ALBERT

Description: The Aspirating Seal GE90 test for engine applications is presented.

Description: This proposal fits within the programmatic long-term development direction for turbine engine seals of the Seal Team of the Mechanical Component Branch. The intended work concerns the further development of the Finger Seal concept which is a compliant passive-adaptive seal meant to mitigate (and eventually replace) the shortcomings of the entire class of rigid seals used today (labyrinth, honeycomb, mechanical face seals) in the gas turbines and compressors,

Description: NASA Glenn hosted the Seals/Secondary Air System Workshop on October 30-31, 2001. Each year NASA and our industry and university partners share their respective seal technology developments. We use these workshops as a technical forum to exchange recent advancements and "lessons-learned" in advancing seal technology and solving problems of common interest. As in the past we are publishing two volumes. Volume I will be publicly available and individual papers will be made available on-line through the web page address listed at the end of this chapter. Volume II will be restricted under International Traffic and Arms Regulations (I.T.A.R.) and/or Export Administration Regulations (E.A.R.).

Description: NASA Glenn Research Center (GRC) has developed a Fault-Tolerant Magnetic Bearing Suspension rig to enhance the bearing system safety. It successfully demonstrated that using only two active poles out of eight redundant poles from each radial bearing (that is, simply 12 out of 16 poles dead) levitated the rotor and spun it without losing stability and desired position up to the maximum allowable speed of 20,000 rpm. In this paper, it is demonstrated that as far as the summation of force vectors of the attracting poles and rotor weight is zero, a fault-tolerant magnetic bearing system maintained the rotor at the desired position without losing stability even at the maximum rotor speed. A proportional-integral-derivative (PID) controller generated autonomous corrective actions with no operator's input for the fault situations without losing load capacity in terms of rotor position. This paper also deals with a centralized modal controller to better control the dynamic behavior over system modes.

Description: The X-33 Advanced Technology Demonstrator is an un-piloted, vertical take-off, horizontal landing spacecraft. The purpose of the X-33 program is to demonstrate technologies that will dramatically lower the cost of access to space. The rocket-powered X-33 will reach an altitude of up to 100 km and speeds between Mach 13 and 15. Fifteen flight tests are planned, beginning in 2000. Some of the key technologies demonstrated will be the linear aerospike engine, improved thermal protection systems, composite fuel tanks and reduced operational timelines. The X-33 vehicle umbilical connections provide monitoring, power, cooling, purge, and fueling capability during horizontal processing and vertical launch operations. Two "rise-off" umbilicals for the X-33 have been developed, tested, and installed. The X-33 umbilical systems mechanisms incorporate several unique design features to simplify horizontal operations and provide reliable disconnect during launch.

Description: Finite element analysis was used to study the bandwidth of alloy hyperco50a and silicon iron laminated rotors and stators in magnetic bearings. A three dimensional model was made of a heteropolar bearing in which all the flux circulated in the plane of the rotor and stator laminate. A three dimensional model of a plate similar to the region of a pole near the gap was also studied with a very fine mesh. Nonlinear time transient solutions for the net flux carried by the plate were compared to steady state time harmonic solutions. Both linear and quasi-nonlinear steady state time harmonic solutions were calculated and compared. The finite element solutions for power loss and flux bandwidth were compared to those determined from classical analytical solutions to Maxwell's equations.

Description: A lot has been learned from past experience with structural and machine element failures. The understanding of failure modes and the application of an appropriate design analysis method can lead to improved structural and machine element safety as well as serviceability. To apply Probabilistic Design Methodology (PDM), all uncertainties are modeled as random variables with selected distribution types, means, and standard deviations. It is quite difficult to achieve a robust design without considering the randomness of the design parameters which is the case in the use of the Deterministic Design Approach. The US Navy has a fleet of submarine-launched ballistic missiles. An umbilical plug joins the missile to the submarine in order to provide electrical and cooling water connections. As the missile leaves the submarine, an umbilical retract mechanism retracts the umbilical plug clear of the advancing missile after disengagement during launch and retrains the plug in the retracted position. The design of the current retract mechanism in use was based on the deterministic approach which puts emphasis on factor of safety. A new umbilical retract mechanism that is simpler in design, lighter in weight, more reliable, easier to adjust, and more cost effective has become desirable since this will increase the performance and efficiency of the system. This paper reports on a recent project performed at Tennessee State University for the US Navy that involved the application of PDM to the design of an umbilical retract mechanism. This paper demonstrates how the use of PDM lead to the minimization of weight and cost, and the maximization of reliability and performance.

Description: NASA GRC's work on high temperature structural seal development began in the late 1980's and early 1990's under the NASP (National Aero-Space Plane) project. Bruce Steinetz led the in-house propulsion system seal development program and oversaw industry efforts for propulsion system and airframe seal development for this vehicle. a propulsion system seal location in the NASP engine is shown. The seals were located along the edge of a movable panel in the engine to seal the gap between the panel and adjacent engine sidewalls. More recently, we worked with Rocketdyne on high temperature seals for the linear aerospike engine ramps. In applications such as the former X-33 program, multiple aerospike engine modules would be installed side by side on the vehicle. Seals are required in between adjacent engine modules along the edges and base of the engines. The seals have to withstand the extreme temperatures produced byt he thrusters at the top of the ramps while accommodating large deflections between adjacent ramps. We came up with several promising seal concepts for this application and shared them with Rocketdyne.

Description: The contents include: 1) Rope Seal; 2) Improvements to porous medial simulation in CFD-ACE+; 3) Porous media heat transfer validation case-stead-state and transient flat plate; 4) Simulation of GRC cold flow seal test fixture; 5) Simulation of calibration plate in the Panel Test Facility (PTF); and 6) Simulation of rope seal test in the PTF. This paper is in viewgraph form.

Description: The program is aimed at enhancing the existing analysis to include the turbulence effect. Several manufacturing methods are being investigated in order to apply our know-how in building the seal hardware. The contents include: 1) Test Facilities; 2) Analysis Enhancements; 3) Accomplishments/Status; and 4) Materials Study.

Description: This paper presents a general overview of NASA's Ultra Efficient Engine Technology (UEET) Program. The program's vision is to develop and hand off revolutionary turbine engine propulsion technologies that will enable future generation vehicles over a wide range of flight speeds. The specific goals include: 1) Perform propulsion technologies to enable increases in system efficiency and, therefore, fuel burn reductions of up to 15% (equivalent reductions in CO2); and 2) Provide combustor technologies (configuration and materials) which will enable reductions in Landing/Take-off (LTO) NOx of 70% relative to 1996 ICAO standards.

Description: Friction Stir Welding (FSW) is a solid state welding process that exhibits characteristics similar to traditional metal cutting processes. The plastic deformation that occurs during friction stir welding is due to the superposition of three flow fields: a primary rotation of a radially symmetric solid plug of metal surrounding the pin tool, a secondary uniform translation, and a tertiary ring vortex flow (smoke rings) surrounding the tool. If the metal sticks to the tool, the plug surface extends down into the metal from the outer edge of the tool shoulder, decreases in diameter like a funnel, and closes up beneath the pin. Since its invention, ten years have gone by and still very little is known about the physics of the friction stir welding process. In this experiment, an H13 steel weld tool (shoulder diameter, 0.797 in; pin diameter, 0.312 in; and pin length, 0.2506 in) was used to weld three 0.255 in thick plates. The deformation behavior during friction stir welding was investigated by metallographically preparing a plan view sections of the weldment and taking Vickers hardness test in the key-hole region.

Description: The two major classes of laminate joints are bonded and bolted. Often the two classes are combined as bonded-bolted joints. Several characteristics of fiber reinforced composite materials render them more susceptible to joint problems than conventional metals. These characteristics include weakness in in-plane shear, transverse tension/compression, interlaminar shear, and bearing strength relative to the strength and stiffness in the fiber direction. Studies on bolted joints of composite materials have been focused on joining assembly subject to in-plane loads. Modes of failure under these loading conditions are net-tension failure, cleavage tension failure, shear-out failure, bearing failure, etc. Although the studies of torque load can be found in literature, they mainly discussed the effect of the torque load on in-plane strength. Existing methods for calculating torque limit for a mechanical fastener do not consider connecting members. The concern that a composite member could be crushed by a preload inspired the initiation of this study. The purpose is to develop a fundamental knowledge base on how to determine a torque limit when a composite member is taken into account. Two simplified analytical models were used: a stress failure analysis model based on maximum stress criterion, and a strain failure analysis model based on maximum strain criterion.

Description: The key points to be gleaned from the effort reported herein are that the CFS (Compliant Foil Seal) has been demonstrated in conjunction with a foil bearing in a small gas turbine simulator at temperatures as high as 1000 F and outperformed a comparable brush seal. Having demonstrated the feasibility of the CFS, it would appear that this new seal design has application potential in a wide range of machines. What remains is to demonstrate performance at higher pressure ratios, consistent performance at large rotor excursions and the ability to manufacture the seal in much larger sizes exceeding by an order of magnitude that which has been tested to date.

Description: NASA Glenn hosted the Seals/Secondary Air System Workshop on October 25-26, 2000. Each year NASA and our industry and university partners share their respective seal technology developments. We use these workshops as a technical forum to exchange recent advancements and 'lessons-learned' in advancing seal technology and solving problems of common interest. As in the past we are publishing two volumes. Volume I will be publicly available and individual papers will be made available online through the web page address listed at the end of this chapter.

Description: The primary objective of the UEET (Ultra-Efficient Engine Technology) Program is to address two of the most critical propulsion issues: performance/efficiency and reduced emissions. High performance, low emissions engine systems will lead to significant improvement in local air quality, minimum impact on ozone depletion and level to an overall reduction in aviation contribution to global warming. The Materials and Structures for High Performance project will develop and demonstrate advanced high temperature materials to enable high-performance, high efficiency, and environmentally compatible propulsion systems.

