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 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: 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: 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: 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: 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: 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: 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: 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: 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: 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: 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: 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 study investigates the application of synchronous interaction dynamics methodology to the design of auxiliary bearing systems. The technique is applied to a flexible rotor system and comparisons are made between the behavior predicted by this analysis method and the observed simulation response characteristics. Of particular interest is the influence of coupled shaft/bearing vibration modes on rotordynamical behavior. Experimental studies are also perFormed to validate the simulation results and provide insight into the expected behavior of such a system.

Description: This study presents an investigation of the dynamics of a rotor system with bearing clearance. Of particular interest is the influence of such effects on coupled disk/shaft vibration. Experimental results for a rotor system with a flexible disk are presented and compared to predictions from a simulation model. Some insights and conclusions are obtained with regard to the conditions under which such vibration may be significant.

Description: This report presents a synopsis of the research work. Specific accomplishments are itemized below: (1) Experimental facilities have been developed. This includes a magnetic bearing test rig and an auxiliary bearing test rig. In addition, components have been designed, constructed, and tested for use with a rotordynamics test rig located at NASA Lewis Research Center. (2) A study of the rotordynamics of an auxiliary bearing supported T-501 engine model was performed. (3) An experimental/simulation study of auxiliary bearing rotordynamics has been performed. (4) A rotordynamical model for a magnetic bearing supported rotor system, including auxiliary bearing effects has been developed and simulation studies performed.(5) A finite element model for a foil bearing has been developed and studies of a rotor supported by foil bearings have been performed. (6) Two students affiliated with this project have graduated with M.S. degrees.

Description: The objective was to evaluate the feasibility of a state-of-the-art health and usage monitoring system (HUMS) to provide monitoring of critical mechanical systems on the helicopter, including motors, drive train, engines, and life-limited components. The implementation of HUMS and cost integration with current maintenance procedures was assessed from the operator's viewpoint in order to achieve expected benefits from these systems, such as enhanced safety, reduced maintenance cost, and increased availability. An operational HUMS that was installed and operated under an independent flight trial program was used as a basis for this study. The HUMS equipment and software were commercially available. Based on the results of the feasibility study, the HUMS used in the flight trial program generally demonstrated a high level of reliability in monitoring the rotor system, engines, drive train, and life-limited components. The system acted as a sentinel to warn of impending failures. A worn tail rotor pitch bearing was detected by HUMS, which had the capability for self testing to diagnose system and sensor faults. Examples of potential payback to the operator with HUMS were identified, including reduced insurance cost through enhanced safety, lower operating costs derived from maintenance credits, increased aircraft availability, and improved operating efficiency. The interfacing of HUMS with current operational procedures was assessed to require only minimal revisions to the operator's maintenance manuals. Finally the success in realizing the potential benefits from HUMS technology was found to depend on the operator, helicopter manufacturer, regulator (FAA), and HUMS supplier working together.

Description: The focus of this research is to numerically predict an infrared image of a jet engine exhaust plume, given field variables such as temperature, pressure, and exhaust plume constituents as a function of spatial position within the plume, and to compare this predicted image directly with measured data. This work is motivated by the need to validate computational fluid dynamic (CFD) codes through infrared imaging. The technique of reducing the three-dimensional field variable domain to a two-dimensional infrared image invokes the use of an inverse Monte Carlo ray trace algorithm and an infrared band model for exhaust gases. This report describes an experiment in which the above-mentioned field variables were carefully measured. Results from this experiment, namely tables of measured temperature and pressure data, as well as measured infrared images, are given. The inverse Monte Carlo ray trace technique is described. Finally, experimentally obtained infrared images are directly compared to infrared images predicted from the measured field variables.

Description: Experimental data from jet-engine tests have indicated that unsteady blade row interaction effects can have a significant impact on the performance of multiple-stage turbines. The magnitude of blade row interaction is a function of both blade-count ratio and axial spacing. In the current research program, numerical simulations have been used to quantify the effects of blade count ratio on the performance of an advanced turbine geometries.

