ALBERT

Description: Unloaded gas, plain journal bearings experience sub-synchronous whirl motion due to fluid film instabilities and wall contact usually occurs immediately after the onset of the whirl motion. An alternative is the wave journal bearing which significantly improves bearing stability. The predicted threshold where the sub-synchronous whirl motion starts was well confirmed by the experimental observation. In addition, both a two-wave and a three-wave journal bearing can operate free of sub-synchronous whirl motion over a large range in speeds. When the sub-synchronous whirl motion occurs, both the two-wave and three-wave bearing can run in a whirl orbit well within the bearing clearance. At large clearances and wave amplitudes a two-wave bearing, unliKe other bearings, can exhibit a sub-synchronous whirl movement at both low and high speeds, but can run extremely stable and without whirl at intermediate speeds. Moreover, in these cases, the whirl frequencies are close to a quarter of the synchronous speed. The three-wave bearing can exhibit sub-synchronous whirl motion only after a specific threshold when the speed increases and the whirl frequencies are close to half of the synchronous speed.

Description: This presentation will summarize Pratt & Whitney's past, present, and future activities toward cryogenic fluid-film bearing and seal technology development and implementation. The three major areas of focus for this technology are analytical models and design tools, component testing, and technology implementation. The analytical models and design tools area will include a summary of current tools along with an overview of P&W's new full 3-D Navier-Stokes solution for hydrostatic bearings, HYDROB3D. P&W's comprehensive component test program, including teaming with the Air Force Phillips Laboratory, NASA's Marshall Space Flight Center, and Carrier Corporation, will be outlined. Component test programs consisting of material development and testing, surface patterns/roughness, pocket and orifice geometry variations, and static and dynamic performance of both journal and thrust bearings will be summarized. Finally, the technology implementation area will show the benefits and plans for P&W to incorporate this technology into products.

Description: Brush seals are compliant, contact seals that have long-life, low-leakage characteristics desirable for use in rocket engine turbopumps. 50.8-mm (2.0 inch) diameter brush seals with a nominal initial radial interference of 0.127-mm (0.005 inch) were tested in liquid nitrogen at shaft speeds up to 35,000 rpm and differential pressure loads up to 1.21 MPa (175 psi) per brush. The measured leakage rate of a single brush was 2-3 times less than that measured for a 12-tooth, 0.127-mm (0.005 inch) radial clearance labyrinth seal used as a baseline. Stage effects were studied and it was found that two brush seals with a large separation distance leaked less than two brushes tightly packed together. The maximum measured groove depth on the Inconel 718 rotor was 25.4 (mu)m (0.001 inch) after 4.31 hours of shaft rotation. The Haynes-25 bristles wore approximately 25.4-76.2 (mu)m (0.001-0.003 inch) under the same conditions. Three seal runner coatings, chromium carbide, Teflon impregnated chromium, and zirconium oxide, were tested in liquid hydrogen at 35,000 and 65,000 rpm with separate 50.8 mm diameter brush seals made of Haynes-25 bristles and having a nominal initial radial interference of 129 rpm. Two bare Inconel-718 rotors were also tested as a baseline. The test results revealed significant differences between the wear characteristics of the uncoated and coated seal runners. At both speeds the brush seal with the bare Inconel-718 seal runner exhibited significant bristle wear with excessive material transferring to the runner surface. In contrast, the coated seal runners inhibited the transfer and deposit of bristle material. The chromium carbide coating showed only small quantities of bristle material transferring to its surface. The Teflon impregnated chromium coating also inhibited material transfer and provided some lubrication. This coating, however, is self-sacrificing. The Teflon remained present on the low speed runner, but it was completely removed from the high speed brush seal, which was tested considerably longer. The tests of the Teflon coating revealed the importance of using a lubricating and low friction coating for brush seals to reduce bristle and seal runner wear. The zirconium oxide coating exhibited the greatest amount of coating wear, while the brushes incurred only slight wear. Further testing of ceramics is recommended before making a final judgement on the viability of ceramic coatings for brush seals because of the contrast between the results reported by Carlile and the results presented herein. Strictly based on the results presented hereinabove, the chromium carbide and Teflon impregnated chromium coatings were considered preferable to the uncoated Inconel-718 and zirconium oxide coatings because of their good wear resistance and characteristics to inhibit bristle material wear and transfer to the seal runner.

Description: In this paper, the two dimensional(radial and circumferential) transient Navier-Stokes equations are used to solve the hydrodynamic problem in conjunction with the time dependent motion of the journal, and the deformable, spring supported foil. The elastic deformation of the foil and its supports are simulated by a finite element model. The time-dependent Navier-Stokes formulation is used to solve for the interaction between the fluid lubricant, the motion of the journal and the deformable foil boundary. The steady state, the quasi-transient and the full transient dynamic simulation of the foil-fluid journal interaction are examined on a comparative basis. For the steady state simulation, the fluid lubricant pressures are evaluated for a particular journal position, by means of an iterative scheme until convergence is achieved in both the fluid pressures and the corresponding foil deformation. For the quasi-transient case, the transient motion of the journal is calculated using a numerical integration scheme for the velocity and displacement of the journal. The deformation of the foil is evaluated through numerical iteration in feedback mode with the fluid film pressure generated by the journal motion until convergence at every time step is achieved. For the full transient simulation, a parallel real-time integration scheme is used to evaluate simultaneously the new journal position and the new deformed shape of the foil at each time step. The pressure of the fluid lubricant is iterated jointly with the corresponding journal position and the deformed foil geometry until convergence is achieved. A variable time-stepping Newmark-Beta integration procedure is used to evaluate the transient dynamics at each time step of the bearing.

Description: The aero design of an inward pumping spiral groove face seal using an in-house spread sheet was compared with predictions from the NASA code SPIRALG. The high pressure compressor exit of an aero gas turbine was chosen as the location for the candidate seal. This is a challenging environment as rotational velocity, pressure drop, and temperature are high. This presentation compares the resulting lift forces, leakages, and friction loss for various ride heights. Within practical ranges of ride height, the lift force predictions agreed well. However, both leakage and friction loss predictions were significantly different.

Description: A consortium has been formed to address seal problems in the Aerospace sector of Allied Signal, Inc. The consortium is represented by makers of Propulsion Engines, Auxiliary Power Units, Gas Turbine Starters, etc. The goal is to improve Face Seal reliability, since Face Seals have become reliability drivers in many of our product lines. Several research programs are being implemented simultaneously this year. They include: Face Seal Modeling and Analysis Methodology; Oil Cooling of Seals; Seal Tracking Dynamics; Coking Formation & Prevention; and Seal Reliability Methods.

Description: This paper investigates several instances where mechanical vibrations are explored to enlighten the reader about some of the results of these vibrations.

Description: This paper gives a description of the application of a simple rebound time measuring device and relates the determination of relative hardness of a variety of common engineering metals. A relation between rebound time and hardness will be sought. The effect of geometry and surface condition will also be discussed in order to acquaint the student with the problems associated with this type of method.

Description: A method has been developed to predict the structural acoustic response of shape memory alloy hybrid composite panels subjected to acoustic excitation. The panel is modeled by a finite element analysis and the radiated field is predicted using Rayleigh's integral. Transmission loss predictions for the case of an aluminum panel excited by a harmonic acoustic pressure are shown to compare very well with a classical analysis. Predictions of the normal velocity response and transmitted acoustic pressure for a clamped aluminum panel show excellent agreement with experimental measurements. Predicted transmission loss performance for a composite panel with and without shape memory alloy reinforcement are also presented. The preliminary results demonstrate that the transmission loss can be significantly increased with shape memory alloy reinforcement.

Description: This laboratory experiment is intended for students in an introductory polymer materials and processes course or engineering materials course. It can be conducted as an introduction to the hand lay-up process, with additional observations regarding the stiffness of the completed composite beams based on core thickness and fiber orientation. Students gain hands-on experience with the hand lay-up process by constructing glass/epoxy composite panels. Each lab group produces a panel with different core thickness or fiber orientation. The panels are then cut into strips and tested for flexural stiffness in a three-point bending fixture. Students plot deflection versus load data for composite beams with two different fiber orientations, two core thicknesses and one beam with laminate plies only (no core). The deflection plots highlight the effects of core thickness and fiber orientation on composite beam stiffness.

Description: Structural durability/damage tolerance characteristics of an aluminum tension specimen possessing a short crack and repaired by applying a fiber composite surface patch is investigated via computational simulation. The composite patch is made of graphite/epoxy plies with various layups. An integrated computer code that accounts for all possible failure modes is used for the simulation of combined fiber-composite/aluminum structural degradation under loading. Damage initiation, growth, accumulation, and propagation to structural fracture are included in the simulation. Results show the structural degradation stages due to tensile loading and illustrate the use of computational simulation for the investigation of a composite patch repaired cracked metallic panel.

Description: This paper investigates the steady-state responses of a rotor system supported by auxiliary bearings in which there is a clearance between the rotor and the inner race of the bearing. A simulation model based upon the rotor of a production jet engine is developed and its steady-state behavior is explored over a wide range of operating conditions for various parametric configurations. Specifically, the influence of rotor imbalance, clearance, support stiffness and damping is studied. Bifurcation diagrams are used as a tool to examine the dynamic behavior of this system as a function of the afore mentioned parameters. The harmonic balance method is also employed for synchronous response cases. The observed dynamical responses is discussed and some insights into the behavior of such systems are presented.

Description: This paper highlights the accomplishments on a joint effort between NASA - Marshall Space Flight Center and Texas A and M University to develop accurate seal analysis software for use in rocket turbopump design, design audits and trouble shooting. Results for arbitrary clearance profile, transient simulation, thermal effects solution and flexible seal wall model are presented. A new solution for eccentric seals based on cubic spline interpolation and ordinary differential equation integration is also presented.

Description: Auxiliary bearings are a critical feature of any magnetic bearing system. They protect the soft iron core of the magnetic bearing during an overload or failure. An auxiliary bearing typically consists of a rolling element bearing or bushing with a clearance gap between the rotor and the inner race of the support. The dynamics of such systems can be quite complex. It is desired to develop a rotordynamic model which describes the dynamic behavior of a flexible rotor system with magnetic bearings including auxiliary bearings. The model is based upon an experimental test facility. Some simulation studies are presented to illustrate the behavior of the model. In particular, the effects of introducing sideloading from the magnetic bearing when one coil fails is studied. These results are presented and discussed.