Description: It has been about six years since any cryogenic seal tests were run at NASA GRC (Glenn Research Center). The Cryogenic Components Lab, where the cryogenic seal test rigs are located, has been shutdown due to the impending expansion of the Cleveland Hopkins International Airport. The current plan is to move the Cryogenic Components Lab (CCL), Cells I and 2 to NASA Plumbrook in Sandusky, Ohio. The purpose of this presentation is to inform the seal community of the cryogenic seal test rig capabilities available at NASA GRC for planning of future programs.

Description: NASA, DOD (Department of Defense), and DOE (Department of Energy) are currently looking to the NASA UEET (Ultra-Efficient Engine Technology) Program to develop ceramic matrix composites (CMC) for hot-section components in advanced power and propulsion systems. Success will greatly depend on developing ceramic fibers with a variety of key thermostructural properties, in particular, high as-produced tensile strength and retention of a large fraction of this strength for long times under the anticipated CMC service conditions. Current UEET approaches center on selecting the optimum fiber type from commercially available fibers since the costs for development of advanced fibers are high and the markets for high-temperature CMC have yet to be established.

Description: This viewgraph presentation provides information on the development of seals for the X-38 spacecraft. This seals will be an important part of the X-38's thermal protection system (TPS) in its service as a crew return vehicle (CRV) associated with the International Space Station (ISS).

Description: An X-38 Crew Return Vehicle Seal Development is presented. The contents include: 1) X-38 Crew Return Vehicle; 2) X-38 TPS Configuration; 3) X-38 Seal Locations; 4) X-38 Rudder/Fin Seal Assembly; 5) Baseline X-38 Rudder/Fin Seal Design; 6) Rudder/Fin Seal to Bracket Assembly; 7) X-38 Rudder/Fin Vertical Rub Surface Inconel-0.10 inches; 8) X-38 Rudder/Fin Seal Analysis; 9) Seal Analysis Model; and 10) Governing Differential Equations for Equilibrium Thermal Assumption. The X-38 Rudder/Fin Seal temperature and pressure properties are also given.

Description: "Friction stir butt welding," as it was originally termed by Wayne Thomas and Christopher Dawes, in the early 1990s, but now commonly called "friction stir welding," has made great progress as a new welding technique. Marshall Space Flight Center has been investigating the use of FSW for assembly of the Shuttle's external fuel tank since the late 1990s and hopes to have the process in use by the summer of 2002. In FSW, a cylindrical pin tool of hardened steel, is rotated and plunged into the abutting edges of the parts to be joined. The tool is plunged into the weldment to within about .050 in of the bottom to assure full penetration. As the tool moves along the joint, the tool shoulder helps produce frictional heating, causing the material to plasticize. The metal of the two abutting plates flows from the front of the tool to the back where it cools and coalesces to form a weld in the solid phase. One quarter inch thick plates of aluminum alloy 2219 were used in this study. Two samples, each consisting of two 4 in x 12 in plates, were friction stir welded. The anvil for one sample was coated with molybdenum sulfide, while for the other sample a sheet of roughened stainless steel was placed between the anvil and the sample. The retractable pin tool was used so that the depth of the pin tool penetration could be varied. As welding proceeded, the length of the pin tool was gradually increased from the starting point. The purpose of this investigation is to find out at what point, in the down ramp, penetration occurs. Differences in root structure of the friction stir weld due to differences in anvil friction will be observed. These observations will be analyzed using friction stir weld theory.

Description: Inflated cylindrical struts constructed of kapton polyimide film and rigidized with foam have considerable practical application and potential for use as components of inflatable concentrator assemblies, antenna structures and space power systems, Because of their importance, it is of great interest to characterize the dynamic behavior of these components and structures both experimentally and analytically. It is very helpful to take a building-block approach to modeling and understanding inflatable assemblies by first investigating in detail the behavior of the components such as the struts. The foam material used for rigidization of such cylinders has varying modulus, which is a function of different factors, such as density of the foam. Thus, the primary motivation of the tests and analytical modeling efforts was to determine and understand the response of foam-rigidized cylinders for different densities, sizes, and construction methods, In recent years, inflatable structures have been the subject of renewed interest for space applications such as communications antennae, solar thermal propulsion, and space solar power. A major advantage of using inflatable structures in space is that they are extremely lightweight. This makes inflatables a perfect match for solar thermal propulsion because of the low thrust levels available. An obvious second advantage is on-orbit deployability and subsequent space savings in launch configuration. It can be seen that inflatable cylindrical struts and torus are critical components of structural assemblies. In view of this importance, structural dynamic and static behaviors of typical rigidized polyimide struts are investigated in this paper. The paper will focus on the finite element models that were used to model the behavior of the complete solar collector structure, and the results that they provided, as compared to test data.

Description: One of the significant challenges in developing a momentum exchange / electrodynamic reboost tether system is in the analysis and design of the capture device and its effects on the overall dynamics of the system. The goal of this work is to develop appropriate tether momentum exchange models that can simulate and evaluate the requirements of such a system, and be used to create specifications on the design of a capture device. This report briefly describes dynamic model development, simulation of the momentum exchange process, evaluation of dynamic effects of errors in the momentum exchange process, and the development of guidelines in selecting dynamic properties in the design of a capture device.

Description: NASA is currently developing the X-38 vehicle that will be used to demonstrate the technologies required for a crew return vehicle (CRV) for the International Space Station (ISS). The CRV will serve both as an ambulance for medical emergencies and as an evacuation vehicle for the Space Station. Control surfaces on the X-38 (body flaps and rudders/fins) require high temperature seals to limit hot gas ingestion and transfer of heat to underlying low-temperature structures to prevent over-temperature of these structures and possible loss of the vehicle. NASA's Johnson Space Center (JSC) and Glenn Research Center (GRC) are working together to develop and evaluate seals for the rudder/fin control surfaces. The specific objectives of this study are to measure seal flow rates, resiliency, and unit loads in as-received and temperature-exposed conditions and compare the measured results to property goals where applicable. Areas for future work would then be identified.

Description: This paper describes the development of a high resolution, six-degree of freedom positioning mechanism. This mechanism, based on the Stewart platform concept, was designed for use with the Developmental Comparative Active Optics Telescope Testbed (DCATT), a ground-based technology testbed for the Next Generation Space Telescope (NGST). The mechanism provides active control to the DCATT telescope's segmented primary mirror. Emphasis is on design decisions and technical challenges. Significant issues include undesirable motion properties of PZT-inchworm actuators, testing difficulties, dimensional stability, and use of advanced composite materials. Supporting test data from prototype mechanisms is presented.

Description: The tribological properties of a disubstituted alkylated cyclopentane, Pennzane (registered) Synthesized Hydrocarbon Fluid X-1000, are presented. This compound is a lower molecular weight version of the commonly used multiply alkylated cyclopentane, Pennzane X-2000, currently used in many space mechanisms. New, lower temperature applications will require liquid lubricants with lower viscosities and pour points and acceptable vapor pressures. Properties reported include: friction and wear studies and lubricated lifetime in vacuum; additionally, typical physical properties (i.e., viscosity-temperature, pour point, flash and fire point, specific gravity, refractive index, thermal properties, volatility and vapor pressure) are reported.

Description: A viewgraph presentation gives an overview of the manufacturing challenges in implementing welding material changes for the super lightweight external tank. Details are given on the external tank configuration, the weld purging equipment used, planning the selection of weld filler wire alloy, the initial weld microstructure, the wide panel tensile testing, and the dome cap welding.

Description: The objective of this research was to assess the B218 weld filler wire for Super Lightweight External Tank production, which could improve current production welding and repair productivity. We took the following approaches: (1) Perform a repair weld quick look evaluation between 4043/B218 and B218/B218 weld filler wire combinations and evaluation tensile properties for planished and unplanished conditions; and (2) Perform repair weld evaluation on structural simulation panel using 4043-B218 and B218/B218 weld filler wire combinations and evaluation tensile and simulated service fracture properties for planished and unplanished conditions.

Description: This viewgraph presentation gives an overview of the Revolutionary Turbine Accelerator (RTA) program. Details are given on the Single Stage To Orbit (SSTO) and Two Stage To Orbit (TSTO) aircraft, and the technological challenges associated with the RTA, SSTO, and TSTO.

Description: This article offers an unfiltered look at a large cross section of the different rapid prototyping technologies available today; from a guy with one of the biggest RP toy boxes in the world as the manager of the Rapid Prototyping Laboratory at NASA's Marshall Space Flight Center (MSFC) in Huntsville, AL, USA. NASA's current operation capacity is nine RP machines, representing eight actual technologies. The article presents a realistic, unbiased look at the technologies and offers advice on what to do and where to go for the best solution to your rapid prototyping needs.

Description: Manufacturing and assembly phases play a crucial role in providing products that meet the strict functional specifications associated with rotating machinery components. The errors resulting during the manufacturing and assembly of such components are correlated with the vibration and noise emanating from the final system during its operational lifetime. Vibration and noise are especially unacceptable elements in high-risk systems such as helicopters, resulting in premature component degradation and an unsafe flying environment. In such applications, individual components often are subject to 100% inspection prior to assembly, as well as during operation through rigorous maintenance, resulting in increased product development cycles and high production and operation costs. In this work, we focus on providing designers and manufacturing engineers with a technique to evaluate vibration modes and levels for each component or subsystem prior to putting them into operation. This paper presents a preliminary investigation of the correlation between vibrations and manufacturing and assembly errors using an experimental test rig, which simulates a simple bearing and shaft arrangement. A factorial design is used to study the effects of: 1) different manufacturing instances; 2) different assembly instances; and, 3) varying shaft speeds. The results indicate a correlation between manufacturing or assembly errors and vibrations measured from accelerometers. Challenges in developing a tool for DFM are identified, followed by a discussion of future work, including a real-world application to helicopter transmission vibrations.