Description: Methods and apparatus are provided for a torque driver including a laterally displaceable gear support member to carry an output spur gear. A biasing assembly biases the output spur gear into engagement with a pinion to which is applied an input torque greater than a desired output torque limit for a threaded fastener such as a nut or screw. A coiled output linkage connects the output spur gear with a fastener adaptor which may be a socket for a nut. A gear tooth profile provides a separation force that overcomes the bias to limit torque at the desired torque limit. Multiple fasteners may be rotated simultaneously to a desired torque limit if additional output spur gears are provided. A gauged selector mechanism is provided to laterally displace multiple driven members for fasteners arranged in differing configurations. The torque limit is selectably adjustable and may be different for fasteners within the same fastener configuration.

Description: Cryogenic damper seals operating close to the liquid-vapor region (near the critical point or slightly su-cooled) are likely to present two-phase flow conditions. Under single phase flow conditions the mechanical energy conveyed to the fluid increases its temperature and causes a phase change when the fluid temperature reaches the saturation value. A bulk-flow analysis for the prediction of the dynamic force response of damper seals operating under two-phase conditions is presented as: all-liquid, liquid-vapor, and all-vapor, i.e. a 'continuous vaporization' model. The two phase region is considered as a homogeneous saturated mixture in thermodynamic equilibrium. Th flow in each region is described by continuity, momentum and energy transport equations. The interdependency of fluid temperatures and pressure in the two-phase region (saturated mixture) does not allow the use of an energy equation in terms of fluid temperature. Instead, the energy transport is expressed in terms of fluid enthalpy. Temperature in the single phase regions, or mixture composition in the two phase region are determined based on the fluid enthalpy. The flow is also regarded as adiabatic since the large axial velocities typical of the seal application determine small levels of heat conduction to the walls as compared to the heat carried by fluid advection. Static and dynamic force characteristics for the seal are obtained from a perturbation analysis of the governing equations. The solution expressed in terms of zeroth and first order fields provide the static (leakage, torque, velocity, pressure, temperature, and mixture composition fields) and dynamic (rotordynamic force coefficients) seal parameters. Theoretical predictions show good agreement with experimental leakage pressure profiles, available from a Nitrogen at cryogenic temperatures. Force coefficient predictions for two phase flow conditions show significant fluid compressibility effects, particularly for mixtures with low mass content of vapor. Under these conditions, an increase on direct stiffness and reduction of whirl frequency ratio are shown to occur. Prediction of such important effects will motivate experimental studies as well as a more judicious selection of the operating conditions for seals used in cryogenic turbomachinery.

Description: Research has been conducted on silicon nitride pin-on-disk sliding contacts at temperatures of up to 520 C, and four-ball rolling contacts with silicon nitride balls and 52100 steel or silicon nitride races at 590 C. These tests were conducted in a variety of gaseous environments in order to determine the effects of simulated engine exhaust gas on the carbonaceous gas decomposition lubrication scheme. In rolling tests with steel races and exhaust gas the wear track depth was roughly half that of tests run in nitrogen gas alone. The deposition of lubricous microcrystalline graphitic carbon on the rolling surfaces, generated from the carbon monoxide within the exhaust gas mixture, was verified by microfocused Raman spectroscopy. Ten-fold reductions in rolling wear could be achieved by the exhaust gas atmosphere in cases where water vapor was removed or not present. The exhaust gas mixture alone was not found to provide any lubricating effect on silicon nitride sliding contacts, where the rate of wear greatly exceeds the rate of carbon deposition. Directed admixture of acetylene (as low as 5% of the exhaust gas flow rates), has provided reductions in both wear volume and coefficient of friction by factors of 60X and 20X respectively for sliding contacts during the initial 80 m of sliding distance. Exhaust gas atmosphere with the acetylene admixture provided 65OX reductions in steady state wear rate compared to that measured for sliding contacts in dry N2. Such acetylene admixture also augments the ability of the exhaust gas atmosphere to lubricate high-temperature rolling contacts, with up to 25-fold reductions in wear track depth compared to those measured in the presence of N2 alone. In addition to providing some lubricating benefit itself, an important potential role of the exhaust gas from rich mixtures would be to shield bearings from 02. Such shielding enables surface deposition of lubricous pyrolytic carbon from the acetylene admixture, instead of combustion, rendering feasible the continuously replenished solid lubrication of high-temperature bearing surfaces.

