical feasibility of implementing optical fibers on cryogenic liquid-fueled rocket engines, and a development plan is included highlighting requirements and issues for such an implementation.

Delcher, R. C.↗

NASA NTRS1982

Status of fiberoptics technology for propulsion control systems

Optical sensors and optically controlled actuators for use in airbreathing engine control systems are discussed. The environmental conditions in which the aircraft will operate require the fiberoptic cables and optical connectors to perform reliably at temperatures over the -55 C to 260 C range. The status of fiberoptics technology for operation in this environment is reviewed.

Baumbick, R. J.↗

NASA NTRS1984

Fiberoptics for propulsion control system

In aircraft systems with digital controls, fiberoptics has advantages over wire systems because of its inherent immunity to electromagnetic noise (EMI) and electromagnetic pulses (EMP). It also offers a weight benefit when metallic conductors are replaced by optical fibers. To take full advantage of the benefits of optical waveguides, passive optical sensors are also being developed to eliminate the need for electrical power to the sensor. Fiberoptics may also be used for controlling actuators on engine and airframe. In this application, the optical fibers, connectors, etc. will be subjected to high temperature and vibrations. This paper discussed the use of fiberoptics in aircraft propulsion systems together with the optical sensors and optically controlled actuators being developed to take full advantage of the benefits which fiberoptics offers. The requirements for sensors and actuators in advanced propulsion systems are identified. The benefits of using fiberoptics in place of conventional wire systems are discussed as well as the environmental conditions under which the optical components must operate.

Baumbick, R. J.↗

NASA NTRS1985

Fiber optics for propulsion control systems

Baumbick, R. J.↗

NASA NTRS1990

Optical fibers in the adverse space environment - The Space Station

On the NASA Space Station, the requirement for high speed data transfer between the exterior experimental bays and the interior research facilities has generated the need for fiberoptics. The adverse vacuum effects in space, temperature extremes, and natural space radiation place extreme conditions on optical fiber interconnects. This report addresses the adverse space environmental effects of temperature and radiation on optical fibers.

Greenwell, Roger A.↗

NASA NTRS1993

Advanced instrumentation for next-generation aerospace propulsion control systems

New control concepts for the next generation of advanced air-breathing and rocket engines and hypersonic combined-cycle propulsion systems are analyzed. The analysis provides a database on the instrumentation technologies for advanced control systems and cross matches the available technologies for each type of engine to the control needs and applications of the other two types of engines. Measurement technologies that are considered to be ready for implementation include optical surface temperature sensors, an isotope wear detector, a brushless torquemeter, a fiberoptic deflectometer, an optical absorption leak detector, the nonintrusive speed sensor, and an ultrasonic triducer. It is concluded that all 30 advanced instrumentation technologies considered can be recommended for further development to meet need of the next generation of jet-, rocket-, and hypersonic-engine control systems.

Barkhoudarian, S.↗

NASA NTRS1998

Electron Beam Welder Used to Braze Sapphire to Platinum

A new use for electron beam brazing was recently developed by NASA Lewis Research Center's Manufacturing Engineering Division. This work was done to fabricate a fiberoptic probe (developed by Sentec Corporation) that could measure high temperatures less than 600 deg C of vibrating machinery, such as in jet engine combustion research. Under normal circumstances, a sapphire fiber would be attached to platinum by a ceramic epoxy. However, no epoxies can adhere ceramic fibers to platinum under such high temperatures and vibration. Also, since sapphire and platinum have different thermal properties, the epoxy bond is subjected to creep over time. Therefore, a new method had to be developed that would permanently and reliably attach a sapphire fiber to platinum. Brazing a sapphire fiber to a platinum shell. The fiber-optic probe assembly consists of a 0.015-in.-diameter sapphire fiber attached to a 0.25-in.-long, 0.059-in.-diameter platinum shell. Because of the small size of this assembly, electron beam brazing was chosen instead of conventional vacuum brazing. The advantage of the electron beam is that it can generate a localized heat source in a vacuum. Gold reactive braze was used to join the sapphire fiber and the platinum. Consequently, the sapphire fiber was not affected by the total heat needed to braze the components together.

Forsgren, Roger C.↗

NASA NTRS1992

Fiberoptic sensors for rocket engine applications

A research effort was completed to summarize and evaluate the current level of technology in fiberoptic sensors for possible applications in integrated control and health monitoring (ICHM) systems in liquid propellant engines. The environment within a rocket engine is particuarly severe with very high temperatures and pressures present combined with extremely rapid fluid and gas flows, and high-velocity and high-intensity acoustc waves. Application of fiberoptic technology to rocket engine health monitoring is a logical evolutionary step in ICHM development and presents a significant challenge. In this extremely harsh environment, the additional flexibility of fiberoptic techniques to augment conventional sensor technologies offer abundant future potential.