Description: The plastic flow field in the vicinity of the pin-tool during Friction Stir Welding (FSW) needs to be understood if a theoretical understanding of the process is to be attained. The structure of welds does not exhibit the flow field itself, but consists in a residue of displacements left by the plastic flow field. The residue requires analysis to extract from it the instantaneous flow field around the pin-tool. A simplified merry-go-round model makes sense of some tracer experiments reported in the literature. A quantitative comparison is made of the displacements of copper wire markers with displacements computed from a hypothetical plastic flow field. The hypothetical plastic flow field consists in a circular rotation field about a translating pin tool with angular velocity varying with radius from the pin centerline. A sharply localized rotational field comprising slip on a surface around the tool agreed better with observations than a distributed slip field occupying a substantial volume around the tool. Both the tracer and the wire displacements support the "rotating plug" model, originally invoked or thermal reasons, of the FSW process.

Description: The focus of this study is on the suitability in the application of classical laminate theory analysis tools for filament wound pressure vessels with adhesive laminated joints in particular: pressure vessel wall performance, joint stiffness and failure prediction. Two 18-inch diameter 12-ply filament wound pressure vessels were fabricated. One vessel was fabricated with a 24-ply pyramid laminated adhesive double strap butt joint. The second vessel was fabricated with the same number of plies in an inverted pyramid joint. Results from hydrostatic tests are presented. Experimental results were used as input to the computer programs GENLAM and Laminate, and the output compared to test. By using the axial stress resultant, the classical laminate theory results show a correlation within 1% to the experimental results in predicting the pressure vessel wall pressure performance. The prediction of joint stiffness for the two adhesive joints in the axial direction is within 1% of the experimental results. The calculated hoop direction joint stress resultant is 25% less than the measured resultant for both joint configurations. A correction factor is derived and used in the joint analysis. The correction factor is derived from the hoop stress resultant from the tank wall performance investigation. The vessel with the pyramid joint is determined to have failed in the joint area at a hydrostatic pressure 33% value below predicted failure. The vessel with the inverted pyramid joint failed in the wall acreage at a hydrostatic pressure within 10% of the actual failure pressure.

Description: As part of the National Aeronautics and Space Administration's ongoing effort to lower the cost of access to space, the Marshall Space Flight Center has developed a rocket engine with 60,000 pounds of thrust for use on the Reusable Launch Vehicle technology demonstrator slated for launch in 2000. This gas generator cycle engine, known as the Fastrac engine, uses liquid oxygen and RP-1 for propellants and includes single stage liquid oxygen and RP-1 pumps and a single stage supersonic turbine on a common shaft. The turbopump design effort included the first use and application of new suction capability prediction codes and three-dimensional blade generation codes in an attempt to reduce the turbomachinery design and certification costs typically associated with rocket engine development. To verify the pump's predicted cavitation performance, a water flow test of a superscale model of the Fastrac liquid oxygen pump was conducted to experimentally evaluate the liquid oxygen pump's performance at and around the design point. The water flow test article replicated the flow path of the Fastrac liquid oxygen pump in a 1.582x scale model, including scaled seal clearances for correct leakage flow at a model operating speed of 5000 revolutions per minute. Flow entered the 3-blade axial-flow inducer, transitioned to a shrouded, 6- blade radial impeller, and discharged into a vaneless radial diffuser and collection volute. The test article included approximately 50 total and static pressure measurement locations as well as flush-mounted, high frequency pressure transducers for complete mapping of the pressure environment. The primary objectives of the water flow test were to measure the steady-state and dynamic pressure environment of the liquid oxygen pump versus flow coefficient, suction specific speed, and back face leakage flow rate. Initial results showed acceptable correlation between the predicted and experimentally measured pump head rise at low suction specific speeds. Likewise, only small circumferential variations in steady-state were observed from 80% to 120% of the design flow coefficient, matching the computational predictions and confirming that the integrated design approach has minimized any exit volute-induced distortions. The test article exhibited suction performance trends typically observed in inducer designs with virtually constant head rise with decreasing inlet pressure until complete pump head breakdown. Unfortunately, the net positive suction head at 3% head fall-off occurred far below that predicted at all tested flow coefficients, resulting in a negative net positive suction head margin at the design point in water. Additional testing to map the unsteady pressure environment was conducted and cavitation-induced flow disturbances at the inducer inlet were observed. Two distinct disturbances were identified, one rotating and one stationary relative to the fixed frame of reference, while the transition from one regime to the next produced significant effects on the steady state pump performance. The impact of the unsteady phenomena and the corresponding energy losses on the unexpectedly poor pump performance is also discussed.

Description: The purpose of this presentation is to demonstrate: low cost photoetching fabrication technique; pressure balanced finger seal design; and finger seal operation. The tests and analyses includes: finger seal air leakage analysis; rotor-run out and endurance tests; and extensive analytical work and rig testing.

Description: The purpose of this presentation is to plan an engine technology program that will enable next generation engines for both commercial and military applications, and to emphasize revolutionary technologies that will enable future subsonic and high-speed applications.

Description: This presentation discuss the x-38 crew return vehicle. As an element of the International Space Station (ISS), there are potential problems that are discussed. These include ISS catastrophe, emergency medical evacuation, and period of Space Shuttle unavailability. The x-38 program purpose was also discussed. The Reduction of the costs and schedule for the development of Crew Return Vehicles (CRV's) and Crew Transfer Vehicles (CTV's) through the use of the rapid development methodology associated with an X-project were also presented. With specific attention to ground testing, atmospheric testing, and space flight testing.

Description: NASA Glenn hosted the Seals/Secondary Air System Workshop on October 2829, 1999. Each year NASA and our industry and university partners share their respective seal technology development. We use these workshops as a technical forum to exchange recent advancements and "lessons-learned" in advancing seal technology and solving problems of common interest. As in the past we are publishing two volumes. Volume 1 will be publicly available and will be made available on-line through the web page address listed at the end of this chapter. Volume 2 will be restricted under International Traffic and Arms Regulations (I.T.A.R.) In this conference participants gained an appreciation of NASA's new Ultra Efficient Engine Technology (UEET) program and how this program will be partnering with ongoing DOE -industrial power production and DOD- military aircraft engine programs. In addition to gaining a deeper understanding into sealing advancements and challenges that lie ahead, participants gained new working and personal relationships with the attendees. When the seals and secondary fluid management program was initiated, the emphasis was on rocket engines with spinoffs to gas turbines. Today, the opposite is true and we are, again building our involvement in the rocket engine and space vehicle demonstration programs.

Description: The objective of this presentation is to increase thrust to weight ratio, decrease specific fuel consumption, and to eliminate wear of sealing components.

Description: The objective of this presentation is to develop an Aspirating Face Seal design for use in the GE90 aft outer LPT seal location, and other new and existing engines. Therefore reducing the secondary flow leakages.

Description: Mr. James Zakrajsek, chief of the Mechanical Components Branch, gave an overview of research conducted by the branch. Branch members perform basic research on mechanical components and systems, including gears and bearings, turbine seals, structural and thermal barrier seals, and space mechanisms. The research is focused on propulsion systems for present and advanced aerospace vehicles. For rotorcraft and conventional aircraft, we conduct research to develop technology needed to enable the design of low noise, ultra safe geared drive systems. We develop and validate analytical models for gear crack propagation, gear dynamics and noise, gear diagnostics, bearing dynamics, and thermal analyses of gear systems using experimental data from various component test rigs. In seal research we develop and test advanced turbine seal concepts to increase efficiency and durability of turbine engines. We perform experimental and analytical research to develop advanced thermal barrier seals and structural seals for current and next generation space vehicles. Our space mechanisms research involves fundamental investigation of lubricants, materials, components and mechanisms for deep space and planetary environments.

Description: Turbopump weight continues to be a dominant parameter in the trade space for reduction of engine weight. Space Shuttle Main Engine weight distribution indicates that the turbomachinery make up approximately 30% of the total engine weight. Weight reduction can be achieved through the reduction of envelope of the turbopump. Reduction in envelope relates to an increase in turbopump speed and an increase in impeller head coefficient. Speed can be increased until suction performance limits are achieved on the pump or due to alternate constraints the turbine or bearings limit speed. Once the speed of the turbopump is set the impeller tip speed sets the minimum head coefficient of the machine. To reduce impeller diameter the head coefficient must be increased. A significant limitation with increasing head coefficient is that the slope of the head-flow characteristic is affected and this can limit engine throttling range. Unshrouded impellers offer a design option for increased turbopump speed without increasing the impeller head coefficient. However, there are several issues with regard to using an unshrouded impeller: there is a pump performance penalty due to the front open face recirculation flow, there is a potential pump axial thrust problem from the unbalanced front open face and the back shroud face, and since test data is very limited for this configuration, there is uncertainty in the magnitude and phase of the rotordynamic forces due to the front impeller passage. The purpose of the paper is to discuss the design of an unshrouded impeller and to examine the hydrodynamic performance, axial thrust, and rotordynamic performance. The design methodology will also be discussed. This work will help provide some guidelines for unshrouded impeller design.

Description: In 1991 The Welding Institute of the United Kingdom patented the Friction Stir Welding (FSW) process. In FSW a rotating pin-tool is inserted into a weld seam and literally stirs the faying surfaces together as it moves up the seam. By April 2000 the American Welding Society International Welding and Fabricating Exposition featured several exhibits of commercial FSW processes and the 81st Annual Convention devoted a technical session to the process. The FSW process is of interest to Marshall Space Flight Center (MSFC) as a means of avoiding hot-cracking problems presented by the 2195 aluminum-lithium alloy, which is the primary constituent of the Lightweight Space Shuttle External Tank. The process has been under development at MSFC for External Tank applications since the early 1990's. Early development of the FSW process proceeded by cut-and-try empirical methods. A substantial and complex body of data resulted. A theoretical model was wanted to deal with the complexity and reduce the data to concepts serviceable for process diagnostics, optimization, parameter selection, etc. A first step in understanding the FSW process is to determine the kinematics, i.e., the flow field in the metal in the vicinity of the pin-tool. Given the kinematics, the dynamics, i.e., the forces, can be targeted. Given a completed model of the FSW process, attempts at rational design of tools and selection of process parameters can be made.