Description: Test welds were made in argon over a range of pressures from 10-5 to 10-3 torr (the latter pressure an order of magnitude above pressures anticipated in the space shuttle bay during welding) with and without plasma on 304 stainless steel, 6Al-4V titanium, and 5456 aluminum in search of any possible unwanted electrical discharges. Only a faint steady glow of beam-excited atoms around the electron beam and sometimes extending out into the vacuum chamber was observed. No signs of current spiking or of any potentially dangerous electrical discharge were found.

Description: A new method for design and generation of spiral bevel gears of uniform tooth depth with localized bearing contact and low level of transmission errors is considered. The main features of the proposed approach are as follows: (1) the localization of the bearing contact is achieved by the mismatch of the generating surfaces. The bearing contact may be provided in the longitudinal direction, or in the direction across the surface; and (2) the low level of transmission errors is achieved due to application of nonlinear relations between the motions of the gear and the gear head-cutter. Such relations may be provided by application of a CNC machine. The generation of the pinion is based on application of linear relations between the motions of the tool and the pinion being generated. The relations described above permit a parabolic function of transmission errors to be obtained that is able to absorb almost linear functions caused by errors of gear alignment. A computer code has been written for the meshing and contact of the spiral bevel gears with the proposed geometry. The effect of misalignment on the proposed geometry has also been determined. Numerical examples for illustration of the proposed theory have been provided.

Description: A rotary blood pump includes a pump housing for receiving a flow straightener, a rotor mounted on rotor bearings and having an inducer portion and an impeller portion, and a diffuser. The entrance angle, outlet angle, axial and radial clearances of blades associated with the flow straightener, inducer portion, impeller portion and diffuser are optimized to minimize hemolysis while maintaining pump efficiency. The rotor bearing includes a bearing chamber that is filled with cross-linked blood or other bio-compatible material. A back emf integrated circuit regulates rotor operation and a microcomputer may be used to control one or more back emf integrated circuits. A plurality of magnets are disposed in each of a plurality of impeller blades with a small air gap. A stator may be axially adjusted on the pump housing to absorb bearing load and maximize pump efficiency.

Description: A push type fastener for fastening a movable structural part to a fixed structural part, wherein the coupling and decoupling actions are both a push type operation, the fastener consisting of a plunger having a shank with a plunger head at one end and a threaded end portion at the other end, an expandable grommet adapted to receive the plunger shank there through, and an attachable head which is securable to the threaded end of the plunger shank. The fastener requires each structural part to be provided with an aperture and the attachable head to be smaller than the aperture in the second structural part. The plunger is extensible through the grommet and is structurally configured with an external camming surface which is cooperatively engageable with internal surfaces of the grommet so that when the plunger is inserted in the grommet, the relative positioning of said cooperable camming surfaces determines the expansion of the grommet. Coupling of the parts is effected when the grommet is inserted in the aperture in the fixed structural part and expanded by pushing the plunger head and plunger at least a minimal distance through the grommet. Decoupling is effected by pushing the attachable head.

Description: A new method for design and generation of spiral bevel gears of uniform tooth depth with localized bearing contact and low level of transmission errors is considered. The main features of the proposed approach are as follows: (1) The localization of the bearing contact is achieved by the mismatch of the generating surfaces. The bearing contact may be provided in the longitudinal direction, or in the direction across the surface; and (2) The low level of transmission errors is achieved due to application of nonlinear relations between the motions of the gear and the gear head-cutter. Such relations may be provided by application of a CNC machine. The generation of the pinion is based on application of linear relations between the motions of the tool and the pinion being generated. The relations described above permit a parabolic function of transmission errors to be obtained that is able to absorb almost linear functions caused by errors of gear alignment. A computer code has been written for the meshing and contact of the spiral bevel gears with the proposed geometry. The effect of misalignment on the proposed geometry has also been determined. Numerical examples for illustration of the proposed theory have been provided.

Description: Face-milled spiral bevel gears with uniform tooth height are considered. An approach is proposed for the design of low-noise and localized bearing contact of such gears. The approach is based on the mismatch of contacting surfaces and permits two types of bearing contact either directed longitudinally or across the surface to be obtained. Conditions to avoid undercutting were determined. A Tooth Contact Analysis (TCA) was developed. This analysis was used to determine the influence of misalignment on meshing and contact of the spiral bevel gears. A numerical example that illustrates the theory developed is provided.

