ALBERT

Description: The as-welded friction stir weld has a cross section that may act as a stress concentrator. The geometry associated with the stress concentration may reduce the weld strength and it makes the weld challenging to inspect with ultrasound. In some cases, the geometry leads to false positive nondestructive evaluation (NDE) indications and, in many cases, it requires manual blending to facilitate the inspection. This study will measure the stress concentration effect and develop an improved phased array ultrasound testing (PAUT) technique for friction stir welding. Post-welding, the friction stir weld (FSW) tool would be fitted with an end mill that would machine the weld smooth, trimmed shaved. This would eliminate the need for manual weld preparation for ultrasonic inspections. Manual surface preparation is a hand operation that varies widely depending on the person preparing the welds. Shaving is a process that can be automated and tightly controlled.

Description: Future NASA space missions will require advanced thermal-to-electric power converters that are reliable, efficient, and lightweight. Creare, LLC, is developing a turbo-Brayton power converter that offers high efficiency and specific power. The converter employs gas bearings to provide maintenance free, long-life operation. Discrete components can be packaged to fit optimally with other subsystems, and the converter's continuous gas flow can communicate directly with remote heat sources and heat rejection surfaces without the need for ancillary heat-transfer components and intermediate flow loops. Creare has completed detailed analyses, trade studies, fabrication trials, and preliminary designs for the components and converter assembly. The company is fabricating and testing a breadboard converter.

Description: Space exploration lies at the inquisitive core of human nature, yet high costs hinder the advancement of this frontier. We are harnessing the replicative properties of biology to create biOrigamibiological, self-folding origamito reduce the mass, volume, and assembly time of materials needed for space missions. biOrigami consists of two main components: manufacturing substrates biologically and bioengineering folding mechanisms. For substrates, we are developing new BioBricks to synthesize two thermoplastics: polystyrene and polyhydroxyalkanoates. For folding mechanisms, we are using heat-induced contraction of thermoplastics and the contractile properties of bacterial spores. After consulting with experts, we believe that biOrigami could be incorporated into rovers, solar sails, and more. In addition to biOrigami, we are creating a novel method to efficiently transform bacteria by using the CRISPRCas9 system, benefitting the broader synthetic biology community. Our project integrates and improves manufacturing processes for space exploration on both the micro and macro levels.

Description: No abstract available

Description: Powder-Bed Additive Manufacturing (AM) through Direct Metal Laser Sintering (DMLS) or Selective Laser Melting (SLM) is being used by NASA and the Aerospace industry to "print" parts that traditionally are very complex, high cost, or long schedule lead items. The process spreads a thin layer of metal powder over a build platform, then melts the powder in a series of welds in a desired shape. The next layer of powder is applied, and the process is repeated until layer-by-layer, a very complex part can be built. This reduces cost and schedule by eliminating very complex tooling and processes traditionally used in aerospace component manufacturing. To use the process to print end-use items, NASA seeks to understand SLM material well enough to develop a method of qualifying parts for space flight operation. Traditionally, a new material process takes many years and high investment to generate statistical databases and experiential knowledge, but computational modeling can truncate the schedule and cost -many experiments can be run quickly in a model, which would take years and a high material cost to run empirically. This project seeks to optimize material build parameters with reduced time and cost through modeling.

Description: No abstract available

Description: No abstract available

Description: A major phase of aerospace hardware verification is vibration testing. The standard approach for such testing is to use a shaker to induce loads into the payload. In preparation for vibration testing at National Aeronautics and Space Administration/Goddard Space Flight Center an analysis is performed to assess the responses of the payload. A new method of modeling the test is presented that takes into account dynamic interactions between the facility and the payload. This dynamic interaction has affected testing in the past, but been ignored or adjusted for during testing. By modeling the combined dynamics of the facility and test article (payload) it is possible to improve the prediction of hardware responses. Many aerospace test facilities work in similar way to those at NASA/Goddard Space Flight Center. Lessons learned here should be applicable to other test facilities with similar setups.

Description: A smart coating system, based on pH sensitive microcontainers (microparticles and microcapsules) has been developed. Various corrosion inhibitors have been encapsulated and incorporated into commercial and formulated coatings to test the functionality imparted on the coating by the incorporation of the inhibitor microcontainers. Coated carbon steel and aluminum alloy panels were tested using salt immersion, salt fog, and coastal atmospheric exposure conditions. This paper provides the details on coating sample preparation, evaluation methods, as well as test results of the inhibiting function of smart coatings.