Description: Within NASA's High Performance Computing and Communication (HPCC) program, NASA Glenn Research Center is developing an environment for the analysis/design of propulsion systems for aircraft and space vehicles called the Numerical Propulsion System Simulation (NPSS). The NPSS focuses on the integration of multiple disciplines such as aerodynamics, structures, and heat transfer, along with the concept of numerical zooming between 0- Dimensional to 1-, 2-, and 3-dimensional component engine codes. The vision for NPSS is to create a "numerical test cell" enabling full engine simulations overnight on cost-effective computing platforms. Current "state-of-the-art" engine simulations are 0-dimensional in that there is there is no axial, radial or circumferential resolution within a given component (e.g. a compressor or turbine has no internal station designations). In these 0-dimensional cycle simulations the individual component performance characteristics typically come from a table look-up (map) with adjustments for off-design effects such as variable geometry, Reynolds effects, and clearances. Zooming one or more of the engine components to a higher order, physics-based analysis means a higher order code is executed and the results from this analysis are used to adjust the 0-dimensional component performance characteristics within the system simulation. By drawing on the results from more predictive, physics based higher order analysis codes, "cycle" simulations are refined to closely model and predict the complex physical processes inherent to engines. As part of the overall development of the NPSS, NASA and industry began the process of defining and implementing an object class structure that enables Numerical Zooming between the NPSS Version I (0-dimension) and higher order 1-, 2- and 3-dimensional analysis codes. The NPSS Version I preserves the historical cycle engineering practices but also extends these classical practices into the area of numerical zooming for use within a companies' design system. What follows here is a description of successfully zooming I-dimensional (row-by-row) high pressure compressor results back to a NPSS engine 0-dimension simulation and a discussion of the results illustrated using an advanced data visualization tool. This type of high fidelity system-level analysis, made possible by the zooming capability of the NPSS, will greatly improve the fidelity of the engine system simulation and enable the engine system to be "pre-validated" prior to commitment to engine hardware.

Description: With the assistance of Small Business Innovation Research (SBIR) funding from NASA's Jet Propulsion Laboratory, Cybersonics, Inc., developed an ultrasonic drill with applications ranging from the medical industry to space exploration. The drill, which has the ability to take a core sample of the hardest granite or perform the most delicate diagnostic medical procedure, is a lightweight, ultrasonic device made to fit in the palm of the hand. Piezoelectric actuators, which have only two moving parts and no gears or motors, drive the components of the device, enabling it to operate in a wide range of temperatures. The most remarkable aspect of the drill is its ability to penetrate even the hardest rock with minimal force application. The ultrasonic device requires 20 to 30 times less force than standard rotating drills, allowing it to be safely guided by hand during operation. Also, the drill is operable at a level as low as three watts of power, where conventional drills require more than three times this level. Potential future applications for the ultrasonic drill include rock and soil sampling, medical procedures that involve core sampling or probing, landmine detection, building and construction, and space exploration. Cybersonics, Inc. developed an ultrasonic drill with applications ranging from the medical industry to space exploration.

Description: A licensing agreement between Marshall Space Flight Center and M&A Screw and Machineworks has brought the quick connect nut to the commerical market. Originally designed as part of a project seeking in-space assembly techniques, the quick connect nut is secured around a bolt merely by pushing it onto the bolt and giving it a single twist. Applications for the nuts include oil drilling platforms, mining industry, and other practices that rely on speedy assembly for success.

Description: A new self-adjusting, retractable pin tool for friction stir welding is now used in the manufacturing of components for NASA Space Shuttles. Friction stir welding is a process that makes straight-line welds without bringing the parent material to a liquid state. This is accomplished through high-speed rotation, which generates frictional heat between the welding tool and the piece being welded. This heat causes the material to soften to the point of plasticity without allowing it to melt. The plasticized material is then transferred from the front edge of the welding tool to the trail edge, where it joins the pieces being welded. However, a major flaw of this method is its reliance on a single-piece pin tool. The weld is left unfinished and a hole remains where the pin was inserted. The hole must be covered with a rivet in order to preserve the integrity of the weld. The NASA-developed pin tool, however, eliminates the need for this finishing step, as its retraction allows continuous rewelding at lesser depths, until the hole is completely closed. With this NASA technology, welding of higher strength alloys, as well as non-planer and variable thickness structures can be achieved.

Description: Automotive Resources, Inc. (ARI) has developed a new device for igniting fuel in engines-the SmartPlug.TM SmartPlug is a self-contained ignition system that may be retrofitted to existing spark-ignition and compression-ignition engines. The SmartPlug needs as little as six watts of power for warm-up, and requires no electricity at all when the engine is running. Unlike traditional spark plugs, once the SmartPlug ignites the engine, and the engine heats up, the power supply for the plug is no longer necessary. In the utility industry, SmartPlugs can be used in tractors, portable generators, compressors, and pumps. In addition to general-purpose applications, such as lawn mowers and chainsaws, SmartPlugs can also be used in the recreational, marine, aviation, and automotive industries. Unlike traditional ignition systems, the SmartPlug system requires no distributor, coil points, or moving parts. SmartPlugs are non-fouling, with a faster and cleaner burn than traditional spark plugs. They prevent detonation and are not sensitive to moisture, allowing them to be used on a variety of engines. Other advantages include no electrical noise, no high voltage, exceptionally high altitude capabilities, and better cold-start statistics than those of standard spark ignition systems. Future applications for the SmartPlug are being evaluated by manufacturers in the snowmobile industry.

Description: Through Small Business Innovation Research (SBIR) funding from NASA's Glenn Research Center, Moller International created a new coating for rotary engines, which significantly improves the fuel consumption of a vehicle while reducing emissions. The new coatings are offered in the new Rotapower(R) engine, which is produced and distributed by Moller subsidiary, Freedom Motors, Inc. The coating allows the Rotapower engine to function smoother than other models, reducing wear and protecting the engine. The Rotapower engine has the ability to operate on a variety of fuels, including gasoline, natural gas, diesel, alcohol, and kerosene. A small and lightweight engine, it is projected to replace many of today's bulkier versions. The 10 horsepower model fits in the palm of one's hand, while the 160 horsepower model fits into a 5-gallon bucket. The clean running Rotapower engine is environmentally appealing, because it eliminates over 98 percent of the total emissions given off by traditional piston engines. Fewer pollutants are spewed into the air, making it especially attractive in areas where air pollution is a major problem. Due to the clean-burning nature of the engine, it meets the stringent standards set by the California Air Resources Board. The engine also has numerous commercial benefits in several types of recreational, industrial, and transportation applications, including personal watercraft, snowmobiles, portable generators. and pumps.

Description: Most of the personal audio and video recording devices currently sold on the open market all require hands to operate. Little consideration was given to designing a hands-free unit. Such a system once designed and made available to the public could greatly benefit mobile police officers, bicyclists, adventurers, street and dirt motorcyclists, horseback riders and many others. With a few design changes water sports and skiing activities could be another large area of application. The cam shell is an innovative design in which an audio and video recording device (such as palm camcorder) is housed in a body-mounted protection system. This system is based on the concept of viewing and recording at the same time. A view cam is attached to a helmet wired to a recording unit encased in a transparent body-mounted protection system. The helmet can also be controlled by remote. The operator will have full control in recording everything. However, the recording unit will be operated completely hands-free. This project will address the design considerations and their effects on material selection and manufacturing. It will enhance the understanding of the structure of materials, and how the structure affects the behavior of the material, and the role that processing play in linking the relationship between structure and properties. A systematic approach to design feasibility study, cost analysis and problem solving will also be discussed.

Description: To many national park campers and mountain climbers saving their foods in a safe and unbreakable storage container without worrying being attacked by a bear is a challenging task. In some parks, the park rangers have mandated that park visitors rent a bear canister for their food storage. Commercially available bear canisters are made of ABS plastic, weigh 2.8 pounds, and have a 180 cubic inch capacity for food storage. A new design with similar capacity was conducted in this study to reduce its weight and make it a stiffer and stronger canister. Two prototypes incorporating carbon prepreg with and without honeycomb constructions were manufactured using hand lay-up and vacuum bag forming techniques. A 6061-T6-aluminum ring was machined to dimensions in order to reinforce the opening area of the canister. Physical properties (weight and volume) along with mechanical properties (flexural strength and specific allowable moment) of the newly fabricated canisters are compared against the commercial ones. The composite canister weighs only 56% of the ABS one can withstand 9 times of the force greater. The advantages and limitations of using composite bear canisters will be discussed in the presentation.

Description: A summary of recent composite structures and materials research at NASA Langley Research Center is presented. Fabrication research to develop low-cost automated robotic fabrication procedures for thermosetting and thermoplastic composite materials, and low-cost liquid molding processes for preformed textile materials is described. Robotic fabrication procedures discussed include ply-by-ply, cure-on-the-fly heated placement head and out-of-autoclave electron-beam cure methods for tow and tape thermosetting and thermoplastic materials. Liquid molding fabrication processes described include Resin Film Infusion (RFI), Resin Transfer Molding (RTM) and Vacuum-Assisted Resin Transfer Molding (VARTM). Results for a full-scale composite wing box are summarized to identify the performance of materials and structures fabricated with these low-cost fabrication methods.

Description: Using an improved valve design developed under an SBIR contract with Stennis Space Center, Marotta Scientific's PRV95 provides stability over the entire operational range, from fully closed to fully open. The valve employs a concept known as upstream control for valve positioning, making it more dependable with excellent repeatability and minimal lag time. The PRV95 design is unique in its ability to maintain a seal near the set point of the relief limit. Typically, relief valves seal tightly up to 90 percent set point and then reseat when pressure is reduced to 85 percent of set point. This new technology maintains seal integrity until 98 percent of set point and will reseat at 95 to 97 percent of set point. This allows the operator to protect a system without exceeding its limits.