Description: Rotordynamic coefficients obtained from testing two different hydrostatic bearings are compared to values predicted by two different computer programs. The first set of test data is from a relatively long (L/D=1) orifice compensated hydrostatic bearing tested in water by Texas A&M University (TAMU Bearing No.9). The second bearing is a shorter (L/D=.37) bearing and was tested in a lower viscosity fluid by Rocketdyne Division of Rockwell (Rocketdyne 'Generic' Bearing) at similar rotating speeds and pressures. Computed predictions of bearing rotordynamic coefficients were obtained from the cylindrical seal code 'ICYL', one of the industrial seal codes developed for NASA-LeRC by Mechanical Technology Inc., and from the hydrodynamic bearing code 'HYDROPAD'. The comparison highlights the difference the bearing has on the accuracy of the predictions. The TAMU Bearing No. 9 test data is closely matched by the predictions obtained for the HYDROPAD code (except for added mass terms) whereas significant differences exist between the data from the Rocketdyne 'Generic' bearing the code predictions. The results suggest that some aspects of the fluid behavior in the shorter, higher Reynolds Number 'Generic' bearing may not be modeled accurately in the codes. The ICYL code predictions for flowrate and direct stiffness approximately equal those of HYDROPAD. Significant differences in cross-coupled stiffness and the damping terms were obtained relative to HYDROPAD and both sets of test data. Several observations are included concerning application of the ICYL code.

Description: Foil bearings provide noncontacting rotor support through a number of thin metal strips attached around the circumference of a stator and separated from the rotor by a fluid film. The resulting support stiffness is dominated by the characteristics of the foils and is a nonlinear function of the rotor deflection. The present study is concerned with characterizing this nonlinear effect and investigating its influence on rotordynamical behavior. A finite element model is developed for an existing bearing, the force versus deflection relation characterized, and the dynamics of a sample rotor system are studied. Some conclusions are discussed with regard to appropriate ranges of operation for such a system.

Description: The objective of this exercise is to provide a phenomenological 'hands-on' experience that shows how geometry can affect the load carrying capacity of a material used in construction, how different materials have different failure characteristics, and how construction affects the performance of a composite material. This will be accomplished by building beams of a single material and composite beams of a mixture of materials (popsicle sticks, fiberboard sheets, and tongue depressors); testing these layered beams to determine how and where they fail; and based on the failure analysis, designing a layered beam that will fail in a predicted manner. The students will learn the effects of lamination, adhesion, and geometry in layered beam construction on beam strength and failure location.

Description: No standard test practice currently exists for strain-controlled thermomechanical fatigue (TMF) testing. This paper discusses recent activities which lay the foundation for standardization of TMF test methods. Specifically, the paper documents the results of two interlaboratory TMF test programs, identifies key TMF symposia and workshops, and discusses efforts toward drafting a TMF standard test practice.

Description: HPOTP and HPFTP vibration test results have exhibited transient and steady characteristics which may be due to impeller leakage path (ILP) related forces. For example, an axial shift in the rotor could suddenly change the ILP clearances and lengths yielding dynamic coefficient and subsequent vibration changes. ILP models are more complicated than conventional-single component-annular seal models due to their radial flow component (coriolis and centrifugal acceleration), complex geometry (axial/radial clearance coupling), internal boundary (transition) flow conditions between mechanical components along the ILP and longer length, requiring moment as well as force coefficients. Flow coupling between mechanical components results from mass and energy conservation applied at their interfaces. Typical components along the ILP include an inlet seal, curved shroud, and an exit seal, which may be a stepped labyrinth type. Von Pragenau (MSFC) has modeled labyrinth seals as a series of plain annular seals for leakage and dynamic coefficient prediction. These multi-tooth components increase the total number of 'flow coupled' components in the ILP. Childs developed an analysis for an ILP consisting of a single, constant clearance shroud with an exit seal represented by a lumped flow-loss coefficient. This same geometry was later extended to include compressible flow. The objective of the current work is to: supply ILP leakage-force impedance-dynamic coefficient modeling software to MSFC engineers, base on incompressible/compressible bulk flow theory; design the software to model a generic geometry ILP described by a series of components lying along an arbitrarily directed path; validate the software by comparison to available test data, CFD and bulk models; and develop a hybrid CFD-bulk flow model of an ILP to improve modeling accuracy within practical run time constraints.

Description: The Micro Conical System (MCS) is a three-part, multi-purpose mechanical interface system used for acquiring and manipulating masses on-orbit by either extravehicular activity (EVA) or telerobotic means. The three components of the system are the micro conical fitting (MCF), the EVA micro tool (EMCT), and the Robot Micro Conical Tool (RMCT). The MCS was developed and refined over a four-year period. This period culminated with the delivery of 358 Class 1 and Class 2 micro conical fittings for the International Space Station and with its first use in space to handle a 1272 kg (2800 lbm) Spartan satellite (11000 times greater than the MCF mass) during an EVA aboard STS-63 in February, 1995. The micro conical system is the first successful EVA/robot-compatible mechanism to be demonstrated in the external environment aboard the U.S. Space Shuttle.

Description: Mechanisms for engaging and disengaging electrical and fluid line connectors are required to be operated repeatedly in hazardous or remote locations on space station, nuclear reactors, toxic chemical and undersea environments. Such mechanisms may require shields to protect the mating faces of the connectors when connectors are not engaged and move these shields out of the way during connector engagement. It is desirable to provide a force-transmitting structure to react the force required to engage or disengage the connectors. It is also desirable that the mechanism for moving the connectors and shields is reliable, simple, and the structure as lightweight as possible. With these basic requirements, an Umbilical Mechanism Assembly (UMA) was originally designed for the Space Station Freedom and now being utilized for the International Space Station.

Description: The Mir Environmental Effects Payload (MEEP) consists of four International Space Station Alpha (ISSA) Risk mitigation experiments to be transported and deployed in a common carrier. This carrier is to be transported to the Mir Space Station aboard the Space Shuttle and deployed during a US Extravehicular Activity (EVA) on the handrails of the Mir Docking Module (DM). This paper describes the design of the handrail clamp/ pointing device used by the astronauts to attach the carrier to the station.

Description: The Hubble Space Telescope (HST) Pistol Grip Tool (PGT) is a self-contained, microprocessor controlled, battery-powered, 3/8-inch-drive hand-held tool. The PGT is also a non-powered ratchet wrench. This tool will be used by astronauts during Extravehicular Activity (EVA) to apply torque to the HST and HST Servicing Support Equipment mechanical interfaces and fasteners. Numerous torque, speed, and turn or angle limits are programmed into the PGT for use during various missions. Batteries are replaceable during ground operations, Intravehicular Activities, and EVA's.

Description: This paper describes the design, development, and qualification of a new lightweight and compact Antenna Pointing Mechanism (APM). The APM was specially designed to meet the stringent mass, envelope, and environmental requirements of OFFEQ experimental satellite. During the development phase, some problems were encountered with the brushless DC motors, slip ring contact resistance, and bearing drag torque. All of these problems were resolved, and two APM units have been operating successfully in orbit since April, 1995.

Description: The Mars Pathfinder Lander employs numerous mechanisms, as well as autonomous mechanical functions, during its Entry, Descent and Landing (EDL) Sequence. This is the first US lander of its kind, since it is unguided and airbag-protected for hard landing using airbags, instead of retro rockets, to soft land. The arrival condition, location, and orientation of the Lander will only be known by the computer on the Lander. The Lander will then autonomously perform the appropriate sequence to retract the airbags, right itself, and open, such that the Lander is nearly level with no airbag material covering the solar cells. This function uses two different types of mechanisms - the Airbag Retraction Actuators and the Lander Petal Actuators - which are designed for the high torque, low temperature, dirty environment and for limited life application. The development of these actuators involved investigating low temperature lubrication, Electrical Discharge Machining (EDM) to cut gears, and gear design for limited life use.

Description: This paper describes a jettison system used to separate a large, inflatable-deployable antenna from a free-flying spacecraft. The jettison system consists of four discrete Marman band clamps, released simultaneously via pyrotechnics. The design, analysis, analytical simulation, and testing of the system are discussed. Of particular note is the correlation of test results with the Marman band design calculations.

Description: Since 1975, MECANEX S.A. has been manufacturing components for solar array drives and mechanisms used in space applications. In 1991, work was started in an early phase C (Engineering Model) on a Coarse Pointing Mechanism Assembly (CPMA) for the Semiconductor-laser Inter-satellite Link EXperiment (SILEX). This paper deals with the history, the evolution, and the lessons learned from taking over a pre-design in 1991 to the delivery of last flight models (FM 5 & 6) in 1995.

Description: On ITALSAT Flight 2, the Italian telecommunications satellite, the two L-Ka antennas (Tx and Rx) use two large deployable reflectors (2000-mm diameter), whose deployment and fine pointing functions are accomplished by means of an innovative mechanism concept. The Antenna Deployment & Pointing Mechanism and Supporting Structure (ADPMSS) is based on a new configuration solution, where the reflector and mechanisms are conceived as an integrated, self-contained assembly. This approach is different from the traditional configuration solution. Typically, a rigid arm is used to deploy and then support the reflector in the operating position, and an Antenna Pointing Mechanism (APM) is normally interposed between the reflector and the arm for steering operation. The main characteristics of the ADPMSS are: combined implementation of deployment, pointing, and reflector support; optimum integration of active components and interface matching with the satellite platform; structural link distribution to avoid hyperstatic connections; very light weight and; high performance in terms of deployment torque margin and pointing range/accuracy. After having successfully been subjected to all component-level qualification and system-level acceptance tests, two flight ADPMSS mechanisms (one for each antenna) are now integrated on ITALSAT F2 and are ready for launch. This paper deals with the design concept, development, and testing program performed to qualify the ADPMSS mechanism.

Description: This study is a continuation of the summer research of 1995 NASA/ASEE Summer Faculty Fellowship Program. This effort is to provide the infrastructure of an integrated Virtual Reality (VR) environment for the International Space Welding Experiment (ISWE) Analytical Tool and Trainer and the Microgravity Science Glovebox (MSG) Analytical Tool study. Due to the unavailability of the MSG CAD files and the 3D-CAD converter, little was done to the MSG study. However, the infrastructure of the integrated VR environment for ISWE is capable of performing the MSG study when the CAD files become available. Two primary goals are established for this research. First, the essential peripheral devices for an integrated VR environment will be studied and developed for the ISWE and MSG studies. Secondly, the training of the flight crew (astronaut) in general orientation, procedures, and location, orientation, and sequencing of the welding samples and tools are built into the VR system for studying the welding process and training the astronaut.