Description: The objective of this study was to evaluate two techniques, Flight Condition Recognition (FCR) and Flight Load Synthesis (FLS), for usage monitoring and assess the potential benefits of extending the retirement intervals of life-limited components, thus reducing the operator's maintenance and replacement costs. Both techniques involve indirect determination of loads using measured flight parameters and subsequent fatigue analysis to calculate the life expended on the life-limited components. To assess the potential benefit of usage monitoring, the two usage techniques were compared to current methods of component retirement. In addition, comparisons were made with direct load measurements to assess the accuracy of the two techniques. The data that was used for the evaluation of the usage monitoring techniques was collected under an independent HUMS Flight trial program, using a commercially available HUMS and data recording system. The usage data collect from the HUMS trial aircraft was analyzed off-line using PC-based software that included the FCR and FLS techniques. In the future, if the technique prove feasible, usage monitoring would be incorporated into the onboard HUMS.

Description: NASA Lewis Research Center's Wheel Abrasion Experiment (WAE) will measure the amount of wear on wheel surfaces of the Mars Pathfinder rover. WAE uses thin films of Al, Ni, and Pt (ranging in thickness from 200 to 1000 angstroms) deposited on black, anodized Al strips attached to the rover wheel. As the wheel moves across the martian surface, changes in film reflectivity will be monitored by reflected sunlight. These changes, measured as output from a special photodetector mounted on the rover chassis, will be due to abrasion of the metal films by martian surface sand, dust, and clay.

Description: Many components of future aircraft will be constructed from novel high-temperature materials, such as superalloys and ceramic composites, to meet expected operating temperatures in excess of 300 C. There are no known liquid lubricants that can lubricate above 300 C without significant decomposition. Solid lubricants could be considered, but problems caused by the higher friction coefficients and wear rates of the solid lubricant film make this an undesirable approach. An alternative method of lubrication is currently being investigated: vapor phase lubrication. In vapor phase lubrication, an organic liquid (in our studies a thioether was used) is vaporized into a flowing air stream that is directed to sliding surfaces where lubrication is needed. The organic vapor reacts at the concentrated contact sliding area generating a lubricous deposit. This deposit has been characterized as a thin polymeric film that can provide effective lubrication at temperatures greater than 400 C. Initial tribological studies were conducted at the NASA Lewis Research Center and Cleveland State University with a high-temperature friction and wear tribometer. A cast iron rod was loaded (a 4-kg mass was used to generate a contact pressure of 1.2 MPa) against a reciprocating, cast iron plate at 500 C. This system was then lubricated with the vapor phase of thioether.

Description: Gearbox-generated noise and vibration is objectionable in many vehicles, particularly helicopters. This noise excitation is caused by the load fluctuation as gear teeth enter and leave mesh. In high-quality gears, a common technique to reduce gear noise and vibration is to modify the tooth profile. Gear noise reduction is a NASA and U.S. Army goal, and a NASA/U.S. Army research project sponsored development of gear dynamics computer codes to help design quiet gears. As part of this project, a series of experiments was performed in the NASA Lewis Research Center's Gear Noise Rig to develop a data base of dynamic test data and to validate the predictions of the codes for several gear designs under a variety of test conditions.

Description: Nickel-cadmium (Ni/Cd) and nickel-hydrogen (Ni/H2) secondary alkaline batteries are vital to aerospace applications. Battery performance and cycle life are significantly affected by the type of separators used in those batteries. A team from NASA Lewis Research Center's Electrochemical Technology Branch developed standardized testing procedures to characterize and evaluate new and existing separator materials to improve performance and cycle life of secondary alkaline batteries. Battery separators must function as good electronic insulators and as efficient electrolyte reservoirs. At present, new types of organic and inorganic separator materials are being developed for Ni/Cd and Ni/H2 batteries. The separator material previously used in the NASA standard Ni/Cd was Pellon 2505, a 100-percent nylon-6 polymer that must be treated with zinc chloride (ZnCl2) to bond the fibers. Because of stricter Environmental Protection Agency regulation of ZnCl2 emissions, the battery community has been searching for new separators to replace Pellon 2505. As of today, two candidate separator materials have been identified; however, neither of the two materials have performed as well as Pellon 2505. The separator test procedures that were devised at Lewis are being implemented to expedite the search for new battery separators. The new test procedures, which are being carried out in the Separator Laboratory at Lewis, have been designed to guarantee accurate evaluations of the properties that are critical for sustaining proper battery operation. These properties include physical and chemical stability, chemical purity, gas permeability, electrolyte retention and distribution, uniformity, porosity, and area resistivity. A manual containing a detailed description of 12 separator test procedures has been drafted and will be used by the battery community to evaluate candidate separator materials for specific applications. These standardized procedures will allow for consistent, uniform, and reliable results that will ensure that separator materials have the desired properties for long life and good performance in secondary alkaline cells.