Description: The Ground Operations Demonstration Unit for Liquid Hydrogen (GODU-LH2) has been developed at NASA Kennedy Space Center in Florida. GODU-LH2 has three main objectives: zero-loss storage and transfer, liquefaction, and densification of liquid hydrogen. A cryogenic refrigerator has been integrated into an existing, previously certified, 33,000 gallon vacuum-jacketed storage vessel built by Minnesota Valley Engineering in 1991 for the Titan program. The dewar has an inner diameter of 9.5 and a length of 71.5; original design temperature and pressure ranges are -423 F to 100 F and 0 to 95 psig respectively. During densification operations the liquid temperature will be decreased below the normal boiling point by the refrigerator, and consequently the pressure inside the inner vessel will be sub-atmospheric. These new operational conditions rendered the original certification invalid, so an effort was undertaken to recertify the tank to the new pressure and temperature requirements (-12.7 to 95 psig and -433 F to 100 F respectively) per ASME Boiler and Pressure Vessel Code, Section VIII, Division 1. This paper will discuss the unique design, analysis and implementation issues encountered during the vessel recertification process.

Description: Testing of instrumented spur gears operating at aerospace rotorcraft conditions was conducted. The instrumented gears were operated in a normal and in a loss-of-lubrication environment. Thermocouples were utilized to measure the temperature at various locations on the test gears and a test utilized a full-field, high-speed infrared thermal imaging system. Data from thermocouples was recorded during all testing at 1 Hz. One test had the gears shrouded and a second test was run without the shrouds to permit the infrared thermal imaging system to take date during loss-of-lubrication operation. Both tests using instrumented spur gears were run in normal and loss-of-lubrication conditions. Also the result from four other loss-of-lubrication tests will be presented. In these tests two different torque levels were used while operating at the same rotational speed (10000 rpm).

Description: An analytical model has been developed for the mechanics of friction plug welding. The model accounts for coupling of plastic deformation (material flow) and thermal response (plastic heating). The model predictions of the torque, energy, and pull force on the plug were compared to the data of a recent experiment, and the agreements between predictions and data are encouraging.

Description: The diagnostics capability of micro-electro-mechanical systems (MEMS) based rotating accelerometer sensors in detecting gear tooth crack failures in helicopter main-rotor transmissions was evaluated. MEMS sensors were installed on a pre-notched OH-58C spiral-bevel pinion gear. Endurance tests were performed and the gear was run to tooth fracture failure. Results from the MEMS sensor were compared to conventional accelerometers mounted on the transmission housing. Most of the four stationary accelerometers mounted on the gear box housing and most of the CI's used gave indications of failure at the end of the test. The MEMS system performed well and lasted the entire test. All MEMS accelerometers gave an indication of failure at the end of the test. The MEMS systems performed as well, if not better, than the stationary accelerometers mounted on the gear box housing with regards to gear tooth fault detection. For both the MEMS sensors and stationary sensors, the fault detection time was not much sooner than the actual tooth fracture time. The MEMS sensor spectrum data showed large first order shaft frequency sidebands due to the measurement rotating frame of reference. The method of constructing a pseudo tach signal from periodic characteristics of the vibration data was successful in deriving a TSA signal without an actual tach and proved as an effective way to improve fault detection for the MEMS.

Description: A user input device for a vehicular electrical system is provided. The user input device includes a handle sized and shaped to be gripped by a human hand and a gimbal assembly within the handle. The gimbal assembly includes a first gimbal component, a second gimbal component coupled to the first gimbal component such that the second gimbal component is rotatable relative to the first gimbal component about a first axis, and a third gimbal component coupled to the second gimbal component such that the third gimbal component is rotatable relative to the second gimbal component about a second axis.