Description: Hydro Dynamics, Inc. received a technical helping hand from NASA that made their Hydrosonic Pump (HPump) a reality. Marshall engineers resolved a bearing problem in the rotor of the pump and recommended new bearings, housings and mounting hardware as a solution. The resulting HPump is able to heat liquids with greater energy efficiency using shock waves to generate heat.

Description: The weld process performance for a given weld joint configuration and tool setup is summarized on a 2-D plot of RPM vs. IPM. A process envelope is drawn within the map to identify the range of acceptable welds. The sweet spot is selected as the nominal weld schedule The nominal weld schedule is characterized in the expected manufacturing environment. The nominal weld schedule in conjunction with process control ensures a consistent and predictable weld performance.

Description: This viewgraph presentation gives examples of possible future uses of nanotechnology, with some emphasis on carbon nanotubes and medical applications. The presentation provides an overview of organizations conducting nanotechnology research in the United States, and suggests a timeline for nanotechnology development.

Description: The NASA Glenn Research Center at Lewis Field and Texas A&M University are developing techniques for accommodating certain types of failures in magnetic suspension systems used in rotating machinery. In recent years, magnetic bearings have become a viable alternative to rolling element bearings for many applications. For example, industrial machinery such as machine tool spindles and turbomolecular pumps can today be bought off the shelf with magnetically supported rotating components. Nova Gas Transmission Ltd. has large gas compressors in Canada that have been running flawlessly for years on magnetic bearings. To help mature this technology and quiet concerns over the reliability of magnetic bearings, NASA researchers have been investigating ways of making the bearing system tolerant to faults. Since the potential benefits from an oil-free, actively controlled bearing system are so attractive, research that is focused on assuring system reliability and safety is justifiable. With support from the Fast Quiet Engine program, Glenn's Structural Mechanics and Dynamics Branch is working to demonstrate fault-tolerant magnetic suspension systems targeted for aerospace engine applications. The Flywheel Energy Storage Program is also helping to fund this research.

Description: In September 1999, the Central Process Systems Engineering Branch and the Maintenance and the Central Process Systems Operations Branch, released for service a new high pressure compressor to supplement the 450-psig Combustion Air System at the NASA Glenn Research Center at Lewis Field. The new compressor, designated C-18, is located in Glenn s Central Air Equipment Building and is remotely operated from the Central Control Building. C-18 can provide 40 pounds per second (pps) of airflow at pressure to our research customers. This capability augments our existing system capacity (compressors C 4 at 38 pps and C-5 at 32 pps), which is generated from Glenn's Engine Research Building. The C-18 compressor was originally part of Glenn's 21-Inch Hypersonic Tunnel, which was transferred from the Jet Propulsion Laboratory to Glenn in the mid-1980's. With the investment of construction of facilities funding, the compressor was modified, new mechanical and electrical support equipment were purchased, and the unit was installed in the basement of the Central Air Equipment Building. After several weeks of checkout and troubleshooting, the new compressor was ready for long-term, reliable operations. With a total of 110 pps in airflow now available, Glenn is well positioned to support the high-pressure air test requirements of our research customers.

Description: Spiral bevel gears are important components on all current rotorcraft drive systems. These components are required to operate at high speeds, high loads, and for an extremely large number of load cycles. In this application, spiral bevel gears are used to redirect the shaft from the horizontal gas turbine engine to the vertical rotor. Because of the high expense of manufacturing these gears, methods that can achieve the same level of performance at reduced cost are highly desirable to aerospace gear manufacturers. Gears manufactured for aerospace applications use high-quality materials and are manufactured to tight tolerances. Special manufacturing machine tools and computer numerically controlled coordinate measurement systems have enabled rotorcraft drive system manufacturers to produce extremely high-quality gears during their normal production. Because of low production rates for rotorcraft, these gears are manufactured in small batches, and thus are unable to benefit from the economics of high production numbers as in other industries. In this investigation, two different manufacturing methods, face-milled and face-hobbed, were used to fabricate spiral bevel gears. For face-milled spiral bevel gears, grinding of the contacting surfaces is the final manufacturing step. At least two different specialty machines are needed to generate the teeth for face-milled spiral bevel gears. For face-hobbed gears, hard cutting is the final manufacturing process. The same machine is used to rough cut and finish cut the gears. This study compared the operational behavior of face-milled spiral bevel gears with that of face-hobbed spiral bevel gears. Test hardware was manufactured to fit within NASA Glenn Research Center's Spiral Bevel Test Facility and to aerospace quality standards. Tests were conducted for stress, vibration, and noise. A comparison of the results attained indicated that the face-hobbed gears had a lower alternating stress level with a more even distribution of loading across the teeth, and slightly reduced levels of vibration and noise. Results of this study show that the face-hobbed method is a viable and lower-cost alternative for producing aerospace-quality spiral-bevel gears.

Description: Vacuum ultraviolet (VUV) radiation of wavelengths between 115 and 200 nm produced by the Sun in the space environment can degrade polymer films, producing changes in their optical, mechanical, and chemical properties. These effects are particularly important for thin polymer films being considered for ultralightweight space structures, because, for most polymers, VUV radiation is absorbed in a thin surface layer. The NASA Glenn Research Center has developed facilities and methods for long-term ground testing of polymer films to evaluate space environmental VUV radiation effects. VUV exposure can also be used as part of combined or sequential simulated space environmental exposures to determine combined damaging effects with other aspects of the space environment, which include solar ultraviolet radiation, solar flare x-rays, electron and proton radiation, atomic oxygen (for low-Earth-orbit missions), and temperature effects. Because the wavelength sensitivity of VUV damage is not well known for most materials, Glenn's VUV facility uses a broad-spectrum deuterium lamp with a magnesium fluoride window that provides output between 115 and 200 nm. Deuterium lamps of this type were characterized by the National Institute of Standards and Technology and through measurements at Glenn. Spectral irradiance measurements show that from approximately 115 to 160 nm, deuterium lamp irradiance can be many times that of air mass zero solar irradiance, and as wavelength increases above approximately 160 nm, deuterium lamp irradiance decreases in comparison to the Sun. The facility is a cryopumped vacuum chamber that achieves a system pressure of approximately 5310(exp -6) torr. It contains four individual VUV-exposure compartments in vacuum, separated by water-cooled copper walls to minimize VUV radiation and any sample contamination cross interactions between compartments. Each VUV-exposure compartment contains a VUV deuterium lamp, a motor-controlled sample stage coupled with a moveable cesium iodide VUV phototube, and two thermocouples for temperature measurement. The vacuum chamber and exterior equipment is shown. Each VUV lamp is located at the top of the chamber with its projection-tube pushed through an O-ring compression fitting. The lamp assemblies are located on ports that can be isolated from the rest of the vacuum chamber, permitting maintenance or replacement of the lamps without breaking vacuum in the main chamber where the samples are located. A view of two of the four interior VUV-exposure compartments, including the moveable sample stages and detector holders is also shown. Glenn is using this facility to support testing of Next Generation Space Telescope sunshield materials that is being led by the NASA Goddard Space Flight Center and to develop an understanding of the wavelength, intensity, and temperature dependence of VUV-induced polymer degradation.

Description: An important aspect of implementing Stirling Radioisotope Generators on future NASA missions is the integration of the generator and controller with potential spacecraft loads. Some recent studies have indicated that the combination of Stirling Radioisotope Generators and electric propulsion devices offer significant trip time and payload fraction benefits for deep space missions. A test was devised to begin to understand the interactions between Stirling generators and electric thrusters. An electrically heated RG- 350 (350-W output) Stirling convertor, designed and built by Stirling Technology Company of Kennewick, Washington, under a NASA Small Business Innovation Research agreement, was coupled to a 300-W SPT-50 Hall-effect thruster built for NASA by the Moscow Aviation Institute (RIAME). The RG-350 and the SPT-50 shown, were installed in adjacent vacuum chamber ports at NASA Glenn Research Center's Electric Propulsion Laboratory, Vacuum Facility 8. The Stirling electrical controller interfaced directly with the Hall thruster power-processing unit, both of which were located outside of the vacuum chamber. The power-processing unit accepted the 48 Vdc output from the Stirling controller and distributed the power to all the loads of the SPT-50, including the magnets, keeper, heater, and discharge. On February 28, 2001, the Glenn test team successfully operated the Hall-effect thruster with the Stirling convertor. This is the world's first known test of a dynamic power source with electric propulsion. The RG-350 successfully managed the transition from the purely resistive load bank within the Stirling controller to the highly capacitive power-processing unit load. At the time of the demonstration, the Stirling convertor was operating at a hot temperature of 530 C and a cold temperature of -6 C. The linear alternator was producing approximately 250 W at 109 Vac, while the power-processing unit was drawing 175 W at 48 Vdc. The majority of power was delivered to the Hall thruster discharge circuit operating at 115 Vdc and 0.9 A. Testing planned for late 2001 will examine the possibility of directly driving the Hall thruster discharge circuit using rectified and filtered output from the Stirling alternator.

Description: The prime source of vibration and noise in a gear system is the transmission error between the meshing gears. Transmission error is caused by manufacturing inaccuracy, mounting errors, and elastic deflections under load. Gear designers often attempt to compensate for transmission error by modifying gear teeth. This is done traditionally by a rough "rule of thumb" or more recently under the guidance of an analytical code. In order for a designer to have confidence in a code, the code must be validated through experiment. NASA Glenn Research Center contracted with the Design Unit of the University of Newcastle in England for a system to measure the transmission error of spur and helical test gears in the NASA Gear Noise Rig. The new system measures transmission error optically by means of light beams directed by lenses and prisms through gratings mounted on the gear shafts. The amount of light that passes through both gratings is directly proportional to the transmission error of the gears. A photodetector circuit converts the light to an analog electrical signal. To increase accuracy and reduce "noise" due to transverse vibration, there are parallel light paths at the top and bottom of the gears. The two signals are subtracted via differential amplifiers in the electronics package. The output of the system is 40 mV/mm, giving a resolution in the time domain of better than 0.1 mm, and discrimination in the frequency domain of better than 0.01 mm. The new system will be used to validate gear analytical codes and to investigate mechanisms that produce vibration and noise in parallel axis gears.