Description: We used molecular dynamics to investigate the properties and design space of molecular gears fashioned from carbon nanotubes with teeth added via a benzyne reaction known to occur with C60. A modified, parallelized version of Brenner's potential was used to model interatomic forces within each molecule. A Leonard-Jones 6-12 potential was used for forces between molecules. One gear was powered by forcing the atoms near the end of the buckytube to rotate, and a second gear was allowed.to rotate by keeping the atoms near the end of its buckytube on a cylinder. The meshing aromatic gear teeth transfer angular momentum from the powered gear to the driven gear. A number of gear and gear/shaft configurations were simulated. Cases in vacuum and with an inert atmosphere were examined. In an extension to molecular dynamics technology, some simulations used a thermostat on the atmosphere while the hydrocarbon gear's temperature was allowed to fluctuate. This models cooling the gears with an atmosphere. Results suggest that these gears can operate at up to 50-100 gigahertz in a vacuum or inert atmosphere at room temperature. The failure mode involves tooth slip, not bond breaking, so failed gears can be returned to operation by lowering temperature and/or rotation rate. Videos and atomic trajectory files in xyz format are presented.

Description: This paper describes the fundamental physical motivations for a minimum surface effect design, and presents a microgripper that incorporates a piezoelectric ceramic actuator and a flexure-based structure and transmission. The microgripper serves effectively as a one degree-of-freedom prototype of a minimum surface effect micromanipulator design. Data is presented that characterizes the microgripper performance under both pure position and pure force control, followed by a discussion of the attributes and limitations of flexure-based design. The microgripper is interfaced with a force reflective macrogripper, and the pair is controlled with a hybrid position/force scheme. Data is presented that illustrates the effective operation of the telerobotic pair.

Description: A two-component foam spray gun is readily disassembled for cleaning. It includes a body (1) with reactant (12, 14) and purge gas (16) inlet ports. A moldable valve packing (32) inside the body has a tapered conical interior surface (142), and apertures which match the reactant ports. A valve/tip (40) has a conical outer surface (48) which mates with the valve packing (32). The valve/tip (40) is held in place by a moldable packing washer (34), held at non-constant pressure by a screw (36, 38). The interior of the valve/tip (40) houses a removable mixing chamber (50). The mixing chamber (50) has direct flow orifices (60) and an auxiliary flow path (58, 60) which ameliorate pressure surges. The spray gun can be disassembled for cleaning without disturbing the seal, by removing the valve/tip (40) to the rear, thereby breaking it free of the conical packing. Rotation of the valve/tip (40) relative to the body (1) shuts off the reactant flow, and starts the purge gas flow.

Description: An arrangement for butt-welding cylindrical sections of large, thin-wall tanks includes a rotatable mandrel with side-by-side sets of radial position adjusters. Each set of adjusters bears on one of the tank sections adjacent the seam, to prevent the sections from sagging out-of-round. The mandrel rotates relative to the welder, so that a continuous seam is formed. A purge chamber is fixed in position behind the seam at the weld head, and is flushed with inert gas. The purge chamber includes a two-sided structure which is contiguous with the cylindrical sections and a circumferential vane to form an open-ended tube-like structure, through which the radial position adjusters pass as the mandrel and cylindrical workpiece sections rotate. The tube-like structure is formed into a chamber by a plurality of movable gates which are controlled to maintain a seal while allowing adjusters to progress through the purge chamber.