Description: The process of joining two pieces of metal together has not significantly changed over the last few decades. The basic idea used is to bring the pieces together and apply enough heat to melt the metal at the interface. The molten metal mixes and after cooling forms a strong joint. This process is called the fusion process. The most significant difference between the many fusion processes is how the heat is generated and applied. The Welding Institute (TWI), in Great Britain, has recently patented an innovative application of mechanical friction. TWI designed a tool and process called Friction Stir Welding (FSW) that uses friction to heat the metal to within a few hundred degrees Fahrenheit of melting, just to the point of being plastic-like. The tool then stirs the plasticized metal together forming a joint that has been shown to be as good or better than an equivalent fusion joint. The FSW process is well suited for the joining of the aluminum alloys used in the aerospace industry. The relatively low melting point of aluminum eliminates the requirements for exotic materials for pin tool design. The FSW process has been successfully used to join alloys such as 7075 which were before considered "unweldable", and aluminum-lithium 2195 which exhibits many problems when fusion welded. The objective this summer was to investigate the design of a FSW system that could take this process from the laboratory to the manufacturing floor. In particular, it was the goal of my NASA colleague to develop a concept for applying the FSW process to the manufacturing of aluminum cryogenic oxygen and hydrogen tanks, of the sort used to make the Shuttle External Tank.

Description: Jet pumps are devices capable of pumping fluids to a higher pressure employing a nozzle/diffuser/mixing chamber combination. A primary fluid is usually allowed to pass through a converging-diverging nozzle where it can accelerate to supersonic speeds at the nozzle exit. The relatively high kinetic energy that the primary fluid possesses at the nozzle exit is accompanied by a low pressure region in order to satisfy Bernoulli's equation. The low pressure region downstream of the nozzle exit permits a secondary fluid to be entrained into and mixed with the primary fluid in a mixing chamber located downstream of the nozzle. Several combinations may exist in terms of the nature of the primary and secondary fluids in so far as whether they are single or two-phase fluids. Depending on this, the jet pump may be classified as gas/gas, gas/liquid, liquid/liquid, two-phase/liquid, or similar combinations. The mixing chamber serves to create a homogeneous single-phase or two-phase mixture which enters a diffuser where the high kinetic energy of the fluid is converted into pressure energy. If the fluid mixture entering the diffuser is in the supersonic flow regime, a normal shock wave usually develops inside the diffuser. If the fluid mixture is one that can easily change phase, a condensation shock would normally develop. Because of the overall rise in pressure in the diffuser as well as the additional rise in pressure across the shock layer, condensation becomes more likely. Associated with the pressure rise across the shock is a velocity reduction from the supersonic to the subsonic range. If the two-phase flow entering the diffuser is predominantly gaseous with liquid droplets suspended in it, it will transform into a predominantly liquid flow containing gaseous bubbles (bubbly flow) somewhere in the diffuser. While past researchers have been able to model the two-phase flow jet pump using the one-dimensional assumption with no shock waves and no phase change, there is no research known to the authors apart from that of Anand (1992) which accounted for condensation shocks. One of the objectives of this research effort is to develop a comprehensive model in which the effects of phase slip and inter-phase heat transfer as well as the wall friction and shock waves are accounted for. While this modeling effort is predominantly analytical in nature and is primarily intended to provide a parametric understanding of the jet pump performance under different operating scenarios, another parallel effort employing a commercial CFD code is also implemented. The latter effort is primarily intended to model an axisymmetric counterpart of the problem in question. The viability of using the CFD code to model a two-phase flow jet pump will be assessed by attempting to recreate some of the existing performance data of similar jet pumps. The code will eventually be used to generate the jet pump performance characteristics of several scenarios involving jet pump geometries as well as flow regimes in order to be able to determine an optimum design which would be suitable for a two-phase flow boiling test facility at NASA-Marshall. Because of the extensive nature of the analytical model developed, the following section will only provide very brief highlights of it, while leaving the details to a more complete report submitted to the NASA colleague. This report will also contain some of the simulation results obtained using the CFD code.

Description: Virtual Reality (VR) is a set of breakthrough technologies that allow a human being to enter and fully experience a 3-dimensional, computer simulated environment. A true virtual reality experience meets three criteria: (1) It involves 3-dimensional computer graphics; (2) It includes real-time feedback and response to user actions; and (3) It must provide a sense of immersion. Good examples of a virtual reality simulator are the flight simulators used by all branches of the military to train pilots for combat in high performance jet fighters. The fidelity of such simulators is extremely high -- but so is the price tag, typically millions of dollars. Virtual reality teaching and training methods are manifestly effective, and we have therefore implemented a VR trainer for the International Space Welding Experiment. My role in the development of the ISWE trainer consisted of the following: (1) created texture-mapped models of the ISWE's rotating sample drum, technology block, tool stowage assembly, sliding foot restraint, and control panel; (2) developed C code for control panel button selection and rotation of the sample drum; (3) In collaboration with Tim Clark (Antares Virtual Reality Systems), developed a serial interface box for the PC and the SGI Indigo so that external control devices, similar to ones actually used on the ISWE, could be used to control virtual objects in the ISWE simulation; (4) In collaboration with Peter Wang (SFFP) and Mark Blasingame (Boeing), established the interference characteristics of the VIM 1000 head-mounted-display and tested software filters to correct the problem; (5) In collaboration with Peter Wang and Mark Blasingame, established software and procedures for interfacing the VPL DataGlove and the Polhemus 6DOF position sensors to the SGI Indigo serial ports. The majority of the ISWE modeling effort was conducted on a PC-based VR Workstation, described below.

Description: In 1997, the United States [NASA] and the Paton Electric Welding Institute are scheduled to cooperate in a flight demonstration on the U.S. Space Shuttle to demonstrate the feasibility of welding in space for a possible repair option for the International Space Station Alpha. This endeavor, known as the International Space Welding Experiment (ISWE), will involve astronauts performing various welding exercises such as brazing, cutting, welding, and coating using an electron beam space welding system that was developed by the E.O. Paton Electric Welding Institute (PWI), Kiev Ukraine. This electron beam welding system known as the "Universal Weld System" consists of hand tools capable of brazing, cutting, autogeneous welding, and coating using an 8 kV (8000 volts) electron beam. The electron beam hand tools have also been developed by the Paton Welding Institute with greater capabilities than the original hand tool, including filler wire feeding, to be used with the Universal Weld System on the U.S. Space Shuttle Bay as part of ISWE. The hand tool(s) known as the Ukrainian Universal Hand [Electron Beam Welding] Tool (UHT) will be utilized for the ISWE Space Shuttle flight welding exercises to perform welding on various metal alloy samples. A total of 61 metal alloy samples, which include 304 stainless steel, Ti-6AI-4V, 2219 aluminum, and 5456 aluminum alloys, have been provided by NASA for the ISWE electron beam welding exercises using the UHT. These samples were chosen to replicate both the U.S. and Russian module materials. The ISWE requires extravehicular activity (EVA) of two astronauts to perform the space shuttle electron beam welding operations of the 61 alloy samples. This study was undertaken to determine if a hazard could exist with ISWE during the electron beam welding exercises in the Space Shuttle Bay using the Ukrainian Universal Weld System with the UHT. The safety issue has been raised with regard to molten metal detachments as a result of several possible causes such as welder procedural error, externally applied impulsive forces(s), filler wire entrainment and snap-out, cutting expulsion, and puddle expulsion. Molten metal detachment from either the weld/cut substrate or weld wire could present harm to a astronaut in the space environment it the detachment was ti burn through the fabric of the astronaut Extravehicular Mobility Unit (EMC). In this paper an experimental test was performed in a 4 ft. x 4 ft. vacuum chamber at MSFC enabling protective garment to be exposed to the molten metal drop detachments to over 12 inches. The chamber was evacuated to vacuum levels of at least 1 x 10(exp -5) torr (50 micro-torr) during operation of the 1.0 kW Universal Hand Tool (UHT). The UHT was manually operated at the power mode appropriate for each material and thickness. The space suit protective welding garment, made of Teflon fabric (10 oz. per yard) with a plain weave, was placed on the floor of the vacuum chamber to catch the molten metal drop detachments. A pendulum release mechanism consisting of four hammers, each weighing approximately 3.65 lbs, was used to apply an impact forces to the weld sample/plate during both the electron beam welding and cutting exercises. Measurements were made of the horizontal fling distances of the detached molten metal drops. The volume of a molten metal drop can also be estimated from the size of the cut. Utilizing equations, calculations were made to determine chande in surafec area (Delat a(surface)) for 304 stainless steel for cutting based on measurements of metal drop sizes at the cut edges. For the cut sample of 304 stainless steel based on measurement of the drop size at the edge, Delta-a(surface) was determined to be 0.0054 2 in . Calculations have indicated only a small amount of energy is required to detach a liquid metal drop. For example, approximately only 0.000005 ft-lb of energy is necessary to detach a liquid metal steel drop based on the above theoretical analysis. However, some of the energy will be absorbed by the plate before it reaches the metal drop. Based on the theoretical calculations, it was determined that during a weld cutting exercise, the titanium alloy would be the most difficult to detach molten metal droplets followed by stainless steel and then by aluminum. The results of the experimental effort have shown that molten metal will detach if large enough of a hammer blow is applied to the weld sample plate during the full penetration welding and cutting exercises. However, no molten metal detachments occurred as a result of the filler wire snap-out tests from the weld puddle since it was too difficult to cause the metal to flick-out from the pool. Molten metal detachments, though not large in size, did result from the direct application of the electron beam on the end of the filler weld wire.

Description: Friction stir welding (FSW) is a relatively new process being applied for joining of metal alloys. The process was initially developed by The Welding Institute (TWI) in Cambridge, UK. The FSW process is being investigated at NASA/MSEC as a repair/initial weld procedure for fabrication of the super-light-weight aluminum-lithium shuttle external tank. The FSW investigations at MSFC were conducted on a horizontal mill to produce butt welds of flat plate material. The weldment plates are butted together and fixed to a backing plate on the mill bed. A pin tool is placed into the tool holder of the mill spindle and rotated at approximately 400 rpm. The pin tool is then plunged into the plates such that the center of the probe lies at, one end of the line of contact, between the plates and the shoulder of the pin tool penetrates the top surface of the weldment. The weld is produced by traversing the tool along the line of contact between the plates. A lead angle allows the leading edge of the shoulder to remain above the top surface of the plate. The work presented here is the first attempt at modeling a complex phenomenon. The mechanical aspects of conducting the weld process are easily defined and the process itself is controlled by relatively few input parameters. However, in the region of the weld, plasticizing and forging of the parent material occurs. These are difficult processes to model. The model presented here addresses only variations in the radial dimension outward from the pin tool axis. Examinations of the grain structure of the weld reveal that a considerable amount of material deformation also occurs in the direction parallel to the pin tool axis of rotation, through the material thickness. In addition, measurements of the axial load on the pin tool demonstrate that the forging affect of the pin tool shoulder is an important process phenomenon. Therefore, the model needs to be expanded to account for the deformations through the material thickness and the forging affect of the shoulder. The energy balance at the boundary of the plastic region with the environment required that energy flow away from the boundary in both radial directions. One resolution to this problem may be to introduce a time dependency into the process model, allowing the energy flow to oscillate across this boundary. Finally, experimental measurements are needed to verify the concepts used here and to aid in improving the model.

