ALBERT

Description: The Additive Manufacturing Infrared Inspection Task started the development of a real-time dimensional inspection technique and digital quality record for the additive manufacturing process using infrared camera imaging and processing techniques. This project will benefit additive manufacturing by providing real-time inspection of internal geometry that is not currently possible and reduce the time and cost of additive manufactured parts with automated real-time dimensional inspections which deletes post-production inspections.

Description: A 40 cm diameter mirror assembly was interferometrically tested at room temperature down to 250 degrees Kelvin for thermal deformation. The 2.5 m radius of curvature spherical mirror assembly was constructed by low temperature fusing three abrasive waterjet core sections between two face sheets. The 93% lightweighted Corning ULE mirror assembly represents the current state of the art for future UV, optical, near IR space telescopes. During the multiple thermal test cycles, test results of interferometric test, thermal IR images of the front face were recorded in order to validate thermal optical model.

Description: Non-intrusive optical diagnostic imaging was used for the first time to visualize multi-rocket plume-induced reacting base flows to simulate launch vehicle ascent from sea-level to 250,000 ft. In particular, planar laser induced florescence (PLIF) and infrared (IR) imaging were implemented for the first time to visualize and quantify base flow and rocket plume environments from sub-scale, short-duration propulsion models within a shock tunnel facility. This report discusses the successful imaging diagnostic methods for capturing base flow features and dynamics as a function of altitude. Important base flow and plume features were captured with PLIF and IR diagnostics to develop a conceptual base flow physics model. This imaging data specifically provides insight into the Space Launch System vehicle core-stage and Exploration Upper Stage base environments and further validates short-duration ground test techniques and computational modeling.

Description: No abstract available

Description: No abstract available

Description: Additive manufacturing is a rapid prototyping technology that allows parts to be built in a series of thin layers from plastic, ceramics, and metallics. Metallic additive manufacturing is an emerging form of rapid prototyping that allows complex structures to be built using various metallic powders. Significant time and cost savings have also been observed using the metallic additive manufacturing compared with traditional techniques. Development of the metallic additive manufacturing technology has advanced significantly over the last decade, although many of the techniques to inspect parts made from these processes have not advanced significantly or have limitations. Several external geometry inspection techniques exist such as Coordinate Measurement Machines (CMM), Laser Scanners, Structured Light Scanning Systems, or even traditional calipers and gages. All of the aforementioned techniques are limited to external geometry and contours or must use a contact probe to inspect limited internal dimensions. This presentation will document the development of a process for real-time dimensional inspection technique and digital quality record of the additive manufacturing process using Infrared camera imaging and processing techniques.

Description: The Space Shuttle Main Engine Liquid Air Insulation redesign was required to prevent the reoccurance of the STS-111 High Pressure Speed Sensor In-Flight Anomaly. The STS-111 In-Flight Anomaly Failure Investigation Team's initial redesign of the High Pressure Fuel Turbopump Pump End Ball Bearing Liquid Air Insulation failed the certification test by producing Liquid Air. The certification test failure indicated not only the High Pressure Fuel Turbopump Liquid Air Insulation, but all other Space Shuttle Main Engine Liquid Air Insulation. This paper will document the original Space Shuttle Main Engine Liquid Air STS-111 In-Flight Anomaly investigation, the heritage Space Shuttle Main Engine Insulation certification testing faults, the techniques and instrumentation used to accurately test the Liquid Air Insulation systems on the Stennis Space Center SSME test stand, the analysis techniques used to identify the Liquid Air Insulation problem areas and the analytical verification of the redesign before entering certification testing, Trade study down selected to three potential design solutions, the results of the development testing which down selected the final Liquid Air Redesign are also documented within this paper.

Description: A 43cm diameter stacked core mirror demonstrator was interferometrically tested at room temperature down to 250 degrees Kelvin for thermal deformation. The 2.5m radius of curvature spherical mirror assembly was constructed by low temperature fusing three abrasive waterjet core sections between two CNC pocket milled face sheets. The 93% lightweighted Corning ULE mirror assembly represents the current state of the art for future UV, optical, near IR space telescopes. During the multiple thermal test cycles, test results of interferometric test, thermal IR images of the front face were recorded in order to validate thermal optical model.

Description: NASA's Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology has been selected for a Technology Demonstration Mission under the Science and Technology Mission Directorate. HIADs are an enabling technology that can facilitate atmospheric entry of heavy payloads to planets such as Earth and Mars using a deployable aeroshell. The deployable nature of the HIAD technology allows it to overcome the size constraints imposed on current rigid aeroshell entry systems. This permits use of larger aeroshells resulting in increased entry system performance (e.g. higher payload mass and/or volume, higher landing altitude at Mars). The Low Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) is currently scheduled for mid-2021. LOFTID will be launched out of Vandenberg Air Force Base as a secondary payload on an expendable launch vehicle. The flight test will employ a 6m diameter, 70-deg sphere-cone aeroshell and will provide invaluable high-energy orbital re-entry flight data. This data will be essential in supporting the HIAD team to mature the technology to diameters of 10m and greater. Aeroshells of this scale will address near-term commercial applications and potential future NASA missions.LOFTID will incorporate an extensive instrumentation suite totaling over 150 science measurements. This will include thermocouples, heat flux sensors, IR cameras, and a radiometer to characterize the aeroheating environment and aeroshell thermal response. An inertial measurement unit (IMU), GPS, and flush air data system will be included in order to reconstruct the flown trajectory and aerodynamic characteristics. Loadcells will be used to measure the HIAD structural loading, and HD cameras will be mounted on the aft segment looking at the aeroshell to monitor structural response. In addition to the primary instrumentation suite, a new fiber optic sensing system will be used to measure nose temperatures as a technology demonstration. The LOFTID instrumentation suites leverages Agency-wide expertise, with hardware development occurring at Ames Research Center, Langley Research Center, Marshall Space Flight Center and Armstrong Flight Research Center.This presentation will discuss the measurement objectives for the LOFTID mission, and the extensive instrumentation suite that has been selected to capture the HIAD's performance during the high-energy orbital re-entry flight test.