Description: Apparatus including a power supply (202) and control system is provided for maintaining the temperature within an enclosed structure (40) using thermoelectric devices (92). The apparatus may be particularly beneficial for use with a refrigerator (20) having superinsulation materials (46) and phase change materials (112) which cooperate with the thermoelectric device (92) to substantially enhance the overall operating efficiency of the refrigerator (20). The electrical power supply (202) and control system allows increasing the maximum power capability of the thermoelectric device (92) in response to increased heat loads within the refrigerator (20). The electrical power supply (202) and control system may also be used to monitor the performance of the cooling system (70) associated with the refrigerator (20).

Description: A refrigerator is provided which combines the benefits of superinsulation materials with thermoelectric devices and phase change materials to provide an environmentally benign system that is energy efficient and can maintain relatively uniform temperatures for extended periods of time with relatively low electrical power requirements. The refrigerator includes a thermoelectric assembly having a thermoelectric device with a hot sink and a cold sink. The superinsulation materials include a plurality of vacuum panels. The refrigerator is formed from an enclosed structure having a door. The vacuum panels may be contained within the walls of the enclosed structure and the door. By mounting the thermoelectric assembly on the door, the manufacturer of the enclosed structure is simplified and the overall R rating of the refrigerator increased. Also an electrical motor and propellers may be mounted on the door to assist in the circulation of air to improve the efficiency of the cold sink and the hot sink. A propeller and/or impeller is preferably mounted within the refrigerator to assist in establishing the desired air circulation flow path.

Description: The purpose of this study was to generate design data and complete dynamic performance estimates for a high performance permanent magnet actuator. The basic configuration selected for analysis is an axisymmetric Nd-B-Fe permanent magnet actuator capable of providing force in one direction along its major axis. The actuator consisted of two main axisymmetric components separated by an air gap. The design was optimized for each value of force, gap and magnetic field to yield minimum weight and maximum lift to weight ratio. The basic conclusion is that, within parameters considered, the 10,000 lb. and 50,000 lb. actuators are lightweight and compact. As expected for most permanent magnet devices, the smaller ones have higher lift to eight ratios.

Description: This paper describes a magnetically suspended linear pulse motor for a semiconductor wafer transfer robot in a vacuum chamber. The motor can drive a wafer transfer arm horizontally without mechanical contact. In the construction of the magnetic suspension system, four pairs of linear magnetic bearings for the lift control are used for the guidance control as well. This approach allows us to make the whole motor compact in size and light in weight. The tested motor consists of a double-sided stator and a transfer arm with a width of 50 mm and a total length of 700 mm. The arm, like a ladder in shape, is designed as the floating element with a tooth width of 4 mm (a tooth pitch of 8 mm). The mover mass is limited to about 1.6 kg by adopting such an arm structure, and the ratio of thrust to mover mass reaches to 3.2 N/kg under a broad air gap (1 mm) between the stator teeth and the mover teeth. The performance testing was carried out with a transfer distance less than 450 mm and a transfer speed less than 560 mm/s. The attitude of the arm was well controlled by the linear magnetic bearings with a combined use, and consequently the repeatability on the positioning of the arm reached to about 2 micron. In addition, the positioning accuracy was improved up to about 30 micron through a compensation of the 128-step wave current which was used for the micro-step drive with a step increment of 62.5 micron.

Description: Passive levitation by superconducting magnetic bearings can be utilized in flywheels for energy storage. Basic design criteria of such a bearing are high levitation force, sufficient vertical and horizontal stability and low friction. A test facility was built for the measurement and evaluation of friction in a superconducting magnetic bearing as a function of operating temperature and pressure in the vacuum vessel. The bearing consists of a commercial disk shaped magnet levitated above single grain, melt-textured YBCO high-temperature superconductor material. The superconductor was conduction cooled by an integrated AEG tactical cryocooler. The temperature could be varied from 50 K to 80 K. The pressure in the vacuum chamber was varied from 1 bar to 10(exp -5) mbar. At the lowest pressure setting, the drag torque shows a linear frequency dependence over the entire range investigated (0 less than f less than 40 Hz). Magnetic friction, the frequency independent contribution, is very low. The frequency dependent drag torque is generated by molecular friction from molecule-surface collisions and by eddy currents. Given the specific geometry of the set-up and gas pressure, the molecular drag torque can be estimated. At a speed of 40 Hz, the coefficient of friction (drag-to-lift ratio) was measured to be mu = 1.6 x 10(exp -7) at 10(exp -5) mbar and T = 60 K. This is equivalent to a drag torque of 7.6 x 10(exp -10) Nm. Magnetic friction causes approx. 1% of the total losses. Molecular friction accounts for about 13% of the frequency dependent drag torque, the remaining 87% being due to eddy currents and losses from rotor unbalance. The specific energy loss is only 0.3% per hour.