Description: NASA Marshall Space Flight Center (MSFC) developed Ultrasonic Stir Welding (USW) to join large pieces of very high-strength metals such as titanium and Inconel. USW, a solid-state weld process, improves current thermal stir welding processes by adding high-power ultrasonic (HPU) energy at 20 kHz frequency. The addition of ultrasonic energy significantly reduces axial, frictional, and shear forces; increases travel rates; and reduces wear on the stir rod, which results in extended stir rod life. The USW process decouples the heating, stirring, and forging elements found in the friction stir welding process allowing for independent control of each process element and, ultimately, greater process control and repeatability. Because of the independent control of USW process elements, closed-loop temperature control can be integrated into the system so that a constant weld nugget temperature can be maintained during welding.

Description: Electron beam freeform fabrication (EBF3) is a cross-cutting technology for producing structural metal parts using an electron beam and wire feed in a layer-additive fashion. This process was developed by researchers at NASA Langley to specifically address needs for aerospace applications. Additive manufacturing technologies like EBF3 enable efficient design of materials and structures by tailoring microstructures and chemistries at the local level to improve performance at the global level. Additive manufacturing also facilitates design freedom by integrating assemblies into complex single-piece components, eliminating flanges, fasteners and joints, resulting in reduced size and mass. These same efficiencies that permit new design paradigms also lend themselves to supportability and sustainability. Long duration space missions will require a high degree of self-sustainability. EBF3 is a candidate technology being developed to allow astronauts to conduct repairs and fabricate new components and tools on demand, with efficient use of feedstock materials and energy.

Description: An eddy-current-minimizing flow plug has an outer radial wall with open flow channels formed between the plug's inlet and outlet. The plug has a central region coupled to the inner surface of the outer radial wall. Each open flow channel includes (i) a first portion originating at the inlet and converging to a location in the plug where convergence is contributed to by changes in thickness of the outer radial wall and divergence of the central region, and (ii) a second portion originating in the plug and diverging to the outlet where divergence is contributed to by changes in thickness of the outer radial wall and convergence of the central region. For at least a portion of the open flow channels, a central axis passing through the first and second portions is non-parallel with respect to the given direction of the flow.

Description: The results of tensile, fracture, and fatigue testing of IN718 coupons produced using the selective laser melting (SLM) additive manufacturing technique are presented. The data has been "generalized" to remove the numerical values, although certain references to material standards are provided. This document provides some knowledge of the effect of variation of controlled build parameters used in the SLM process, a snapshot of the capabilities of SLM in industry at present, and shares some of the lessons learned along the way. For the build parameter characterization, the parameters were varied over a range about the machine manufacturer's recommended value, and in each case they were varied individually, although some covariance of those parameters would be expected. SLMproduced IN718, tensile, fracture, and highcycle fatigue properties equivalent to wrought IN718 are achievable. Build and postbuild processes need to be determined and then controlled to established limits to accomplish this. It is recommended that a multivariable evaluation, e.g., designofexperiment (DOE), of the build parameters be performed to better evaluate the covariance of the parameters.

Description: The Selective Laser Melting (SLM) manufacturing technique has been utilized in the manufacture of a flex joint typical of those found in rocket engine and main propulsion system ducting. The SLM process allowed for the combination of parts that are typically machined separately and welded together. This resulted in roughly a 65% reduction of the total number of parts, roughly 70% reduction in the total number of welds, and an estimated 60% reduction in the number of machining operations. The majority of the new design was in three SLM pieces. These pieces, as well as a few traditionally fabricated parts, were assembled into a complete unit, which has been pressure tested. The design and planned cryogenic testing of the unit will be presented.

Description: Selective Laser Melting (SLM) was utilized to fabricate a liquid hydrogen valve housing typical of those found in rocket engines and main propulsion systems. The SLM process allowed for a valve geometry that would be difficult, if not impossible to fabricate by traditional means. Several valve bodies were built by different SLM suppliers and assembled with valve internals. The assemblies were then tested with liquid nitrogen and operated as desired. One unit was also burst tested and sectioned for materials analysis. The design, test results, and planned testing are presented herein.