Ballard, R. O.↗

NASA NTRS1997

Optical Sensors for Use in Propulsion Control Systems

This final technical report describes the results of a cooperative effort which was originally established between John Carroll University and the Instrumentation and Control Technology Division at NASA Lewis Research Center on November, 1982, and then continued with the Engine Sensor Technology Branch at NASA Lewis until March, 1995. All work at John Carroll University was directed by the principal investigator of this grant, Klaus Fritsch, Ph.D. For the first two years of this grant this effort was supervised at NASA by Mr. Robert J. Baumbick and for the remainder of the grant by Dr. Glenn M. Beheim. All research was carried out in close cooperation with Dr. Beheim. Electrically passive optical sensors for measurands such as pressure, temperature, position, and rotational speed are required for aircraft engine control in fly-by-light digital aircraft control systems. Fiberoptic data links and optical multiplexing techniques should be used for combining and processing the outputs from several sensors, sharing as many optical end electronic parts as possible. The overall objective of this grant was to explore techniques for designing and constructing such electrically passive optical sensors for measuring physical parameters in jet aircraft engines and for use in aircraft control systems. We have concentrated our efforts on pressure, temperature, and position sensors employing techniques which are relatively immune to transmissivity variations of the fiber links and to variations in intensity of the light source. Infrared light-emitting diodes are employed because of their longevity and immunity to vibration. We have also studied a number of multiplexing techniques. On the following pages I will give thumbnail sketches of the projects carried out under this grant and provide references to publications and John Carroll M.S. theses which resulted directly from this work and which describe these projects in greater detail.

Fritsch, Klaus↗

NASA NTRS1991

A dual-eigenstate polarization preserving fiberoptic sensor

A dual-eigenstate polarization preserving fiberoptic sensor is tested, in which each eigenstate in a polarization preserving fiber forms an interferometer which could measure the temperature and the strain simultaneously. The temperature and strain coefficients for different polarization fibers are measured at the room temperature, indicating that there exist differences in temperature coefficients between two eigenstates in a polarization preserving fiber. The different temperature effects from those eigenstates make it possible to perform the temperature measurement and/or temperature compensation.

Yu, Dong X.↗

NASA NTRS2006

Ultrasonic/Sonic Driller/Corer (USDC) as a Subsurface Sampler and Sensors Platform for Planetary Exploration Applications

The search for existing or past life in the Universe is one of the most important objectives of NASA's mission. For this purpose, effective instruments that can sample and conduct in-situ astrobiology analysis are being developed. In support of this objective, a series of novel mechanisms that are driven by an Ultrasonic/Sonic actuator have been developed to probe and sample rocks, ice and soil. This mechanism is driven by an ultrasonic piezoelectric actuator that impacts a bit at sonic frequencies through the use of an intermediate free-mass. Ultrasonic/Sonic Driller/Corer (USDC) devices were made that can produce both core and powdered cuttings, operate as a sounder to emit elastic waves and serve as a platform for sensors. For planetary exploration, this mechanism has the important advantage of requiring low axial force, virtually no torque, and can be duty cycled for operation at low average power. The advantage of requiring low axial load allows overcoming a major limitation of planetary sampling in low gravity environments or when operating from lightweight robots and rovers. The ability to operate at duty cycling with low average power produces a minimum temperature rise allowing for control of the sample integrity and preventing damage to potential biological markers in the acquired sample. The development of the USDC is being pursued on various fronts ranging from analytical modeling to mechanisms improvements while considering a wide range of potential applications. While developing the analytical capability to predict and optimize its performance, efforts are made to enhance its capability to drill at higher power and high speed. Taking advantage of the fact that the bit does not require rotation, sensors (e.g., thermocouple and fiberoptics) were integrated into the bit to examine the borehole during drilling. The sounding effect of the drill was used to emit elastic waves in order to evaluate the surface characteristics of rocks. Since the USDC is driven by piezoelectric actuation mechanism it can designed to operate at extreme temperature environments from very cold as on Titan and Europa to very hot as on Venus. In this paper, a review of the latest development and applications of the USDC will be given.

sampling↗

NASA NTRS1990

Determination of the durability of the fiberoptics in rocket engine environments

The results of a testing program in which selected optical fibers were exposed to extreme environments representative of those experienced on rocket engines are discussed. Included in the experiment are cold-bend testing, a moisture embrittlement test, a thermal cycling test, temperature extremes testing, vibration testing, and shock testing. Two of the fibers selected, the titanium-carbide-coated and the aluminum-jacketed silica samples succeeded in passing all the tests without a failure.