Description: This document describes a simple, light weight, and scalable mechanism capable of deploying flexible or rigid substrate solar arrays that have been configured in an accordion-like folding scheme. This mechanism is unique in that it incorporates a Shape Memory Alloy (SMA) actuator made of Nitinol. This paper documents the design of the mechanism in full detail while offering to designers a foundation of knowledge by which they can develop future applications with SMA's.

Description: A methodology for designing velocity-controlled magnetic bearings with laminated cores has been extended to those with solid cores. The eddy-current effect of the solid cores is modeled as an opposing magnetomotive force. The bearing control dynamics is formulated in a dimensionless fashion which can be readily reviewed on a root-locus plot for stability. This facilitates the controller design and tuning process for solid core magnetic bearings using no displacement sensors.

Description: This paper presents a collocated capacitance sensor for magnetic bearings. The main feature of the sensor is that it is made of a specific compact printed circuit board (PCB). The signal processing unit has been also developed. The results of the experimental performance evaluation on the sensitivity, resolution and frequency response of the sensor are presented. Finally, an application example of the sensor to the active control of a magnetic bearing is described.

Description: Active magnetic radial bearings are constructed with a combination of permanent magnets to provide bias forces and electromagnets to generate control forces for the reduction of cost and the operating energy consumption. Ring-shaped permanent magnets with axial magnetization are attached to a shaft and share their magnet stators with the electromagnets. The magnet cores are made of solid iron for simplicity. A simplified magnetic circuit of the combined magnet system is analyzed with linear circuit theory by approximating the characteristics of permanent magnets with a linear relation. A linearized dynamical model of the control force is presented with the first-order approximation of the effects of eddy currents. Frequency responses of the rotor motion to disturbance inputs and the motion for impulsive forces are tested in the non-rotating state. The frequency responses are compared with numerical results. The decay of rotor speed due to magnetic braking is examined. The experimental results and the presented linearized model are similar to those of the all-electromagnetic design.

Description: Recent breakthroughs in several different fields now make it possible to incorporate the use of superconducting magnets in structures in ways which enhance the performance of structural members or components of structural systems in general and Maglev guideway mega-structures in particular. The building of structural systems which connect appropriately scaled superconducting magnets with the post-tensioned tensile components of beams, girders, or columns would, if coupled with 'state of the art' structure monitoring, feedback and control systems, and advanced computer software, constitute a distinct new generation of structures that would possess the unique characteristic of being heuristic and demand or live-load responsive. The holistic integration of powerful superconducting magnets in structures so that they do actual structural work, creates a class of 'technologically endowed' structures that, in part - literally substitute superconductive electric power and magnetism for concrete and steel. The research and development engineering, and architectural design issues associated with such 'technologically endowed' structural system can now be conceptualized, designed, computer simulates built and tested. The Maglev guideway mega-structure delineated herein incorporates these concepts, and is designed for operation in the median strip of U.S. Interstate Highway 5 from San Diego to Seattle an Vancouver, and possibly on to Fairbanks, Alaska. This system also fits in the median strip of U.S. Interstate Highway 55 and 95 North-South, and 80 and 10, East-West. As a Western Region 'Peace Dividend' project, it could become a National or Bi-National research, design and build, super turnkey project that would create thousands of jobs by applying superconducting, material science, electronic aerospace and other defense industry technologies to a multi-vehicle, multi-use Maglev guideway megastructure that integrates urban mass transit Lower Speed (0-100 mph), High Speed (100-200 mph), Super Speed (200-400 mph), and Hypersonic evacuated tube (400-10,000 mph) Maglev systems.

Description: This paper presents recent work in magnetic suspension wind tunnel development in National Cheng Kung University. In this phase of research, a control-based study is emphasized to implement a robust control system into the experimental system under study. A ten-coil 10 cm x 10 cm magnetic suspension wind tunnel is built using a set of quadrant detectors for six degree of freedom control. To achieve the attitude control of suspended model with different attitudes, a spacial electromagnetic field simulation using OPERA 3D is studied. A successful test for six degree of freedom control is demonstrated in this paper.

Description: Magnetic bearings are capable of applying force and torque to a suspended object without rigidly constraining any degrees of freedom. Additionally, the resolution of magnetic bearings is limited only by sensors and control, and not by the finish of a bearing surface. For these reasons, magnetic bearings appear to be ideal for precision wafer positioning in lithography systems. To demonstrate this capability a linear magnetic bearing has been constructed which uses variable reluctance actuators to control the motion of a 14.5 kg suspended platen in five degrees of freedom. A Lorentz type linear motor of our own design and construction is used to provide motion and position control in the sixth degree of freedom. The stage performance results verify that the positioning requirements of photolithography can be met with a system of this type. This paper describes the design, control, and performance of the linear magnetic bearing.

Description: This paper presents an analytical method of modelling eddy currents inside axial bearings. The problem is solved by dividing an axial bearing into elementary geometric forms, solving the Maxwell equations for these simplified geometries, defining boundary conditions and combining the geometries. The final result is an analytical solution for the flux, from which the impedance and the force of an axial bearing can be derived. Several impedance measurements have shown that the analytical solution can fit the measured data with a precision of approximately 5%.

Description: This paper presents the results of modeling and system identification efforts on the NASA Large-Angle Magnetic Suspension Test Fixture (LAMSTF). The LAMSTF consists of a cylindrical permanent magnet which is levitated above a planar array of five electromagnets mounted in a circular configuration. The analytical model is first developed and open-loop characteristics are described. The system is shown to be highly unstable and requires feedback control in order to apply system identification. Limitations on modeling accuracy due to the effect of eddy-currents on the system are discussed. An algorithm is derived to identify a state-space model for the system from input/output data acquired during closed-loop operation. The algorithm is tested on both the baseline system and a perturbed system which has an increased presence of eddy currents. It is found that for the baseline system the analytic model adequately captures the dynamics, although the identified model improves the simulation accuracy. For the system perturbed by additional unmodeled eddy-currents the analytic model is no longer adequate and a higher-order model, determined through system identification, is required to accurately predict the system's time response.

Description: Magnetic bearings are often designed using magnetic circuit theory. When these bearings are built, however, effects not included in the usual circuit theory formulation have a significant influence on bearing performance. Two significant sources of error in the circuit theory approach are the neglect of leakage and fringing effects and the neglect of eddy current effects. This work formulates an augmented circuit model in which eddy current and flux leakage and fringing effects are included. Through the use of this model, eddy current power losses and actuator bandwidth can be derived. Electrical impedance predictions from the model are found to be in good agreement with experimental data from a typical magnetic bearing.

Description: This paper is concerned with the prediction of the low cycle thermal fatigue behavior of a component in a developmental (ATD) high pressure liquid oxygen turbopump (HPOTP) for the Space Shuttle Main Engine (SSME). This component is called the Turnaround Duct (TAD). The TAD is a complex single piece casting of MAR-M-247 material. Its function is to turn the hot turbine exhaust gas (1200 F hydrogen rich gas steam) such that it can exhaust radially out of the turbopump. In very simple terms, the TAD consists of two rings connected axially by 22 hollow airfoil shaped struts with the turning vanes placed at the top, middle, and bottom of each strut. The TAD is attached to the other components of the pump via bolts passing through 14 of the 22 struts. Of the remaining 8 struts, four are equally spaced (90 deg interval) and containing a cooling tube through which liquid hydrogen passes on its way to cool the shaft bearing assemblies. The remaining 4 struts are empty. One of the pump units in the certification test series was destructively examined after 22 test firings. Substantial axial cracking was found in two of the struts which contain cooling tubes. None of the other 20 struts showed any sign of internal cracking. This unusual low cycle thermal fatigue behavior within the two cooling tube struts is the focus of this study.

Description: The electron-beam welding process is well adapted to function in the environment of space. The Soviets were the first to demonstrate welding in space in the mid-1980's. Under the auspices of the International Space Welding Experiment (ISWE), an on-orbit test of a Ukrainian designed electron-beam welder (the Universal Hand Tool or 'UHT') is scheduled for October of 1997. The potential for sustained presence in space with the development of the international space station raises the possibility of the need for construction and repair in space. While welding is not scheduled to be used in the assembly of the space station, repair of damage from orbiting debris or meteorites is a potential need. Furthermore, safe and successful welding in the space environment may open new avenues for design and construction. The safety issue has been raised with regard to hot particle emissions (spatter) sometimes observed from the weld during operations. On earth the hot particles pose no particular hazard, but in space there exists the possibility for burn-through of the space suit which could be potentially lethal. Contamination of the payload bay by emitted particles could also be a problem.

Description: The threat of damage from high speed meteoroid and orbital debris particle impacts has become a significant design consideration in the development and construction of long duration earth-orbiting spacecraft. Historically, significant amounts of resources have been devoted to developing shielding for such structures as a means of reducing the penetration potential of high speed on-orbit impacts. These efforts have typically focused on simply whether or not the inner (or 'pressure') walls of candidate multi-wall structural systems would be perforated. Only recently the nature and extent of pressure wall penetration damage have begun to be explored. This report presents the results of a study whose objective was to characterize the hole formation and cracking phenomena associated with the penetration of the multi-wall systems being considered for the International Space Station Alpha (ISSA).

Description: The rolling element bearings (REB's) which support many turbomachinery rotors offer high load capacity, low power requirements, and durability. Two disadvantages of REB's are as follows: rolling or sliding contact within the bearing has life-limiting consequences; and REB's provide essentially no damping. The REB's in the Space Shuttle Main Engine (SSME) turbopumps must sustain high static and dynamic loads, at high speeds, with a cryogenic fluid as lubricant and coolant. The pump end ball bearings limit the life of the SSME high pressure oxygen turbopump (HPOTP). Compliant foil bearing (CFB) manufacturers have proposed replacing turbopump REB's with CFB's. CFB's work well in aircraft air cycle machines, auxiliary power units, and refrigeration compressors. In a CFB, the rotor only contacts the foil support structure during start up and shut down. CFB damping is higher than REB damping. However, the load capacity of the CFB is low, compared to a REB. Furthermore, little stiffness and damping data exist for the CFB. A rotordynamic analysis for turbomachinery critical speeds and stability requires the input of bearing stiffness and damping coefficients. The two basic types of CFB are the tension-dominated bearing and the bending-dominated bearing. Many investigators have analyzed and measured characteristics of tension-dominated foil bearings, which are applied principally in magnetic tape recording. The bending-dominated CFB is used more in rotating machinery. Recently, a new tension-foil bearing configuration has been proposed for turbomachinery applications.