Description: Friction Pull Plug Welding (FPPW) is a solidstate process that is the primary close out method for Self Reacting Friction Stir Welding (SRFSW). This process uses a servo hydraulic machine to spin an aluminum plug to several thousand revolutions per minute and pull the plug with several thousand pound force into an aluminum piece of material. This process, which has been around for approximately a decade, has proven to be a very difficult process to develop. There are large number of variables with interactions and correlations that are difficult to detect. Historically this method only provided good results on aluminum material up to 0.327" thick. The SLS rocket required weld land configurations of up to 0.625" thick. This not only pushed the limits of the process but also of the tools procured for materials 1/2 as thick. Ultimate Tensile Results was typically the response used for FPPW input variables. The problem was there were multiple processes including, welding, post weld machining, Non Destructive Evaluation, specimen fabrication and mechanical testing between the FPPW inputs and the mechanical test results. This only compiled the list of variables and made the process of FPPW even more difficult to develop. This presentation and paper describes the new process development methodology, which uses the FPPW tool's feedback to observe the process and develop it systematically. It captures 6 months and 600 plugs worth of work using only the tool's feedback as a response to the process. This presentation describes the solution to the issue, a solution whose methodology could apply to a variety of other processes.

Description: Reviving industry standards for coating parts in tungsten disulfide, a dry lubricant developed for the Mariner space probes managed by the Jet Propulsion Laboratory in the 1960s and '70s, Applied Tungstenite, a relatively new Temecula, California-based company, has found a client base in the mushrooming commercial space industry, as well as other manufacturers.

Description: The present invention is a versatile hermetic seal leak detection apparatus for testing hermetically sealed containers and devices for leaks without the need to create a custom or specially manufactured testing chamber conforming to the dimensions of the specific object under test. The size of the testing chamber may be mechanically adjusted by the novel use of bellows to reduce and optimize the amount of gas space in a test chamber which surrounds the hermetically sealed object under test. The present invention allows the size of the test chamber to be selectively adjusted during testing to provide an optimum test chamber gas space. The present invention may be further adapted to isolate and test specific portions of the hermetically sealed object under test for leaks.

Description: A modular apparatus for attaching sensors and electronics is disclosed. The modular apparatus includes a square recess including a plurality of cavities and a reference cavity such that a pressure sensor can be connected to the modular apparatus. The modular apparatus also includes at least one voltage input hole and at least one voltage output hole operably connected to each of the plurality of cavities such that voltage can be applied to the pressure sensor and received from the pressure sensor.

Description: The present invention is an intelligent flow control valve which may be inserted into the flow coming out of a pipe and activated to provide a method to stop, measure, and meter flow coming from the open or possibly broken pipe. The intelligent flow control valve may be used to stop the flow while repairs are made. Once repairs have been made, the valve may be removed or used as a control valve to meter the amount of flow from inside the pipe. With the addition of instrumentation, the valve may also be used as a variable area flow meter and flow controller programmed based upon flowing conditions. With robotic additions, the valve may be configured to crawl into a desired pipe location, anchor itself, and activate flow control or metering remotely.

Description: A variable-aperture reciprocating reed valve includes a valve body defining a through hole region having a contoured-profile portion. A semi-rigid plate is affixed on one side thereof to the valve body to define a cantilever extending across the through hole region. At least one free edge of the cantilever opposes the contoured-profile portion of the through hole region in a non-contact relationship.

Description: No abstract available

Description: The Molecular Adsorber Coating (MAC) is a new, innovative technology that was developed to reduce the risk of molecular contamination on spaceflight applications. Outgassing from materials, such as plastics, adhesives, lubricants, silicones, epoxies, and potting compounds, pose a significant threat to the spacecraft and the lifetime of missions. As a coating made of highly porous inorganic materials, MAC offers impressive adsorptive capabilities that help capture and trap contaminants. Past research efforts have demonstrated the coating's promising adhesion performance, optical properties, acoustic durability, and thermal stability. These results advocate its use near or on surfaces that are targeted by outgassed materials, such as internal optics, electronics, detectors, baffles, sensitive instruments, thermal control coatings, and vacuum chamber test environments. The MAC technology has significantly progressed in development over the recent years. This presentation summarizes the many NASA spaceflight applications of MAC and how the coatings technology has been integrated as a mitigation tool for outgassed contaminants. For example, this sprayable paint technology has been beneficial for use in various vacuum chambers for contamination control and hardware bake-outs. The coating has also been used in small instrument cavities within spaceflight instrument for NASA missions.