Description: At the NASA Glenn Research Center, we have been training artificial neural networks to interpret the characteristic patterns (see the leftmost image) generated from electronic holograms of vibrating structures. These patterns not only visualize the vibration properties of structures, but small changes in the patterns can indicate structural changes, cracking, or damage. Neural networks detect these small changes well. Our objective has been to adapt the neural-network, electronic-holography combination for inspecting components in Glenn's Spin Rig.

Description: Three tests are described which evaluate the oxygen compatibility characteristics of multiple composite materials: 1) Mechanical Impact Bruceton 'Up and Down' Method; 2) Promoted Combustion; 3) Electrostatic Discharge.

Description: The plan for session are: 1. Are issues in the draft document appropriate and complete? 2. Are the issues properly organized and prioritized? 3. Is the plan well defined and suitable? 4. Are the proposed facilities adequate?

Description: This effort is to investigate and design testing strategies to determine the mechanical properties of MicroElectroMechanical Systems (MEMS) as well as investigate the development of a MEMS Probabilistic Design Methodology (PDM). One item of potential interest is the design of a test for the Weibull size effect in pressure membranes. The Weibull size effect is a consequence of a stochastic strength response predicted from the Weibull distribution. Confirming that MEMS strength is controlled by the Weibull distribution will enable the development of a probabilistic design methodology for MEMS - similar to the GRC developed CARES/Life program for bulk ceramics. However, the primary area of investigation will most likely be analysis and modeling of material interfaces for strength as well as developing a strategy to handle stress singularities at sharp corners, filets, and material interfaces. This will be a continuation of the previous years work. The ultimate objective of this effort is to further develop and verify the ability of the Ceramics Analysis and Reliability Evaluation of Structures Life (CARES/Life) code to predict the time-dependent reliability of MEMS structures subjected to multiple transient loads.

Description: Sketches and chemical diagrams of state-of-the-art device and novel proposed device are presented. Current device uses a diode laser that emits into a fluorescent fluid only one wavelength and a photodetector diode that detects only one wavelength. Only one type of bacteria can be detected. The proposed device uses a quantum dot array that emits into a fluorescent fluid multiple wavelengths and an NIR 512 spectrometer that scans 0.8- to 1.7-mm wavelengths. Hundreds of different bacteria and viruses can be detected. A novel biomedical device is being developed at the NASA Glenn Research Center in cooperation with the University of Michigan. This device uses nano-structured quantum dots that emit light in the near-infrared (IR) region. The nanostructured quantum dots are used as a source and excite fluorochrome polymers coupled with antibodies that seek out and attach to specific bacteria and viruses. The fluorochrome polymers/antibodies fluoresce at specific wavelengths in the near-IR spectrum, but these wavelengths are offset from the excitation wavelength and can be detected with a tunable spectrometer. The device will be used to detect the presence of viruses and bacteria in simple fluids and eventually in more complex fluids, such as blood. Current state-of-the-art devices are limited to single bacteria or virus detection and a considerable amount of time and effort is required to prepare samples for analysis. Most importantly, the devices are quite large and cumbersome, which prohibits them from being used on the International Space Station and the space shuttles. This novel device uses nanostructured quantum dots which, through molecular beam epitaxy and highly selective annealing processes, can be developed into an illumination source that could potentially generate hundreds of specific wavelengths. As a result, this device will be able to excite hundreds of antibody/fluorochrome polymer combinations, which in turn could be used to detect hundreds of bacteria and viruses in fluids. A novel sample preparation technique that exploits micromembrane filtration and centrifugation methods has been developed for this device. The technique greatly reduces the time required to prepare the sample and the amount of sample needed to perform an accurate and comprehensive analysis. Last, and probably most important, because of the nano-light-emitting source and the novel sample preparation technique, the overall size of the device could be reduced dramatically. This device will serve as a nanoscale lab-on-a-chip for in situ microorganism detection and will enable tests to be performed on a time scale of minutes rather than days. Thus, it is ideally suited for monitoring the environmental conditions onboard the International Space Station and the space shuttles, thereby enhancing the safety of the astronauts. In addition, the device has important commercial applications, such as detecting the presence of bacteria and viruses in water at food- and beverage-processing centers, water treatment plants, and restaurants. Also, this technology has the potential to be used to detect bacteria and viruses in more complex fluids, such as blood--which in all likelihood would revolutionize blood analysis as it is performed today. This project was made possible through the Director's Discretionary Fund and is ongoing. In addition, this project provides funding to Dr. Rachel Goldman of the University of Michigan for the research and development of nanostructured quantum dots.

Description: Thermal barrier coatings (TBCs) are used extensively in modern gas turbine engines to thermally insulate air-cooled metallic components from the hot gases in the engine. These coatings typically consist of a zirconia-yttria ceramic that has been applied by either plasma spraying or physical vapor deposition. Future engines will rely even more heavily on TBCs and will require materials that have even higher temperature capability with improved insulation (i.e., lower thermal conductivity even after many hours at high temperature). This report discusses new TBCs that have been developed with these future requirements in mind. The Ultra-Efficient Engine Technology Program at the NASA Glenn Research Center is funding this effort, which has been conducted primarily at Glenn with contractor support (GE and Howmet) for physical vapor deposition. As stated, the new TBC not only had to be more insulating but the insulation had to persist even after many hours of exposure-that is, the new TBC had to have both lower conductivity and improved sintering resistance. A new type of test rig was developed for this task. This new test approach used a laser to deliver a known high heat flux in an essentially uniform pattern to the surface of the coating, thereby establishing a realistic thermal gradient across its thickness. This gradient was determined from surface and backside pyrometry; and since the heat flux and coating thickness are known, this permitted continuous monitoring of thermal conductivity. Thus, this laser rig allowed very efficient screening of candidate low-conductivity, sinter-resistant TBCs. The coating-design approach selected for these new low-conductivity TBCs was to identify oxide dopants that had the potential to promote the formation of relatively large and stable groupings of defects known as defect clusters. This approach was used because it was felt that such clusters would reduce conductivity while enhancing stability. The approach proved to be successful: low-conductivity TBCs having improved sintering resistance were developed.

Description: The prime driving force for using microsystem and micromachine technologies in transport vehicles, such as spacecraft, aircraft, and automobiles, is to reduce the weight, power consumption, and volume of components and systems to lower costs and increase affordability and reliability. However, a number of specific issues need to be addressed with respect to using microsystems and micromachines in aerospace applications--such as the lack of understanding of material characteristics; methods for producing and testing the materials in small batches; the limited proven durability and lifetime of current microcomponents, packaging, and interconnections; a cultural change with respect to system designs; and the use of embedded software, which will require new product assurance guidelines. In regards to material characteristics, there are significant adhesion, friction, and wear issues in using microdevices. Because these issues are directly related to surface phenomena, they cannot be scaled down linearly and they become increasingly important as the devices become smaller. When microsystems have contacting surfaces in relative motion, the adhesion and friction affect performance, energy consumption, wear damage, maintenance, lifetime and catastrophic failure, and reliability. Ceramics, for the most part, do not have inherently good friction and wear properties. For example, coefficients of friction in excess of 0.7 have been reported for ceramics and ceramic composite materials. Under Alternate Fuels Foundation Technologies funding, two-phase oxide ceramics developed for superior high-temperature wear resistance in NASA's High Operating Temperature Propulsion Components (HOTPC) project and new two-layered carbon nanotube (CNT) coatings (CNT topcoat/iron bondcoat/quartz substrate) developed in NASA's Revolutionary Aeropropulsion Concepts (RAC) project have been chosen as a materials couple for aerospace applications, including micromachines, in the nanotechnology lubrication task because of their potential for superior friction and wearf properties in air and in an ultrahigh vacuum, spacelike environment. At the NASA Glenn Research Center, two-phase oxide ceramic eutectics, Al2O3/ZrO2(Y2O3), were directionally solidified using the laser-float-zone process, and carbon nanotubes were synthesized within a high-temperature tube furnace at 800 C. Physical vapor deposition was used to coat all quartz substrates with 5-nm-thick iron as catalyst and bondcoat, which formed iron islands resembling droplets and serving as catalyst particles on the quartz. A series of scanning electron micrographs showing multiwalled carbon nanotubes directionally grown as aligned "nanograss" on quartz is presented. Unidirectional sliding friction eperiments were conducted at Glenn with the two-layered CNT coatings in contact with the two-phase Al2O3/ZrO2(Y2O3) eutectics in air and in ultrachigh vacuum. The main criteria for judging the performance of the materials couple for solid lubrication and antistick applications in a space environment were the coefficient of friction and the wear resistance (reciprocal of wear rate), which had to be less than 0.2 and greater than 10(exp 5) N(raised dot)/cubic millimetes, respectively, in ultrahigh vacuum. In air, the coefficient of friction for the CNT coatings in contact with Al2O3/ZrO2 (Y2O3) eutectics was 0.04, one-fourth of that for quartz. In an ultrahigh vacuum, the coefficient of friction for CNT coatings in contact with Al2O3/ZrO2 (Y2O3) was one-third of that for quartz. The two-phase Al2O3/ZrO2 (Y2O3) eutectic coupled with the two-layered CNT coating met the coefficient of friction and wear resistance criteria both in air and in an ultrahigh vacuum, spacelike environment. This material's couple can dramatically improve the stiction (or adhesion), friction, and wear resistance of the contacting surfaces, which are major issues for microdevices and micromachines.