Description: The use of prefabricated pultruded carbon-epoxy rods has reduced the manufacturing complexity and costs of stiffened composite panels while increasing the damage tolerance of the panels. However, repairability of these highly efficient discrete stiffeners has been a concern. Design, analysis, and test results are presented in this paper for a bolted-joint repair for the pultruded rod concept that is capable of efficiently transferring axial loads in a hat-section stiffener on the upper skin segment of a heavily loaded aircraft wing component. A tension and a compression joint design were evaluated. The tension joint design achieved approximately 1.0% strain in the carbon-epoxy rod-reinforced hat-section and failed in a metal fitting at 166% of the design ultimate load. The compression joint design failed in the carbon-epoxy rod-reinforced hat-section test specimen area at approximately 0.7% strain and at 110% of the design ultimate load. This strain level of 0.7% in compression is similar to the failure strain observed in previously reported carbon-epoxy rod-reinforced hat-section column tests.

Description: A planetary gear system includes a sun gear coupled to an annular ring gear through a plurality of twist-planet gears, a speeder gear, and a ground structure having an internal ring gear. Each planet gear includes a solid gear having a first half portion in the form of a spur gear which includes vertical gear teeth and a second half portion in the form of a spur gear which includes helical gear teeth that are offset from the vertical gear teeth and which contact helical gear teeth on the speeder gear and helical gear teeth on the outer ring gear. One half of the twist planet gears are preloaded downward, while the other half are preloaded upwards, each one alternating with the other so that each one twists in a motion opposite to its neighbor when rotated until each planet gear seats against the sun gear, the outer ring gear, the speeder gear, and the inner ring gear. The resulting configuration is an improved stiff anti-backlash gear system.

Description: A heated shoe and cooled pressure roller assembly for composite prepreg application is provided. The shoe assembly includes a heated forward contact surface having a curved pressure surface. The following cooled roller provides a continuous pressure to the thermoplastic while reducing the temperature to approximately 5.degree. C. below glass transition temperature. Electric heating coils inside the forward portion of the shoe heat a thermoplastic workpiece to approximately 100.degree. C. above the glass transition. Immediately following the heated contact surface, a cooled roller cools the work. The end sharpened shape of the heated shoe trailing edge tends to prevent slag buildup and maintain a uniform, relaxed stress fabrication.

Description: A torque coupling sprag system which provides contact between the sides of at least one groove and at least two contact surfaces angled with respect to the central axial direction of at least one rotatable 3-D sprag member located between a drive member and a reaction member. The surface contacts between the members include various combinations of surface segments arranged in a predetermined manner to define a desired configuration. The contact radius of the 3-D sprag member is significantly larger than its rolling radius; however, radii can be varied in size and shape independently of each other, particularly the contact radius.

Description: A double-acting electromagnetic thrust bearing is normally used to counter the axial loads in many rotating machines that employ magnetic bearings. It essentially consists of an actuator and drive electronics. Existing thrust bearing design programs are based on several assumptions. These assumptions, however, are often violated in practice. For example, no distinction is made between maximum external loads and maximum bearing forces, which are assumed to be identical. Furthermore, it is assumed that the maximum flux density in the air gap occurs at the nominal gap position of the thrust runner. The purpose of this paper is to present a clear theoretical basis for the design of the electromagnetic thrust bearing which obviates such assumptions.

Description: A possibility of an effective damping of rotor nutations by modulating the field of the moment transducers in synchronism with the nutation frequency is considered. The algorithms for forming the control moments are proposed and their application is discussed.

Description: Aerospatiale magnetic bearings are based on the use of permanent magnets and on the control of the rotor around a zero force equilibrium point. The present developments of magnetic bearing wheels for space applications focus on the versatility of a basic design which leads to a family of reaction and momentum wheels with tailored torque and kinetic momentum, leading to competitive mass and cost. The present industrial applications concern kinetic energy accumulators, medical x-ray rotating devices, avionics equipment, cryotechnic compressors and vacuum pumps.