Description: A major phase of aerospace hardware verification is vibration testing. The standard approach for such testing is to use a shaker to induce loads into the payload. In preparation for vibration testing at NASA/GSFC there is an analysis to assess the responses of the payload. A new method of modeling the test is presented that takes into account dynamic interactions between the facility and the payload. This dynamic interaction has affected testing in the past, but been ignored or adjusted for during testing. By modeling the combination of the facility and test article (payload) it is possible to improve the prediction of hardware responses. Many aerospace test facilities work in similar way to those at NASA Goddard Space Flight Center. Lessons learned here should be applicable to other test facilities with similar setups.

Description: Development work in Environmental Barrier Coatings (EBCs) for Ceramic Matrix Composites (CMCs) has focused considerably on the identification of materials systems and coating architectures to meet application needs. The evolution of these systems has occurred so quickly that modeling efforts and requisite data for modeling lag considerably behind development. Materials property data exists for many systems in the bulk form, but the effects of deposition on the critical properties of strength and fracture behavior are not well studied. We have plasma sprayed bulk samples of baseline EBC materials (silicon, ytterbium disilicate) and tested the mechanical properties of these materials to elicit differences in strength and toughness. We have also endeavored to assess the mixed-mode fracture resistance, Gc, of silicon in a baseline EBC applied to SiCSiC CMC via four point bend test. These results are compared to previously determined properties of the comparable bulk material.

Description: Coil, tube, and other structures configured with a plurality of individual coils, internal structures, legs or extensions with each having multiple cants per coil, internal structure, leg or extension, and wherein the cants formed therein allow for a load-deflection force when each is compressed. In addition, any horizontal or moment forces are substantially reduced and/or eliminated when a downward vertical force is applied, as minimal or no torsion is created in the individual coils, legs or extensions.

Description: NASA's Marshall Space Flight Center has developed a device and method for blocking the flow of fluid from an open pipe. Motivated by the sea-bed oil-drilling catastrophe in the Gulf of Mexico in 2010, NASA innovators designed the device to plug, control, and meter the flow of gases and liquids. Anchored with friction fittings, spikes, or explosively activated fasteners, the device is well-suited for harsh environments and high fluid velocities and pressures. With the addition of instrumentation, it can also be used as a variable area flow metering valve that can be set based upon flow conditions. With robotic additions, this patent-pending innovation can be configured to crawl into a pipe then anchor and activate itself to block or control fluid flow.

Description: No abstract available

Description: NASA's Marshall Space Flight Center has developed a joint that employs a unique spring-loaded mechanism that automatically secures a ball hitch upon insertion into a coupler. This eliminates the need for the locking lever found in most conventional ball joints. Connections made using MSFC's quick-connect joint are easier, safer, and more reliable than those made using conventional ball joints.

Description: A modular pre-filtration apparatus may be beneficial to extend the life of a filter. The apparatus may include an impactor that can collect a first set of particles in the air, and a scroll filter that can collect a second set of particles in the air. A filter may follow the pre-filtration apparatus, thus causing the life of the filter to be increased.

Description: A thermal-powered reciprocating-force motor includes a shutter switchable between a first position that passes solar energy and a second position that blocks solar energy. A shape memory alloy (SMA) actuator is coupled to the shutter to control switching thereof between the shutter's first and second position. The actuator is positioned with respect to the shutter such that (1) solar energy impinges on the SMA when the shutter is in its first position so that the SMA experiences contraction in length until the shutter is switched to its second position, and (2) solar energy is impeded from impingement on the SMA when the shutter is in its second position so that the SMA experiences extension in length. Elastic members coupled to the actuator apply a force to the SMA that aids in its extension in length until the shutter is switched to its first position.

Description: An enhancement to the pressure decay leak rate method with mass point analysis solved deficiencies in the standard method. By adding a control system, a constant gas pressure differential across the test article was maintained. As a result, the desired pressure condition was met at the onset of the test, and the mass leak rate and measurement uncertainty were computed in real-time. The data acquisition and control system were programmed to automatically stop when specified criteria were met. Typically, the test was stopped when a specified level of measurement uncertainty was attained. Using silicone O-ring test articles, the new method was compared with the standard method that permitted the downstream pressure to be non-constant atmospheric pressure. The two methods recorded comparable leak rates, but the new method recorded leak rates with significantly lower measurement uncertainty, statistical variance, and test duration. Utilizing this new method in leak rate quantification, projects will reduce cost and schedule, improve test results, and ease interpretation between data sets.