Description: The ability to measure emissions from aeronautic engines and in commercial applications such as automotive emission control and chemical process monitoring is a necessary first step if one is going to actively control those emissions. One single sensor will not give all the information necessary to determine the chemical composition of a high-temperature, harsh environment. Rather, an array of gas sensor arrays--in effect, a high-temperature electronic "nose"--is necessary to characterize the chemical constituents of a diverse, high-temperature environment, such as an emissions stream. The signals produced by this nose could be analyzed to determine the constituents of the emission stream. Although commercial electronic noses for near-room temperature applications exist, they often depend significantly on lower temperature materials or only one sensor type. A separate development effort necessary for a high-temperature electronic nose is being undertaken by the NASA Glenn Research Center, Case Western Reserve University, Ohio State University, and Makel Engineering, Inc. The sensors are specially designed for hightemperature environments. A first-generation high-temperature electronic nose has been demonstrated on a modified automotive engine. This nose sensor array was composed of sensors designed for hightemperature environments fabricated using microelectromechanical-systems- (MEMS-) based technology. The array included a tin-oxide-based sensor doped for nitrogen oxide (NOx) sensitivity, a SiC-based hydrocarbon (CxHy) sensor, and an oxygen sensor (O2). These sensors operate on different principles--resistor, diode, and electrochemical cell, respectively--and each sensor has very different responses to the individual gases in the environment. A picture showing the sensor head for the array is shown in the photograph on the left and the sensors installed in the engine are shown in the photograph on the right. Electronics are interfaced with the sensors for temperature control and signal conditioning, and packaging designed for high temperatures is necessary for the array to survive the engine environment.

Description: The Structural Mechanics and Dynamics Branch has successfully demonstrated a fail-safe controller for the Fault-Tolerant Magnetic Bearing rig at the NASA Glenn Research Center. The rotor is supported by two 8-pole redundant radial bearings, and coil failing situations are simulated by manually shutting down their control current commands from the controller cockpit. The effectiveness of the controller was demonstrated when only two active coils from each radial bearing could be used (that is, 14 coils failed). These remaining two coils still levitated the rotor and spun it without losing stability or desired position up to the maximum allowable speed of 20,000 rpm.

Description: Various disturbances that are synchronous with the shaft speed can complicate radial magnetic bearing control. These include position sensor target irregularities (runout) and shaft imbalance. The method presented here allows the controller to ignore all synchronous harmonics of the shaft position input (within the closed-loop bandwidth) and to respond only to asynchronous motions. The result is reduced control effort.

Description: A magnetic-bearing-supported shaft may have a number of concentricity and alignment problems. One of these involves the relationship of the position sensors, the centerline of the backup bearings, and the magnetic center of the magnetic bearings. For magnetic bearings with permanent magnet biasing, the average control current for a given control axis that is not bearing the shaft weight will be minimized if the shaft is centered, on average over a revolution, at the magnetic center of the bearings. That position may not yield zero sensor output or center the shaft in the backup bearing clearance. The desired shaft position that gives zero average current can be achieved if a simple additional term is added to the control law. Suppose that the instantaneous control currents from each bearing are available from measurements and can be input into the control computer. If each control current is integrated with a very small rate of accumulation and the result is added to the control output, the shaft will gradually move to a position where the control current averages to zero over many revolutions. This will occur regardless of any offsets of the position sensor inputs. At that position, the average control effort is minimized in comparison to other possible locations of the shaft. Nonlinearities of the magnetic bearing are minimized at that location as well.

Description: For magnetic-bearing-supported high-speed machines with significant gyroscopic effects, it is necessary to stabilize both forward and backward tilt whirling modes. Instability or the low damping of these modes can prevent the attainment of desired shaft speeds. Previous work elsewhere showed that cross-axis derivative gain in the magnetic bearing control law can improve the stability of the forward whirl mode, but it is commonly recognized that derivative gains amplify high-frequency noise and increase the required control effort. At the NASA Glenn Research Center, it has been shown previously that a simple cross-axis proportional gain can add stability (without adding noise) to either forward whirl or backward whirl, depending on the sign of the gain, but that such a gain destabilizes the other mode. It has been predicted by Glenn analysis that both modes can be stabilized by cross-axis proportional gains by utilizing the large-frequency separation of the two modes at speeds where the gyroscopic effects are significant. We use a modal controller that decouples the tilt and center-of-mass-translation modes. Only the tilt modes exhibit speed-dependent gyroscopic effects. The key to controlling them by the present method is to stabilize the backward whirl tilt mode with the appropriate sign of cross-axis proportional gain in the control law, but to include a low-pass filter on that gain term to restrict its effect only to the low-frequency backward-whirl mode. A second cross-axis term with the opposite sign and a high-pass filter stabilizes the forward whirl, which can have a frequency one or two orders of magnitude higher than the backward whirl, permitting very independent action of the two terms. Because the physical gyroscopic torques are proportional to the spinning speed of the shaft, it is convenient to gain-schedule the cross-axis control terms by making them proportional to shaft speed. This has the added benefit of avoiding a somewhat awkward zero-speed splitting of the tilt-mode eigenvalues.

Description: Wall thinning due to corrosion in utility boiler water wall tubing is a significant operational concern for boiler operators. Historically, conventional ultrasonics has been used for inspection of these tubes. Unfortunately, ultrasonic inspection is very manpower intense and slow. Therefore, thickness measurements are typically taken over a relatively small percentage of the total boiler wall and statistical analysis is used to determine the overall condition of the boiler tubing. Other inspection techniques, such as electromagnetic acoustic transducer (EMAT), have recently been evaluated, however they provide only a qualitative evaluation - identifying areas or spots where corrosion has significantly reduced the wall thickness. NASA Langley Research Center, in cooperation with ThermTech Services, has developed a thermal NDE technique designed to quantitatively measure the wall thickness and thus determine the amount of material thinning present in steel boiler tubing. The technique involves the movement of a thermal line source across the outer surface of the tubing followed by an infrared imager at a fixed distance behind the line source. Quantitative images of the material loss due to corrosion are reconstructed from measurements of the induced surface temperature variations. This paper will present a discussion of the development of the thermal imaging system as well as the techniques used to reconstruct images of flaws. The application of the thermal line source coupled with the analysis technique represents a significant improvement in the inspection speed and accuracy for large structures such as boiler water walls. A theoretical basis for the technique will be presented to establish the quantitative nature of the technique. Further, a dynamic calibration system will be presented for the technique that allows the extraction of thickness information from the temperature data. Additionally, the results of the application of this technology to actual water wall tubing samples and in-situ inspections will be presented.

Description: The mixed-mode bending (MMB) test for delamination toughness was first introduced in 1988. This simple test is a combination of the standard Mode I (opening) test and a Mode II (sliding) test. This MMB test has become widely used in the United States and around the world for mixed-mode toughness measurements. Because of the widespread use of this test method, it is being considered for standardization by ASTM Committee D30. This paper discusses several improvements to the original test method. The improvements to the MMB test procedure include an improved method for calculating toughness from the measured test quantities, a more accurate way of setting the mixed-mode ratio to be tested, and the inclusion of a new alignment criterion for improved consistency in measured values.

Description: Thermal and environmental barrier coatings (T/EBCs) will play a crucial role in advanced gas turbine engine systems because of their ability to significantly increase engine operating temperatures and reduce cooling requirements, and thus help achieve engine goals of low emissions and high efficiency. Under the NASA Ultra-Efficient Engine Technology (UEET) Project, advanced T/EBCs are being developed for low-emission SiC/SiC ceramic matrix composite (CMC) combustor applications by extending the CMC liner and vane temperature capability to 1650 C (3000 F) in oxidizing and water-vaporcontaining combustion environments. The coating system is required to have increased phase stability, lower lattice and radiation thermal conductivity, and improved sintering and thermal stress resistance under high-heat-flux and thermal-cycling engine conditions. Advanced heat-flux testing approaches (refs. 1 to 4) have been established at the NASA Glenn Research Center for 1650 C coating developments. The simulated combustion water-vapor environment is also being incorporated into the heat-flux test capabilities (ref. 3).

Description: Classical design methods involved in magnetic bearings and magnetic suspension systems have always had their limitations. Because of this, the overall effectiveness of a design has always relied heavily on the skill and experience of the individual designer. This paper combines two approaches that have been developed to aid the accuracy and efficiency of magnetostatic design. The first approach integrates classical magnetic circuit theory with modern optimization theory to increase design efficiency. The second approach uses loss factors to increase the accuracy of classical magnetic circuit theory. As an example, an axial magnetic thrust bearing is designed for minimum power.

Description: Active stall control is a current research area at the NASA Glenn Research Center that offers a great benefit in specific fuel consumption by allowing the gas turbine to operate beyond the onset of stall. Magnetic bearings are being investigated as a new method to perform active stall control. This enabling global aviation safety technology would result in improved fuel efficiency and decreased carbon dioxide emissions, as well as improve safety and reliability by eliminating oil-related delays and failures of engine components, which account for 40 percent of the commercial aircraft departure delays. Active stall control works by perturbing the flow in front of the compressor stage such that it cancels the pressure wave, which causes the compressor to go into stall. Radial magnetic bearings are able to whirl the shaft so that variations in blade tip leakage would flow upstream causing a perturbation wave that could cancel the rotating stall cell. Axial or thrust magnetic bearings cannot be used to cancel the surge mode in the compressor because they have a very low bandwidth and thus cannot modulate at a high enough frequency. Frequency response is limited because the thrust runner cannot be laminated. To improve the bandwidth of magnetic thrust bearings, researchers must use laminations to suppress the eddy currents. A conical magnetic bearing can be laminated, resulting in increased bandwidth in the axial direction. In addition, this design can produce both radial and thrust force in a single bearing, simplifying the installation. The proposed solution combines the radial and thrust bearing into one design that can be laminated--a conical magnetic bearing. The new conical magnetic bearing test rig, funded by a Glenn fiscal year 2002 Director's Discretionary Fund, was needed because none of the existing rigs has an axial degree of freedom. The rotor bearing configuration will simulate that of the main shaft on a gas turbine engine. One conical magnetic bearing replaces the ball bearing in front of the compressor, and the second replaces the roller bearing behind the burner. The rig was made operational to 10,000 rpm under Smart Efficient Components funding, and both position and current adaptive vibration control have been demonstrated. Upon program completion, recommendations will be made as to the efficacy of the conical magnetic bearing for active stall control.