Delcher, R.↗

NASA NTRS1998

Fiber Optic Cable Feedthrough and Sealing

A novel fiberoptic hermetic bulkhead feedthrough has been developed which will offer cryogenic sealing at leak rates of 10(exp -11) cc/sec helium. This feedthrough was developed for NASA in response to needs for a hermetically sealed feedthrough which could withstand a range of temperatures from low cryogenic (-196 C), due to liquid fuels and oxidizers, to high temperatures (+200 C) encountered in the proximity of combustion gasses. The development effort will be reported from conceptual design of single and multi-channel feedthrough units with single interconnection interfaces to units with double-ended interconnection interfaces. Various combinations of fiber/buffers are reported with recommendations based on test results. A comprehensive series of environmental and mechanical tests were performed to evaluate the feedthroughs in adverse conditions. Test results are reported including insertion loss, salt spray, sinusoidal vibration, random vibration, mechanical shock, thermal shock and humidity. A second set of feedthrough units was exposed to 3 different types of radiation. Optical transmittance changes during the tests were monitored and leak rate testing was done after each test. State-of-the-art technology in optical fiber feedthroughs constructed with polycrystalline ceramic is presented.

Fan, Robert J.↗

NASA NTRS2011

Scatterometer-Calibrated Stability Verification Method

The requirement for scatterometer-combined transmit-receive gain variation knowledge is typically addressed by sampling a portion of the transmit signal, attenuating it with a known-stable attenuation, and coupling it into the receiver chain. This way, the gain variations of the transmit and receive chains are represented by this loop-back calibration signal, and can be subtracted from the received remote radar echo. Certain challenges are presented by this process, such as transmit and receive components that are outside of this loop-back path and are not included in this calibration, as well as the impracticality for measuring the transmit and receive chains stability and post fabrication separately, without the resulting measurement errors from the test set up exceeding the requirement for the flight instrument. To cover the RF stability design challenge, the portions of the scatterometer that are not calibrated by the loop-back, (e.g., attenuators, switches, diplexers, couplers, and coaxial cables) are tightly thermally controlled, and have been characterized over temperature to contribute less than 0.05 dB of calibration error over worst-case thermal variation. To address the verification challenge, including the components that are not calibrated by the loop-back, a stable fiber optic delay line (FODL) was used to delay the transmitted pulse, and to route it into the receiver. In this way, the internal loopback signal amplitude variations can be compared to the full transmit/receive external path, while the flight hardware is in the worst-case thermal environment. The practical delay for implementing the FODL is 100 s. The scatterometer pulse width is 1 ms so a test mode was incorporated early in the design phase to scale the 1 ms pulse at 100-Hz pulse repetition interval (PRI), by a factor of 18, to be a 55 s pulse with 556 s PRI. This scaling maintains the duty cycle, thus maintaining a representative thermal state for the RF components. The FODL consists of an RF-modulated fiber-optic transmitter, 20 km SMF- 28 standard single-mode fiber, and a photodetector. Thermoelectric cooling and insulating packaging are used to achieve high thermal stability of the FODL components. The chassis was insulated with 1-in. (.2.5-cm) thermal isolation foam. Nylon rods support the Micarta plate, onto which are mounted four 5-km fiber spool boxes. A copper plate heat sink was mounted on top of the fiber boxes (with thermal grease layer) and screwed onto the thermoelectric cooler plate. Another thermal isolation layer in the middle separates the fiberoptics chamber from the RF electronics components, which are also mounted on a copper plate that is screwed onto another thermoelectric cooler. The scatterometer subsystem fs overall stability was successfully verified to be calibratable to within 0.1 dB error in thermal vacuum (TVAC) testing with the fiber-optic delay line, while the scatterometer temperature was ramped from 10 to 30 C, which is a much larger temperature range than the worst-case expected seasonal variations.

McWatters, Dalia A.↗

NASA NTRS1983

Fiberoptics technology and its application to propulsion control systems

Current work on optical sensors and optically controlled actuators for use in air-breathing engine control systems is reviewed with particular reference to the design and operation of several new fiber-optic devices. These include a tachometer, a rotary position encoder, a Fabry-Perot interferometer and a rare-earth sensor for measuring engine gas temperatures, a high-temperature photoswitch designed for the range -55 to 260 C, and optical cables and connectors. The advantages of optics over conventional wire systems used for sensing and actuator control are briefly discussed.

Baumbick, R. J.↗