Description: No abstract available

Description: No abstract available

Description: Damage evolution of electron beam-physical vapor deposited (EBVD-PVD) ZrO2-7 wt.% Y2O3 thermal barrier coatings (TBCs) under thermal cyclic conditions was monitored using an acoustic emission (AE) technique. The coatings were heated using a laser heat flux technique that yields a high reproducibility in thermal loading. Along with AE, real-time thermal conductivity measurements were also taken using infrared thermography. Tests were performed on samples with induced stress concentrations, as well as calcium-magnesium-alumino-silicate (CMAS) exposure, for comparison of damage mechanisms and AE response to the baseline (as-produced) coating. Analysis of acoustic waveforms was used to investigate damage development by comparing when events occurred, AE event frequency, energy content and location. The test results have shown that AE accumulation correlates well with thermal conductivity changes and that AE waveform analysis could be a valuable tool for monitoring coating degradation and provide insight on specific damage mechanisms.

Description: This paper presents a simple computational model for determining whether additive manufacturing or subtractive manufacturing is more energy efficient for production of a given metallic part. The key discriminating variable is the fraction of the bounding envelope that contains material i.e. the volume fraction of solid material. For both the additive process and the subtractive process, the total energy associated with the production of a part is defined in terms of the volume fraction of that part. The critical volume fraction is that for which the energy consumed by subtractive manufacturing equals the energy consumed by additive manufacturing. For volume fractions less than the critical value, additive manufacturing is more energy efficient. For volume fractions greater than the critical value, subtractive manufacturing is more efficient. The model considers the entire manufacturing lifecycle from production and transport of feedstock material through processing to return of post-production scrap for recycling. Energy consumed by processing equipment while idle is also accounted for in the model. Although the individual energy components in the model are identified and accounted for in the expressions for additive and subtractive manufacturing, values for many of these components may not be currently available. Energy values for some materials production and subtractive and additive manufacturing processes can be found in the literature. However, since many of these data are reported for a very specific application, it may be difficult, if not impossible, to reliably apply these data to new process-material manufacturing scenarios since, very often, insufficient information is provided to enable extrapolation to broader use. Consequently, this paper also highlights the need to develop improved knowledge of the energy embodied in each phase of the manufacturing process. To be most valuable, users of the model should determine the energy consumed by their manufacturing process equipment on the basis of energy-per-unit-volume of production for each material of interest considering both alloy composition and form. Energy consumed during machine idle per unit time should also be determined by the user then scaled to specific processing scenarios. Energy required to generate feedstock material (billet, plate, bar, wire, powder) must be obtained from suppliers.

Description: Generalized formulations for dynamic capacity and life of ball bearings, based on the models introduced by Lundberg and Palmgren and Zaretsky, have been developed and implemented in the bearing dynamics computer code, ADORE. Unlike the original Lundberg-Palmgren dynamic capacity equation, where the elastic properties are part of the life constant, the generalized formulations permit variation of elastic properties of the interacting materials. The newly updated Lundberg-Palmgren model allows prediction of life as a function of elastic properties. For elastic properties similar to those of AISI 52100 bearing steel, both the original and updated Lundberg-Palmgren models provide identical results. A comparison between the Lundberg-Palmgren and the Zaretsky models shows that at relatively light loads the Zaretsky model predicts a much higher life than the Lundberg-Palmgren model. As the load increases, the Zaretsky model provides a much faster drop off in life. This is because the Zaretsky model is much more sensitive to load than the Lundberg-Palmgren model. The generalized implementation where all model parameters can be varied provides an effective tool for future model validation and enhancement in bearing life prediction capabilities.

Description: Rolling-element bearings operated at high speed or high vibration may require a tight interference fit between the bore of the bearing and shaft to prevent rotation of the bearing bore around the shaft and fretting damage at the interfaces. Previous work showed that the hoop stresses resulting from tight interference fits can reduce bearing lives by as much as 65 percent. Where tight interference fits are required, case-carburized steel such as AISI 9310 or M50 NiL is often used because the compressive residual stresses inhibit subsurface crack formation and the ductile core inhibits inner-ring fracture. The presence of compressive residual stress and its combination with hoop stress also modifies the Hertz stress-life relation. This paper analyzes the beneficial effect of residual stresses on rolling-element bearing fatigue life in the presence of high hoop stresses for three bearing steels. These additional stresses were superimposed on Hertzian principal stresses to calculate the inner-race maximum shearing stress and the resulting fatigue life of the bearing. The load-life exponent p and Hertz stress-life exponent n increase in the presence of compressive residual stress, which yields increased life, particularly at lower stress levels. The Zaretsky life equation is described and is shown to predict longer bearing lives and greater load- and stress-life exponents, which better predicts observed life of bearings made from vacuum-processed steel.