Description: Aluminum-Lithium is a modern material that NASA MSFC is evaluating as an option for the aluminum alloys and other aerospace metals presently in use. The importance of aluminum-lithium is in it's superior weight to strength characteristics. However, aluminum-lithium has produced many challenges in regards to manufacturing and maintenance. The solution to these problems are vital to the future uses of the shuttle for delivering larger payloads into earth orbit and are equally important to future commercial applications of aluminum-lithium. The Metals Processes Branch at MSFC is conducting extensive tests on aluminum-lithium which includes the collection of large amounts of data. This report discusses the automation and data acquisition for two processes: the initial weld and the repair. The new approach reduces the time required to collect the data, increases the accuracy of the data, and eliminates several types of human errors during data collection and entry. The same material properties that enhance the weight to strength characteristics of aluminum-lithium contribute to the problems with cracks occurring during welding, especially during the repair/rework process. The repairs are required to remove flaws or defects discovered in the initial weld, either discovered by x-ray, visual inspection, or some other type of nondestructive evaluation. It has been observed that cracks typically appear as a result of or beyond the second repair. MSFC scientists have determined that residual mechanical stress introduced by the welding process is a primary cause of the cracking. Two obvious solutions are to either prevent or minimize the stress introduced during the welding process, or remove or reduce the stress after the welding process and MSFC is investigating both of these.

Description: High-speed (500 kph) trains using magnetic forces for levitation, propulsion and control offer many advantages for the nation and a good opportunity for the aerospace community to apply 'high tech' methods to the domestic sector. One area of many that will need advanced research is the aerodynamics of such MAGLEV (Magnetic Levitation) vehicles. There are important issues with regard to wind tunnel testing and the application of CFD to these devices. This talk will deal with the aerodynamic design of MAGLEV vehicles with emphasis on wind tunnel testing. The moving track facility designed and constructed in the 6 ft. Stability Wind Tunnel at Virginia Tech will be described. Test results for a variety of MAGLEV vehicle configurations will be presented. The last topic to be discussed is a Multi-disciplinary Design approach that is being applied to MAGLEV vehicle configuration design including aerodynamics, structures, manufacturability and life-cycle cost.

Description: A laser vibrometry based dynamic technique for biaxial residual stress determination in micromembranes is reported. Layered, low pressure chemical vapor deposition grown, rectangular shaped micromembranes are ultrasonically excited. The resulting micromembrane displacement, as a function of frequency and position, is recorded to yield resonance frequencies and associated vibrational mode numbers. The stress is determined from this information. Vibrations forced from ultrasonic pressure (-25 Pa) resulted in peak displacements of tens of nanometers at resonance. For the sample set studied, the (3,1) mode resonance peak displayed the least damping in atmospheric testing and was used to establish stress levels approximately 10(exp 8)N/m2 . A trend for this stress showing an overall decrease by approximately 40% as a result of thermomechanical cycling was identified.

Description: The trend toward smaller satellites has challenged component manufacturers to reduce the size, weight, and cost of their products while maintaining high performance. Both a new stepper motor and a new harmonic drive were developed to meet this need. The resulting actuator embodies small angle stepper technology usually reserved for larger units and incorporates an integral approach to harmonic drive design. By product simplifications, costs were significantly reduced over prior designs.

Description: The Remote Manual Operator (RMO) is a mechanism used for manual operation of the Space Station Intermodule Ventilation (IMV) valve and for visual indication of valve position. The IMV is a butterfly-type valve, located in the ventilation or air circulation ducts of the Space Station, and is used to interconnect or isolate the various compartments. The IMV valve is normally operated by an electric motor-driven actuator under computer or astronaut control, but it can also be operated manually with the RMO. The IMV valve RMO consists of a handle with a deployment linkage, a gear-driven flexible shaft, and a linkage to disengage the electric motor actuator during manual operation. It also provides visual indication of valve position. The IMV valve RMO is currently being prepared for qualification testing.

Description: The modification of a multi-jackbolt mechanism, Superbolt(TM), for on-orbit release of highly loaded bolts is described. Preload and release test data demonstrate that modification of a commercial product produced a solution for the deployment of the Space Station Remote Manipulator System (SSRMS) that was less expensive, faster, and lighter than other alternatives. Using the Superbolt design, virtually unlimited bolt loads can be applied or released with a standard wrench.

Description: The thermal conductance of Hertzian contacts is of great importance to cryogenic spacecraft mechanisms such as the Infra-Red Space Observatory (ISO) and the Far Infra-Red Space Telescope (FIRST). At cryogenic temperatures, cooling of mechanism shafts and associated components occurs via conduction through the bearings. When fluid lubricants are cooled below their pour points, they no longer lubricate effectively, and it is necessary to use low shear strength solid lubricants. Currently, only very limited low temperature data exists on the thermal conductance of Hertzian contacts in both unlubricated and lubricated conditions. This paper reports on measurements of thermal conductance made on stationary ball bearings under cryo-vacuum conditions. Quantitative data is provided to support the development of computer models predicting the thermal conductance of Hertzian contacts and solid lubricants at cryogenic temperatures.

Description: In order to improve the design procedure of constant-torque springs used in aerospace applications, several new analysis techniques have been developed. These techniques make it possible to accurately construct a torque-rotation curve for any general constant-torque spring configuration. These new techniques allow for friction in the system to be included in the analysis, an area of analysis that has heretofore been unexplored. The new analysis techniques also include solutions for the deflected shape of the spring as well as solutions for drum and roller support reaction forces. A design procedure incorporating these new capabilities is presented.

Description: INTA is currently developing a two-degree-of-freedom antenna pointing mechanism (APM) as part of the ESA ENVISAT POLAR PLATFORM (PPF) program. This mechanism will drive a Ka-band antenna within the Data-Relay Satellite System (DRS) on board the Polar Platform satellite. The first mission using PPF is ENVISAT, which is expected to be flown in 1998. This paper describes the main requirements, design, and test results of this pointing system, as well as the main technical problems from customer requirements and how those have been faced to achieve a final design.

Description: Early in 1993, a servo motor within one of three Fine Guidance Sensors (FGS) aboard the Hubble Space Telescope (HST) reached stall torque levels on several occasions. Little time was left to plan replacement during the first servicing mission, scheduled at the end of '93. Accelerated bearing life tests confirmed that a small angle rocking motion, known as Coarse Track (CT), accelerated bearing degradation. Saturation torque levels were reached after approximately 20 million test cycles, similar to the flight bearings. Reduction in CT operation, implemented in flight software, extended FGS life well beyond the first servicing mission. However in recent years, bearing torques have resumed upward trends and together with a second, recent bearing torque anomaly has necessitated a scheduled FGS replacement during the upcoming second servicing mission in '97. The results from two series of life tests to quantify FGS bearing remaining life, discussion of bearing on-orbit performance, and future plans to service the FGS servos are presented in this paper.

Description: Under contract to Jet Propulsion Laboratory, Richard Dudgeon, Inc. developed a heavy lifting load cell system to lift segments of giant antennas in NASA's Deep Space Network. The company commercialized the technology in its Dudgeon High Pressure Ultrathin Pancake Jacks/Hydraulic Load Cells. They are ultralight and ultrathin -- a system weighing 79 pounds can lift 700 tons and can fit between points that measure fractions of an inch. They can be used for bridge weighing/lifting, heavy industrial and turbine weighing/positioning, and weighing/positioning of utilities and power plant equipment.

Description: International Machinery Corporation (IMC) developed a miniature earthmover, the 1/8 scale Caterpillar D11N Track-type Tractor, with trademark product approval and manufacturing/marketing license from Caterpillar, Inc. Through Marshall Space Flight Center assistance, the company has acquired infrared remote control technology, originally developed for space exploration. The technology is necessary for exports because of varying restrictions on radio frequency in foreign countries. The Cat D11N weighs only 340 pounds and has the world's first miniature industrial internal combustion engine. The earthmover's uses include mining, construction and demolition work, and hazardous environment work. IMC also has designs of various products for military use and other Caterpillar replicas.

Description: AVCON, Inc. produces advanced magnetic bearing systems for industrial use, offering a unique technological approach based on contract work done at Marshall Space Flight Center and Lewis Research Center. Designed for the turbopump of the Space Shuttle main engine, they are now used in applications such as electric power generation, petroleum refining, machine tool operation and natural gas pipelines. Magnetic bearings support moving machinery without physical contact; AVCON's homopolar approach is a hybrid of permanent and electromagnets which are one-third the weight, smaller and more power- efficient than previous magnetic bearings.

Description: Lewis Research Center developed the CARES/LIFE software, which predicts the performance of brittle structures over time, such as ceramic compounds. Over 300 companies have used a version of the code, including Philips Display Components Company, AlliedSignal, Solar Turbines Incorporated, and TRW, Inc. for everything from engines to television tubes. The software enables a designer to test a variety of configurations for probability of failure and to adjust the structure's geometry to minimize the predicted failure or maximize durability for the lifetime of the ceramic component.

Description: Three Sun Coast Chemicals (SCC) of Daytona, Inc. products were derived from NASA technology: Train Track Lubricant, Penetrating Spray Lube, and Biodegradable Hydraulic Fluid. NASA contractor Lockheed Martin Space Operations contacted SCC about joining forces to develop an environmentally safe spray lubricant for the Shuttle Crawler. The formula was developed over an eight-month period resulting in new products which are cost effective and environmentally friendly. Meeting all Environmental Protection Agency requirements, the SCC products are used for applications from train tracks to bicycle chains.

Description: Under the Aircraft Structural Integrity program, Langley Research Center and Stress Photonics developed an infrared-based stress measurement system for use in nondestructive evaluation of materials and structures. Stress Photonics commercialized the technology in the DeltaTherm 1000 system, used to compare designs and detect cracks in structures, especially for aging aircraft and bridges. The system combines digital signal processing technology with a special infrared camera to provide instantaneous thermal images and live differential images.

Description: Correct pointing direction and scanning motions are essential in the operation of many flight payloads, such as balloon-borne telescopes and space-based X- ray and gamma-ray telescopes. Rotating unbalanced mass (RUM) devices have been recently proposed, implemented and successfully tested to produce a variety of scanning motions. Linear scans, raster scans, and circular scans have been successfully generated on a gimbaled payload using pairs of RUM devices. Theoretical analysis, computer simulations, and experiments have also been used to study the feasibility of using RUM devices to control instrument pointing direction, in addition to generating scanning motion. Dynamic modeling of a gimbaled payload equipped with a pair of RUM devices has been studied, and preliminary testing indicates that the pointing control is indeed feasible. However, there is also great potential for significant performance improvements through more advanced control system analysis, modeling and design. In this paper, modeling and control methods are described to achieve simultaneous scanning and pointing control of a gimbaled payload using rotating unbalance mass (RUM) devices. The model development work builds upon the results of Polites et al. and also some modeling approaches from robotics research. Results of some preliminary experiments are discussed and some nonlinear control methods will be proposed.