Description: Cylindrical roller bearings typically employ roller profile modification to equalize load distribution, minimize stress concentration at roller ends and allow for a small amount of misalignment. The 1947 Lundberg-Palmgren analysis reported an inverse fourth power relation between load and life for roller bearings with line contact. In 1952, Lundberg and Palmgren changed their load-life exponent to 10/3 for roller bearings, assuming mixed line and point contact. The effect of roller-crown profile was reanalyzed in this paper to determine the actual load-life relation for modified roller profiles. For uncrowned rollers (line contact), the load-life exponent is p = 4, in agreement with the 1947 Lundberg-Palmgren value but crowning reduces the value of the exponent, p. The lives of modern roller bearings made from vacuum-processed steels significantly exceed those predicted by the Lundberg-Palmgren theory. The Zaretsky rolling-element bearing life model of 1996 produces a load-life exponent of p = 5 for flat rollers, which is more consistent with test data. For the Zaretsky model with fully crowned rollers p = 4.3. For an aerospace profile and chamfered rollers, p = 4.6. Using the 1952 Lundberg-Palmgren value p = 10/3, the value incorporated in ANSI/ABMA and ISO bearing standards, can create significant life calculation errors for roller bearings.

Description: A grasp assist device includes a glove with first and second tendon-driven fingers, a tendon, and a sleeve with a shared tendon actuator assembly. Tendon ends are connected to the respective first and second fingers. The actuator assembly includes a drive assembly having a drive axis and a tendon hook. The tendon hook, which defines an arcuate surface slot, is linearly translatable along the drive axis via the drive assembly, e.g., a servo motor thereof. The flexible tendon is routed through the surface slot such that the surface slot divides the flexible tendon into two portions each terminating in a respective one of the first and second ends. The drive assembly may include a ball screw and nut. An end cap of the actuator assembly may define two channels through which the respective tendon portions pass. The servo motor may be positioned off-axis with respect to the drive axis.

Description: An apparatus includes a shaft, a device, a fastener, and an anti-rotation clip. The shaft is configured for rotation. The device is mounted on, and surrounds at least a portion of, the shaft, and has first and second protrusions that are formed on one side and are spaced apart to define a tab space. The fastener is rotationally mounted relative to the shaft, and includes a tab slot formed in its outer surface that extends radially inwardly and is disposed radially inwardly of the tab space. The anti-rotation clip includes a main body portion and a head portion that has a first tab portion and a second tab portion. At least a portion the main body portion is disposed between the device and the fastener, the first tab is disposed in the tab space, and the second tab is disposed in the tab slot.

Description: A system and method of measuring a residence time in a gas-turbine engine is provided, whereby the method includes placing pressure sensors at a combustor entrance and at a turbine exit of the gas-turbine engine and measuring a combustor pressure at the combustor entrance and a turbine exit pressure at the turbine exit. The method further includes computing cross-spectrum functions between a combustor pressure sensor signal from the measured combustor pressure and a turbine exit pressure sensor signal from the measured turbine exit pressure, applying a linear curve fit to the cross-spectrum functions, and computing a post-combustion residence time from the linear curve fit.

Description: The design of the free-mass in an ultrasonic driller/corer (USDC) has been refined in order to improve the performance and operational reliability of the system. In one embodiment, the improvements in performance and operational reliability include decreasing the impact surface area of the free-mass to increase the transfer of impact energy from the piezoelectric transducer and reductions in the likelihood that the system will jam.

Description: A small scale, high speed turbomachine is described, as well as a process for manufacturing the turbomachine. The turbomachine is manufactured by diffusion bonding stacked sheets of metal foil, each of which has been pre-formed to correspond to a cross section of the turbomachine structure. The turbomachines include rotating elements as well as static structures. Using this process, turbomachines may be manufactured with rotating elements that have outer diameters of less than four inches in size, and/or blading heights of less than 0.1 inches. The rotating elements of the turbomachines are capable of rotating at speeds in excess of 150 feet per second. In addition, cooling features may be added internally to blading to facilitate cooling in high temperature operations.