Description: A robot manipulator controller for a flexible manipulator arm having plural bodies connected at respective movable hinges and flexible in plural deformation modes corresponding to respective modal spatial influence vectors relating deformations of plural spaced nodes of respective bodies to the plural deformation modes, operates by computing articulated body quantities for each of the bodies from respective modal spatial influence vectors, obtaining specified body forces for each of the bodies, and computing modal deformation accelerations of the nodes and hinge accelerations of the hinges from the specified body forces, from the articulated body quantities and from the modal spatial influence vectors. In one embodiment of the invention, the controller further operates by comparing the accelerations thus computed to desired manipulator motion to determine a motion discrepancy, and correcting the specified body forces so as to reduce the motion discrepancy. The manipulator bodies and hinges are characterized by respective vectors of deformation and hinge configuration variables, and computing modal deformation accelerations and hinge accelerations is carried out for each one of the bodies beginning with the outermost body by computing a residual body force from a residual body force of a previous body and from the vector of deformation and hinge configuration variables, computing a resultant hinge acceleration from the body force, the residual body force and the articulated hinge inertia, and revising the residual body force modal body acceleration.

Description: Significant advantages in specific mechanical properties, when compared to conventional aluminum (Al) alloys, make aluminum-lithium (Al-Li) alloys attractive candidate materials for use in cryogenic propellant tanks and dry bay structures. However, the cost of Al-Li alloys is typically five times that of 2219 aluminum. If conventional fabrication processes are employed to fabricate launch vehicle structure, the material costs will restrict their utilization. In order to fully exploit the potential cost and performance benefits of Al-Li alloys, it is necessary that near-net manufacturing methods be developed to off-set or reduce raw material costs. Near-net forging is an advanced manufacturing method that uses elevated temperature metal movement (forging) to fabricate a single piece, near-net shape, structure. This process is termed 'near-net' because only a minimal amount of post-forge machining is required. The near-net forging process was developed to reduce the material scrap rate (buy-to-fly ratio) and fabrication costs associated with conventional manufacturing methods. The goal for the near-net forging process, when mature, is to achieve an overall cost reduction of approximately 50 percent compared with conventional manufacturing options for producing structures fabricated from Al-Li alloys. This NASA Marshall Space Flight Center (MSFC) sponsored program has been a part of a unique government / industry partnership, coordinated to develop and demonstrate near-net forging technology. The objective of this program was to demonstrate scale-up of the near-net forging process. This objective was successfully achieved by fabricating four integrally stiffened, 170- inch diameter by 20-inch tall, Al-Li alloy 2195, Y-ring adapters. Initially, two 2195 Al-Li ingots were converted and back extruded to produce four cylindrical blockers. Conventional ring rolling of the blockers was performed to produce ring preforms, which were then contour ring rolled to produce 'contour preforms'. All of the contour preforms on this first-of-a-kind effort were imperfect, and the ingot used to fabricate two of the preforms was of an earlier vintage. As lessons were learned throughout the program, the tooling and procedures evolved, and hence the preform quality. Two of the best contour preforms were near- net forged to produce a process pathfinder Y-ring adapter and a 'mechanical properties pathfinder' Y-ring adapter. At this point, Lockheed Martin Astronautics elected to procure additional 2195 aluminum-lithium ingot of the latest vintage, produce two additional preforms, and substitute them for older vintage material non-perfectly filled preforms already produced on this contract. The existing preforms could have been used to fulfill the requirements of the contract.

Description: The RSRM 10% Scaled Model under design will make use of drilled hole liners to provide mass addition along the axial length of the model. The model will have two sets of liners in use at a time. The outer most liner is a flow distribution tube, the purpose of which is to help distribute the flow evenly over each model segment. The inner most liner will simulate the propellant burning surface at a burn time of 80 seconds. This liner will replicate as closely as possible the actual geometry of the full scale RSRM at the 80 second burn time. In order to obtain the correct mass flow rate for the burn time selected, it is necessary to determine the porosity of the holes drilled in each liner and the performance of those holes. The pressure drop across the liners directly effects the uniformity of the flow in the axial direction for a given model section. It is desired to have a pressure drop across the liners which is greater than the axial pressure drop in a given section. However, the pressure drop across the liner also has a bearing on the structural soundness of the model. The performance of the model was determined analytically, but there was some uncertainty as to the value of the discharge coefficient used. This uncertainty was the impetus for these drilled hole plate tests. Experimentally obtaining the discharge coefficients for sample plates of the porosity to be used in the model would increase the fidelity of the model design. These tests were developed in order to provide the required information with the least amount of testing time and hardware.

Description: This guide describes the input data required for using MSAP2D (Multi Stage Aeroelastic analysis Program - Two Dimensional) computer code. MSAP2D can be used for steady, unsteady aerodynamic, and aeroelastic (flutter and forced response) analysis of bladed disks arranged in multiple blade rows such as those found in compressors, turbines, counter rotating propellers or propfans. The code can also be run for single blade row. MSAP2D code is an extension of the original NPHASE code for multiblade row aerodynamic and aeroelastic analysis. Euler equations are used to obtain aerodynamic forces. The structural dynamic equations are written for a rigid typical section undergoing pitching (torsion) and plunging (bending) motion. The aeroelastic equations are solved in time domain. For single blade row analysis, frequency domain analysis is also provided to obtain unsteady aerodynamic coefficients required in an eigen analysis for flutter. In this manual, sample input and output are provided for a single blade row example, two blade row example with equal and unequal number of blades in the blade rows.

Description: In this report, the properties of two carbon-epoxy prepreg materials are presented. The epoxy resin used in these two materials can yield lower manufacturing costs due to its low initial cure temperature, and the capability of being cured using vacuum pressure only. The two materials selected for this study are MR50/LTM25, and CFS003/LTM25 with Amoco T300 fiber; both prepregs are manufactured by The Advanced Composites Group. MR50/LTM25 is a unidirectional prepreg tape using Mitsubishi MR50 carbon fiber impregnated with LTM25 epoxy resin. CRS003/LTM25 is a 2 by 2 twill fabric using Amoco T300 fiber and impregnated with LTM25 epoxy resin. Among the properties presented in this report are strength, stiffness, bolt bearing, and damage tolerance. Many of these properties were obtained at three environmental conditions: cold temperature/dry (CTD), room temperature/dry (RTD), and elevated temperature/wet (ETW). A few properties were obtained at room temperature/wet (RTW), and elevated temperature/dry (ETD). The cold and elevated temperatures used for testing were -125 F and 180 F, respectively. In addition, several properties related to processing are presented.

Description: Cylindrical, sliding contact bearings made entirely of a self-lubricating powder metallurgy composite (PM212) or of super alloy shells lined with clad PM212 were tested in an oscillating mode at temperatures from 25 to 700 C. Tests of 100 hr duration or longer were conducted at a bearing unit load of 3.45 Mpa (500 psi). Shorter duration tests at various unit loads up to 24.1 Mpa (3500 psi) were also conducted. In comparison tests, bearings lubricated with PM212 had superior anti-wear characteristics compared to the baseline, unlubricated, super alloy bearings: no galling of PM212-lubricated bearings occurred, while severe surface damage including galling occurred, especially at high loads, during the baseline tests. A heat treatment procedure, which dimensionally stabilizes PM212 and thereby minimizes clearance changes during high temperature bearing operation, is described.

Description: The stress analysis of orthogrid structures, specifically with I-beam sections, is regularly performed using finite elements. Various modeling techniques are often used to simplify the modeling process but still adequately capture the actual hardware behavior. The accuracy of such 'Oshort cutso' is sometimes in question. This report compares three modeling techniques to actual test results from a loaded orthogrid panel. The finite element models include a beam, shell, and mixed beam and shell element model. Results show that the shell element model performs the best, but that the simpler beam and beam and shell element models provide reasonable to conservative results for a stress analysis. When deflection and stiffness is critical, it is important to capture the effect of the orthogrid nodes in the model.

Description: Space agencies are under pressure to utilize better bandwidth-efficient communication methods due to the actual allocated frequency bands becoming more congested. Also budget reductions is another problem that the space agencies must deal with. This budget constraint results in simpler spacecraft carrying less communication capabilities and also the reduction in staff to capture data in the earth stations. It is then imperative that the most bandwidth efficient communication methods be utilized. This thesis presents a study of 8-ary Phase Shift Keying (8PSK) modulation with respect to bandwidth, power efficiency, spurious emissions and interference susceptibility over a non-linear satellite channel.

Description: Static modelling of magnetic bearings is often carried out using magnetic circuit theory. This theory cannot easily include nonlinear effects such as magnetic saturation or the fringing of flux in air-gaps. Modern computational tools are able to accurately model complex magnetic bearing geometries, provided some care is exercised. In magnetic suspension applications, the magnetic fields are highly three-dimensional and require computational tools for the solution of most problems of interest. The dynamics of a magnetic bearing or magnetic suspension system can be strongly affected by eddy currents. Eddy currents are present whenever a time-varying magnetic flux penetrates a conducting medium. The direction of flow of the eddy current is such as to reduce the rate-of-change of flux. Analytic solutions for eddy currents are available for some simplified geometries, but complex geometries must be solved by computation. It is only in recent years that such computations have been considered truly practical. At NASA Langley Research Center, state-of-the-art finite-element computer codes, 'OPERA', 'TOSCA' and 'ELEKTRA' have recently been installed and applied to the magnetostatic and eddy current problems. This paper reviews results of theoretical analyses which suggest general forms of mathematical models for eddy currents, together with computational results. A simplified circuit-based eddy current model proposed appears to predict the observed trends in the case of large eddy current circuits in conducting non-magnetic material. A much more difficult case is seen to be that of eddy currents in magnetic material, or in non-magnetic material at higher frequencies, due to the lower skin depths. Even here, the dissipative behavior has been shown to yield at least somewhat to linear modelling. Magnetostatic and eddy current computations have been carried out relating to the Annular Suspension and Pointing System, a prototype for a space payload pointing and vibration isolation system, where the magnetic actuator geometry resembles a conventional magnetic bearing. Magnetostatic computations provide estimates of flux density within airgaps and the iron core material, fringing at the pole faces and the net force generated. Eddy current computations provide coil inductance, power dissipation and the phase lag in the magnetic field, all as functions of excitation frequency. Here, the dynamics of the magnetic bearings, notably the rise time of forces with changing currents, are found to be very strongly affected by eddy currents, even at quite low frequencies. Results are also compared to experimental measurements of the performance of a large-gap magnetic suspension system, the Large Angle Magnetic Suspension Test Fixture (LAMSTF). Eddy current effects are again shown to significantly affect the dynamics of the system. Some consideration is given to the ease and accuracy of computation, specifically relating to OPERA/TOSCA/ELEKTRA.