Description: A monolithic optical absorber and methods of making same. The monolithic optical absorber uses an array of mutually aligned carbon nanotubes that are grown using a PECVD growth process and a structure that includes a conductive substrate, a refractory template layer and a nucleation layer. Monolithic optical absorbers made according to the described structure and method exhibit high absorptivity, high site densities (greater than 10.sup.9 nanotubes/cm.sup.2), very low reflectivity (below 1%), and high thermal stability in air (up to at least 400.degree. C.). The PECVD process allows the application of such absorbers in a wide variety of end uses.

Description: This paper details the development of an electrically-controlled, variable-stiffness spring based on magnetostrictive materials. The device, termed a magnetostrictive Varispring, can be applied as a semi-active vibration isolator or switched stiffness vibration controller for reducing transmitted vibrations. The Varispring is designed using 1D linear models that consider the coupled electrical response, mechanically-induced magnetic diffusion, and the effect of internal mass on dynamic stiffness. Modeling results illustrate that a Terfenol-D-based Varispring has a rise time almost an order of magnitude smaller and a magnetic diffusion cut-off frequency over two orders of magnitude greater than a Galfenol-based Varispring. The results motivate the use of laminated Terfenol-D rods for a greater stiffness tuning range and increased bandwidth. The behavior of a prototype Varispring is examined under vibratory excitation up to 6 MPa and 25 Hz using a dynamic load frame. For this prototype, stiffness is indirectly varied by controlling the excitation current. Preliminary measurements of continuous stiffness tuning via sinusoidal currents up to 1 kHz are presented. The measurements demonstrate that the Young's modulus of the Terfenol-D rod inside the Varispring can be continuously varied by up to 21.9 GPa. The observed stiffness tuning range is relatively constant up to 500 Hz, but significantly decreases thereafter. The stiffness tuning range can be greatly increased by improving the current and force control such that a more consistent current can be applied and the Varispring can be accurately tested at a more optimal bias stress.

Description: Additive manufacturing (AM) offers tremendous promise for the rocket propulsion community. Foundational work must be performed to ensure the safe performance of AM parts. Government, industry, and academia must collaborate in the characterization, design, modeling, and process control to accelerate the certification of AM parts for humanrated flight.

Description: Force transducer designs used in the ground testing aeronautics community have seen minimal change over the last few decades. With increased focus on data quality and long-term performance capabilities over the life of these instruments, it is critical to investigate new methods that improve these designs. One area of focus in the past few years at NASA has been on the design of the flexural elements of traditional force balance transducers. Many of the heritage balances that have been heavily used over the last few decades have started to develop fatigue cracks. The recent focus on the flexural design of traditional single-piece force balances revolves around the design of these elements such that stress concentrations are minimized, with the overall goal of increasing the fatigue life of the balance. Recent research in the area of using conic shaped fillets in the highly stressed regions of traditional force balances will be discussed, with preliminary numerical and experimental data results. A case study will be presented which discusses integration of this knowledge into a new high-capacity semi-span force balance.

Description: The effect of the lubrication regime on gear performance has been recognized, qualitatively, for decades. Often the lubrication regime is characterized by the specific film thickness defined as the ratio of lubricant film thickness to the composite surface roughness. It can be difficult to combine results of studies to create a cohesive and comprehensive dataset. In this work gear surface fatigue lives for a wide range of specific film values were studied using tests done with common rigs, speeds, lubricant temperatures, and test procedures. This study includes previously reported data, results of an additional 50 tests, and detailed information from lab notes and tested gears. The dataset comprised 258 tests covering specific film values (0.47 to 5.2). The experimentally determined surface fatigue lives, quantified as 10-percent life estimates, ranged from 8.7 to 86.8 million cycles. The trend is one of increasing life for increasing specific film. The trend is nonlinear. The observed trends were found to be in good agreement with data and recommended practice for gears and bearings. The results obtained will perhaps allow for the specific film parameter to be used with more confidence and precision to assess gear surface fatigue for purpose of design, rating, and technology development.