Description: A study was performed to determine the feasibility of testing a large-scale High Speed Civil Transport wing component in the Structures and Materials Testing Laboratory in Building 1148 at NASA Langley Research Center. The report includes a survey of the electrical and hydraulic resources and identifies the backing structure and floor hard points which would be available for reacting the test loads. The backing structure analysis uses a new finite element model of the floor and backstop support system in the Structures Laboratory. Information on the data acquisition system and the thermal power requirements is also presented. The study identified the hardware that would be required to test a typical component, including the number and arrangement of hydraulic actuators required to simulate expected flight loads. Load introduction and reaction structure concepts were analyzed to investigate the effects of experimentally induced boundary conditions.

Description: The analytical and experimental results of an all-composite wing stub box are presented in this report. The wing stub box, which is representative of an inboard portion of a commercial transport high-aspect-ratio wing, was fabricated from stitched graphite-epoxy material with a Resin Film Infusion manufacturing process. The wing stub box was designed and constructed by the McDonnell Douglas Aerospace Company as part of the NASA Advanced Composites Technology program. The test article contained metallic load-introduction structures on the inboard and outboard ends of the graphite-epoxy wing stub box. The root end of the inboard load introduction structure was attached to a vertical reaction structure, and an upward load was applied to the outermost tip of the outboard load introduction structure to induce bending of the wing stub box. A finite element model was created in which the center portion of the wing-stub-box upper cover panel was modeled with a refined mesh. The refined mesh was required to represent properly the geometrically nonlinear structural behavior of the upper cover panel and to predict accurately the strains in the stringer webs of the stiffened upper cover panel. The analytical and experimental results for deflections and strains are in good agreement.

Description: In an effort to support the design of zirconium diboride composite leading edges for hypersonic vehicles, a finite element model (FEM) of a prototype leading edge was created and finite element analysis (FEA) was employed to assess its thermal and structural response to aerothermal boundary conditions. Unidirectional material properties for the structural components of the leading edge, a continuous fiber reinforced diboride composite, were computed with COSTAR. These properties agree well with those experimentally measured. To verify the analytical approach taken with COSMOS/M, an independent FEA of one of the leading edge assembly components was also done with COSTAR. Good agreement was obtained between the two codes. Both showed that a unidirectional lay-up had the best margin of safety for a simple loading case. Both located the maximum stress in the same region and ply. The magnitudes agreed within 4 percent. Trajectory based aerothermal heating was then applied to the leading edge assembly FEM created with COSMOS/M to determine steady state temperature response, displacement, stresses, and contact forces due to thermal expansion and thermal strains. Results show that the leading edge stagnation line temperature reached 4700 F. The maximum computed failure index for the laminated composite components peaks at 4.2, and is located at the bolt flange in layer 2 of the side bracket. The temperature gradient in the tip causes a compressive stress of 279 ksi along its width and substantial tensile stresses within its depth.

Description: Thermal and structural finite-element analyses were performed on the first high pressure fuel turbopump turbine blade of the space shuttle main engine (SSME). A two-dimensional (2-D) finite-element model of the blade and firtree disk attachment was analyzed using the general purpose MARC (finite-element) code. The loading history applied is a typical test stand engine cycle mission, which consists of a startup condition with two thermal spikes, a steady state and a shutdown transient. The blade material is a directionally solidified (DS) Mar-M 246 alloy, the blade rotor is forged with waspalloy material. Thermal responses under steady-state and transient conditions were calculated. The stresses and strains under the influence of mechanical and thermal loadings were also determined. The critical regions that exhibited high stresses and severe localized plastic deformation were the blade-rotor gaps.

Description: This manual describes the input data required for using the second version of the ASTROP2 (Aeroelastic STability and Response Of Propulsion systems - 2 dimensional analysis) computer code. In ASTROP2, version 2.0, the program is divided into two modules: 2DSTRIP, which calculates the structural dynamic information; and 2DASTROP, which calculates the unsteady aerodynamic force coefficients from which the aeroelastic stability can be determined. In the original version of ASTROP2, these two aspects were performed in a single program. The improvements to version 2.0 include an option to account for counter rotation, improved numerical integration, accommodation for non-uniform inflow distribution, and an iterative scheme to flutter frequency convergence. ASTROP2 can be used for flutter analysis of multi-bladed structures such as those found in compressors, turbines, counter rotating propellers or propfans. The analysis combines a two-dimensional, unsteady cascade aerodynamics model and a three dimensional, normal mode structural model using strip theory. The flutter analysis is formulated in the frequency domain resulting in an eigenvalue determinant. The flutter frequency and damping can be inferred from the eigenvalues.

Description: This report covers a portion of an ongoing investigation of the durability of titanium alloys for the High Speed Civil Transport (HSCT). Candidate alloys need to possess an acceptable combination of properties including strength and toughness as well as fatigue and corrosion resistance when subjected to the HSCT operational environment. These materials must also be capable of being processed into required product forms while maintaining their properties. Processing operations being considered for this airplane include forming, welding, adhesive bonding, and superplastic forming with or without diffusion bonding. This program was designed to develop the material properties database required to lower the risk of using advanced titanium alloys on the HSCT.

Description: Material characterization parameters obtained from naturally flawed specimens are necessary for reliability evaluation of non-deterministic advanced ceramic structural components. The least squares best fit method is applied to the three parameter uniaxial Weibull model to obtain the material parameters from experimental tests on volume or surface flawed specimens subjected to pure tension, pure bending, four point or three point loading. Several illustrative example problems are provided.

Description: The ability to accurately predict the thermomechanical deformation response of advanced composite materials continues to play an important role in the development of these strategic materials. Analytical models that predict the effective behavior of composites are used not only by engineers performing structural analysis of large-scale composite components but also by material scientists in developing new material systems. For an analytical model to fulfill these two distinct functions it must be based on a micromechanics approach which utilizes physically based deformation and life constitutive models and allows one to generate the average (macro) response of a composite material given the properties of the individual constituents and their geometric arrangement. Here the user guide for the recently developed, computationally efficient and comprehensive micromechanics analysis code's (MAC) who's predictive capability rests entirely upon the fully analytical generalized method of cells (GMC), micromechanics model is described. MAC is a versatile form of research software that 'drives' the double or triply periodic micromechanics constitutive models based upon GMC. MAC enhances the basic capabilities of GMC by providing a modular framework wherein (1) various thermal, mechanical (stress or strain control) and thermomechanical load histories can be imposed, (2) different integration algorithms may be selected, (3) a variety of constituent constitutive models may be utilized and/or implemented, and (4) a variety of fiber and laminate architectures may be easily accessed through their corresponding representative volume elements.

Description: A compendium was compiled and is described to provide a diverse set of limit-state relationships for use in demonstrating the application of probabilistic reliability methods to mechanical systems. The different limit-state relationships can be used to analyze the reliability of a candidate mechanical system. In determining the limit-states to be included in the compendium, a comprehensive listing of the possible failure modes that could affect mechanical systems reliability was generated. Previous literature defining mechanical modes of failure was studied, and cited failure modes were included. From this, classifications for failure modes were derived and are described in some detail.

Description: Described are the theoretical development and computer implementation of reliable and efficient methods for the analysis of coupled mechanical problems that involve the interaction of mechanical, thermal, phase-change and electromagnetic subproblems. The focus application has been the modeling of superconductivity and associated quantum-state phase-change phenomena. In support of this objective the work has addressed the following issues: (1) development of variational principles for finite elements, (2) finite element modeling of the electromagnetic problem, (3) coupling of thermal and mechanical effects, and (4) computer implementation and solution of the superconductivity transition problem. The main accomplishments have been: (1) the development of the theory of parametrized and gauged variational principles, (2) the application of those principled to the construction of electromagnetic, thermal and mechanical finite elements, and (3) the coupling of electromagnetic finite elements with thermal and superconducting effects, and (4) the first detailed finite element simulations of bulk superconductors, in particular the Meissner effect and the nature of the normal conducting boundary layer. The theoretical development is described in two volumes. This volume, Volume 1, describes mostly formulations for specific problems. Volume 2 describes generalization of those formulations.

Description: Under an interagency agreement with the Department of Energy, the NASA Lewis Research Center manages a Heavy-Duty Diesel Engine Technology (HDET) research program. The overall program objectives are to reduce fuel consumption through increased engine efficiency, reduce engine exhaust emissions, and provide options for the use of alternative fuels. The program is administered with a balance of research contracts, university research grants, and focused in-house research. The Cummins Engine Company participates in the HDET program under a cost-sharing research contract. Cummins is researching and developing in-cylinder component technologies for heavy-duty diesel engines. An objective of the Cummins research is to develop technologies for a low-emissions, 55-percent thermal efficiency (LE-55) engine. The best current-production engines in this class achieve about 46-percent thermal efficiency. Federal emissions regulations are driving this technology. Regulations for heavy duty diesel engines were tightened in 1994, more demanding emissions regulations are scheduled for 1998, and another step is planned for 2002. The LE-55 engine emissions goal is set at half of the 1998 regulation level and is consistent with plans for 2002 emissions regulations. LE-55 engine design requirements to meet the efficiency target dictate a need to operate at higher peak cylinder pressures. A key technology being developed and evaluated under the Cummins Engine Company LE-55 engine concept is the spherical joint piston and connecting rod. Unlike conventional piston and connecting rod arrangements which are joined by a pin forming a hinged joint, the spherical joint piston and connecting rod use a ball-and-socket joint. The ball-and-socket arrangement enables the piston to have an axisymmetric design allowing rotation within the cylinder. The potential benefits of piston symmetry and rotation are reduced scuffing, improved piston ring sealing, improved lubrication, mechanical and thermal load symmetry, reduced bearing stresses, reduced running clearances, and reduced oil consumption. The spherical joint piston is a monolithic, squeeze-cast, fiber-reinforced aluminum piston. The connecting rod has a ball end that seats on a spherical saddle within the piston and is retained by a pair of aluminum bronze holder rings. The holder rings are secured by a threaded ring that mates with the piston. As part of the ongoing research and development activity, the Cummins Engine Company successfully completed a 100-hr test of the spherical joint piston and connecting rod at LE- 55 peak steady-state engine conditions. In addition, a 100-hr transient cycle test that varied engine conditions between LE-55 no-load and LE-55 full-load was successfully completed.

Description: Structural components in aeronautical gas turbine engines typically experience multiaxial states of stress under nonisothermal conditions. To estimate the durability of the various components in the engine, one must characterize the cyclic deformation and fatigue behavior of the materials used under thermal and complex mechanical loading conditions. To this end, a testing protocol and associated test control software were developed at the NASA Lewis Research Center for thermomechanical axial-torsional fatigue tests. These tests are to be performed on thin-walled, tubular specimens fabricated from the cobalt-based superalloy Haynes 188. The software is written in C and runs on an MS-DOS based microcomputer.

Description: A detailed experimental evaluation is underway at the NASA Lewis Research Center to compare and contrast the performance of the PdCr/Pt dual-element temperature-compensated wire resistance strain gage with that of conventional high-temperature extensometry. The advanced PdCr gage, developed by researchers at Lewis, exhibits desirable properties and a relatively small and repeatable apparent strain to 800 C. This gage represents a significant advance in technology because existing commercial resistance strain gages are not reliable for quasi-static strain measurements above approximately 400 C. Various thermal and mechanical loading spectra are being applied by a high-temperature thermomechanical uniaxial testing system to evaluate the two strain-measurement systems. This is being done not only to compare and contrast the two strain sensors, but also to investigate the applicability of the PdCr strain gage to the coupon-level specimen testing environment typically employed when the high-temperature mechanical behavior of structural materials is characterized. Strain measurement capabilities to 800 C are being investigated with a nickel-base superalloy, Inconel 100 (IN 100), substrate material and application to TMC's is being examined with the model system, SCS-6/Ti-15-3. Furthermore, two gage application techniques are being investigated in the comparison study: namely, flame-sprayed and spot welding.

Description: The results of an analytical and experimental investigation of 4-ply Kevlar-49-epoxy panels loaded by in-plane shear are presented. Approximately one-half of the panels are thin-core sandwich panels and the other panels are solid-laminate panels. Selected panels were impacted with an aluminum sphere at a velocity of either 150 or 220 ft/sec. The strength of panels impacted at 150 ft/sec was not reduced when compared to the strength of the undamaged panels, but the strength of panels impacted at 220 ft/sec was reduced by 27 to 40 percent. Results are presented for panels that were cyclically loaded from a load less than the buckling load to a load in the postbuckling load range. The thin-core sandwich panels had a lower fatigue life than the solid panels. The residual strength of the solid and sandwich panels cycled more than one million cycles exceeded the baseline undamaged panel strengths. The effect of hysteresis in the response of the sandwich panels is not significant. Results of a nonlinear finite element analysis conducted for each panel design are presented.

Description: Sound transmission through an infinite cylindrical sandwich shell is studied in the context of the transmission of airborne sound into aircraft interiors. The cylindrical shell is immersed in fluid media and excited by an oblique incident plane sound wave. The internal and external fluids are different and there is uniform airflow in the external fluid medium. An explicit expression of transmission loss is derived in terms of modal impedance of the fluids and the shell. The results show the effects of (a) the incident angles of the plane wave; (b) the flight conditions of Mach number and altitude of the aircraft; (c) the ratios between the core thickness and the total thickness of the shell; and (d) the structural loss factors on the transmission loss. Comparisons of the transmission loss are made among different shell constructions and different shell theories.

Description: This research reports on an experimental study of the effects of materials and surface roughness on the scuffing characteristics of rolling/sliding contacts cooled and lubricated with liquid oxygen. Experiments were carried out under heavy loading with a Hertzian pressure in the range of 2.0 GPa to 3.0 GPa and with a high rolling velocity of up to 48 m/s. For contacts between AISI 440 C stainless-steel elements, the results showed that the scuffing behavior of the system was fairly consistent under a wide range of rolling velocity. Scuffing commenced at a small slide-to-roll ratio of around 0.02, and the scuffing behavior of the contact was not sensitive to surface roughness for the test-sample RMS roughness ranging from 0.02 microns to 0.10 microns. For contacts between 440 C and Si3N4 elements, on the other hand, the scuffing behavior of the system was not very consistent and somewhat unpredictable. The results were sensitive to surface roughness particularly that of the Si3N4 test sample. With well polished test samples, consistent results were obtained; the level of traction was lower than that with a 440 C toroid and scuffing did not take place up to a slide-to-roll ratio of near 0.03. The results strongly suggest that significant hydrodynamic effect can be generated by liquid oxygen under heavy loading and high velocity conditions. The results also suggest that the hydrodynamic action is likely generated by the conventional viscous mechanism as it can be largely destroyed by a narrow circumferential surface scratch running through the central region of the contact.

Description: An apparatus for coating and bonding parts in a vacuum includes a floating mount assembly holding one part and applying a bonding load to the parts. A pivoting mount assembly holds one part and is pivoted between a coating position and a bonding position. At least one coating source is provided for depositing a thin film of a metal onto a surface of each of the parts to improve the cold weld between the two parts. A restraining lever controls the application of the bonding load to the parts. The coating and bonding process occurs in a vacuum chamber with a single set-up.

Description: Stress analysis of the primary structure of the Meteorological Satellites Project (METSAT) Advanced Microwave Sounding Units-A, A1 Module using static loads is presented. The structural margins of safety and natural frequency predictions for the METSAT design are reported.

Description: Stress analysis of the primary structure of the Meteorological Satellites Project (METSAT) Advanced Microwave Sounding Units-A, A1 Module performed using the Meteorological Operational (METOP) Qualification Level 9.66 grms Random Vibration PSD Spectrum is presented. The random vibration structural margins of safety and natural frequency predictions are summarized.

Description: This report describes a structural optimization procedure developed for use with the Engineering Analysis Language (EAL) finite element analysis system. The procedure is written primarily in the EAL command language. Three external processors which are written in FORTRAN generate equivalent stiffnesses and evaluate stress and local buckling constraints for the sections. Several built-up structural sections were coded into the design procedures. These structural sections were selected for use in aircraft design, but are suitable for other applications. Sensitivity calculations use the semi-analytic method, and an extensive effort has been made to increase the execution speed and reduce the storage requirements. There is also an approximate sensitivity update method included which can significantly reduce computational time. The optimization is performed by an implementation of the MINOS V5.4 linear programming routine in a sequential liner programming procedure.

Description: A preliminary probabilistic structural assessment of the critical section of National Wind Tunnel (NWT) is performed using NESSUS (Numerical Evaluation of Stochastic Structures Under Stress) computer code. Thereby, the capabilities of NESSUS code have been demonstrated to address reliability issues of the NWT. Uncertainties in the geometry, material properties, loads and stiffener location on the NWT are considered to perform the reliability assessment. Probabilistic stress, frequency, buckling, fatigue and proof load analyses are performed. These analyses cover the major global and some local design requirements. Based on the assumed uncertainties, the results reveal the assurance of minimum 0.999 reliability for the NWT. Preliminary life prediction analysis results show that the life of the NWT is governed by the fatigue of welds. Also, reliability based proof test assessment is performed.

Description: This report describes an investigation to predict first-ply failure and final fracture in selected composite laminates subjected to inplane loads. The laminates were composed of glass fiber and graphite fibers in epoxy matrices. Failure envelopes based on first-ply failure and laminate fracture were generated for combined loading of these laminates. Predictions were evaluated by micromechanics-based theory and progressive fracture. The results show that, for most cases, combined tensile loading significantly enhanced the laminate fracture stress in comparison to the uniaxial loading.

Description: Nonlinear programming algorithms play an important role in structural design optimization. Fortunately, several algorithms with computer codes are available. At NASA Lewis Research Center, a project was initiated to assess performance of different optimizers through the development of a computer code CometBoards. This paper summarizes the conclusions of that research. CometBoards was employed to solve sets of small, medium and large structural problems, using different optimizers on a Cray-YMP8E/8128 computer. The reliability and efficiency of the optimizers were determined from the performance of these problems. For small problems, the performance of most of the optimizers could be considered adequate. For large problems however, three optimizers (two sequential quadratic programming routines, DNCONG of IMSL and SQP of IDESIGN, along with the sequential unconstrained minimizations technique SUMT) outperformed others. At optimum, most optimizers captured an identical number of active displacement and frequency constraints but the number of active stress constraints differed among the optimizers. This discrepancy can be attributed to singularity conditions in the optimization and the alleviation of this discrepancy can improve the efficiency of optimizers.

Description: The effective use of active magnetic bearings for vibration control in turbomachinery depends on an understanding of the forces available from a magnetic bearing actuator. The purpose of this project was to characterize the forces as functions shaft position. Both numerical and experimental studies were done to determine the characteristics of the forces exerted on a stationary shaft by a magnetic bearing actuator. The numerical studies were based on finite element computations and included both linear and nonlinear magnetization functions. Measurements of the force versus position of a nonrotating shaft were made using two separate measurement rigs, one based on strain gage measurement of forces, the other based on deflections of a calibrated beam. The general trends of the measured principal forces agree with the predictions of the theory while the magnitudes of forces are somewhat smaller than those predicted. Other aspects of theory are not confirmed by the measurements. The measured forces in the normal direction are larger than those predicted by theory when the rotor has a normal eccentricity. Over the ranges of position examined, the data indicate an approximately linear relationship between the normal eccentricity of the shaft and the ratio of normal to principal force. The constant of proportionality seems to be larger at lower currents, but for all cases examined its value is between 0.14 and 0.17. The nonlinear theory predicts the existence of normal forces, but has not predicted such a large constant of proportionality for the ratio. The type of coupling illustrated by these measurements would not tend to cause whirl, because the coupling coefficients have the same sign, unlike the case of a fluid film bearing, where the normal stiffness coefficients often have opposite signs. They might, however, tend to cause other self-excited behavior. This possibility must be considered when designing magnetic bearings for flexible rotor applications, such as gas turbines and other turbomachinery.

Description: This paper describes the development of an aeroelastic code (TURBO-AE) based on an Euler/Navier-Stokes unsteady aerodynamic analysis. A brief review of the relevant research in the area of propulsion aeroelasticity is presented. The paper briefly describes the original Euler/Navier-Stokes code (TURBO) and then details the development of the aeroelastic extensions. The aeroelastic formulation is described. The modeling of the dynamics of the blade using a modal approach is detailed, along with the grid deformation approach used to model the elastic deformation of the blade. The work-per-cycle approach used to evaluate aeroelastic stability is described. Representative results used to verify the code are presented. The paper concludes with an evaluation of the development thus far, and some plans for further development and validation of the TURBO-AE code.

Description: Structural materials in the form of graphite epoxy composites with embedded rubber layers are being used to reduce vibrations in rocket motor tubes. Four filament-wound, graphite epoxy tubes were studied to evaluate the effects of the rubber layer on the modal parameters (natural vibration frequencies, damping, and mode shapes). Tube 1 contained six alternating layers of 30-degree helical wraps and 90-degree hoop wraps. Tube 2 was identical to tube 1 with the addition of an embedded 0.030-inch-thick rubber layer. Tubes 3 and 4 were identical to tubes 1 and 2, respectively, with the addition of a Textron Kelpoxy elastomer. This report compares experimental modal parameters obtained by impact testing with analytical modal parameters obtained by NASTRAN finite-element analysis. Four test modes of tube 1 and five test modes of tube 3 correlate highly with corresponding analytical predictions. Unsatisfactory correlation of test and analysis results occurred for tubes 2 and 4 and these comparisons are not shown. Work is underway to improve the analytical models of these tubes. Test results clearly show that the embedded rubber layers significantly increase structural modal damping as well as decrease natural vibration frequencies.