Description: The Dynamic Spin Rig Facility at the NASA Glenn Research Center is used to determine the structural response of rotating engine components without the effects of aerodynamic loading. Recently, this rig's capabilities were enhanced through the replacement of grease-lubricated ball bearings with magnetic bearings. Magnetic bearings offer a number of advantages--the most important here being that they not only fully support the rotor system, but excite it as well. Three magnetic bearings support the rotor and provide five axes of controlled motion: an x- and y-axis translation at each of two radial bearings and a z-axis translation in the vertical or axial direction. Sinusoidal excitation (most commonly used) can be imparted on the rotor through the radial magnetic bearings in either a fixed or rotating frame of reference. This excitation is added directly to the magnetic bearing control output. Since the rotor is fully levitated, large translations and rotations of the rotor system can be achieved. Some of the capabilities of this excitation system were determined and reported. The accelerations obtained at the tip of a titanium flat plate test article versus the swept sine excitation sent to both radial bearings in phase and perpendicular to the plane containing the two blades are shown. Recent tests required the excitation of fundamental bending and torsional blade resonances at rotor speeds up to 10,000 rpm. Successful fixed synchronous rotation of the excitation signal provided the best detectable blade resonant vibrations at excitation frequencies up to 1100 Hz for the particular blades of interest. A noncontacting laser measurement system was used to collect blade-tip motions. From these data, the amplitude and frequency of the motion could be determined as well as the blade damping properties. Damping could be determined using two methods: (1) free decay and (2) curve fitting the vibration amplitude as a function of frequency in and around the resonance of interest and using the half-power method. The free decay of a composite blade vibrating at its first bending resonance while rotating at 3000 rp is shown. This new system is currently being used to support the Efficient Low-Noise Fan project at Glenn. The damping properties of prototype hollow composite blades specially designed to reduce fan noise are currently being determined.

Description: High-speed and heavily loaded gearing are commonplace in the rotorcraft systems employed in helicopter and tiltrotor transmissions. The components are expected to deliver high power from the gas turbine engines to the high-torque, low-speed rotor, reducing the shaft rotational speed in the range of 25:1 to 100:1. These components are designed for high power-to-weight ratios, thus the components are fabricated as light as possible with the best materials and processing to transmit the required torque and carry the resultant loads without compromising the reliability of the drive system. This is a difficult task that is meticulously analyzed and thoroughly tested experimentally prior to being applied on a new or redesigned aircraft.

Description: NASA and Pratt & Whitney will collaborate under a Space Act Agreement to perform spin testing of the impact damper to verify damping effectiveness and durability. Pratt & Whitney will provide the turbine blade and damper hardware for the tests. NASA will provide the facility and perform the tests. Effectiveness and durability will be investigated during and after sustained sweeps of rotor speed through resonance. Tests of a platform wedge damper are also planned to compare its effectiveness with that of the impact damper. Results from baseline tests without dampers will be used to measure damping effectiveness. The self-tuning impact damper combines two damping methods-the tuned mass damper and the impact damper. It consists of a ball located within a cavity in the blade. This ball rolls back and forth on a spherical trough under centrifugal load (tuned mass damper) and can strike the walls of the cavity (impact damper). The ball s rolling natural frequency is proportional to the rotor speed and can be designed to follow an engine-order line (integer multiple of rotor speed). Aerodynamic forcing frequencies typically follow these engineorder lines, and a damper tuned to the engine order will most effectively reduce blade vibrations when the resonant frequency equals the engine-order forcing frequency. This damper has been tested in flat plates and turbine blades in the Dynamic Spin Facility. During testing, a pair of plates or blades rotates in vacuum. Excitation is provided by one of three methods--eddy-current engine-order excitation (ECE), electromechanical shakers, and magnetic bearing excitation. The eddy-current system consists of magnets located circumferentially around the rotor. As a blade passes a magnet, a force is imparted on the blade. The number of magnets used can be varied to change the desired engine order of the excitation. The magnets are remotely raised or lowered to change the magnitude of the force on the blades. The other two methods apply force to the rotating shaft itself at frequencies independent of the rotor speed. During testing, blade vibration is monitored with strain gauges and laser displacement probes.

Description: Researchers at the NASA Glenn Research Center have developed a new air-mass-flow sensor to solve the problems of existing mass flow sensor designs. NASA's design consists of thin-film resistors in a Wheatstone bridge arrangement. The resistors are fabricated on a thin, constant-thickness airfoil to minimize disturbance to the airflow being measured. The following photograph shows one of NASA s prototype sensors. In comparison to other air-mass-flow sensor designs, NASA s thin-film sensor is much more robust than hot wires, causes less airflow disturbance than pitot tubes, is more accurate than vane anemometers, and is much simpler to operate than thermocouple rakes. NASA s thin-film air-mass-flow sensor works by converting the temperature difference seen at each leg of the thin-film Wheatstone bridge into a mass-flow rate. The following figure shows a schematic of this sensor with air flowing around it. The sensor operates as follows: current is applied to the bridge, which increases its temperature. If there is no flow, all the arms are heated equally, the bridge remains in balance, and there is no signal. If there is flow, the air passing over the upstream legs of the bridge reduces the temperature of the upstream legs and that leads to reduced electrical resistance for those legs. After the air has picked up heat from the upstream legs, it continues and passes over the downstream legs of the bridge. The heated air raises the temperature of these legs, increasing their electrical resistance. The resistance difference between the upstream and downstream legs unbalances the bridge, causing a voltage difference that can be amplified and calibrated to the airflow rate. Separate sensors mounted on the airfoil measure the temperature of the airflow, which is used to complete the calculation for the mass of air passing by the sensor. A current application for air-mass-flow sensors is as part of the intake system for an internal combustion engine. A mass-flow sensor is used to provide accurate information about the amount of air entering the engine so that the amount of fuel can be adjusted to give the most efficient combustion. The ideal mass-flow sensor would be a rugged design that minimizes the disturbance to the flow stream and provides an accurate reading of both smooth and turbulent flows; NASA's design satisfies these requirements better than any existing design. Most of the mass-flow sensors used today are the hot wire variety. Hot wires can be fragile and cannot accurately measure a turbulent or reversing flow, which is often encountered in an intake manifold. Other types of mass-flow sensors include pitot tubes, vane anemometers, and thermocouple rakes-all of which suffer from some type of performance problem. Because it solves these performance problems while maintaining a simple design that lends itself to low-cost manufacturing techniques, NASA s thin-film resistance temperature detector air-mass-flow sensor should lead to more widespread use of mass-flow sensors.

Description: The Department of Energy, the Stirling Technology Company (STC), and the NASA Glenn Research Center are developing Stirling convertors for Stirling radioisotope generators to provide electrical power for future NASA deep space missions. STC is developing the 55-We technology demonstration convertor (TDC) under contract to the Department of Energy. The Department of Energy recently named Lockheed Martin as the system integration contractor for the Stirling radioisotope generator development project. Lockheed Martin will develop the Stirling radioisotope generator engineering unit and has contract options to develop the qualification unit and the first flight unit. Glenn s role includes an in-house project to provide convertor, component, and materials testing and evaluation in support of the overall power system development. As a part of this work, Glenn has established an in-house Stirling research laboratory for testing, analyzing, and evaluating Stirling machines. STC has built four 55-We convertors for NASA, and these are being tested at Glenn. A cross-sectional view of the 55-We TDC is shown in the figure. Of critical importance to the successful development of the Stirling convertor for space power applications is the development of a lightweight and highly efficient linear alternator. In support, Glenn has been developing finite element analysis and finite element method tools for performing various linear alternator thermal and electromagnetic analyses and evaluating design configurations. A three-dimensional magnetostatic finite element model of STC's 55-We TDC linear alternator was developed to evaluate the demagnetization fields affecting the alternator magnets. Since the actual linear alternator hardware is symmetric to the quarter section about the axis of motion, only a quarter section of the alternator was modeled. The components modeled included the mover laminations, the neodymium-iron-boron magnets, the stator laminations, and the copper coils. The three-dimensional magnetostatic model was then coupled with a circuit simulator model of the alternator load and convertor controller. The coupled model was then used to generate alternator terminal voltage and current predictions. The predicted voltage and current waveforms agreed well with the experimental data, which tended to validate the accuracy of the coupled model. The model was then used to generate predictions of the demagnetization fields acting on the alternator magnets for the alternator under load. The preliminary model predictions indicate that the highest potential for demagnetization is along the inside surface of the uncovered magnets. The demagnetization field for the uncovered magnets when the mover is positioned at the end of a stroke is higher than it is when the mover is at the position of maximum induced voltage or maximum alternator current. Assuming normal load conditions, the model predicted that the onset of demagnetization is most likely to occur for magnet temperatures above 101 C.

Description: Polymer matrix composites (PMCs) are increasingly used in aerospace and automotive applications because of their light weight and high strength-to-weight ratio relative to metals. However, a major drawback of PMCs is poor abrasion resistance, which restricts their use, especially at high temperatures. Simply applying a hard coating on PMCs to improve abrasion and erosion resistance is not effective since coating durability is short lived (ref. 1). Generally, PMCs have higher coefficients of thermal expansion than metallic or ceramic coatings have, and coating adhesion suffers because of poor interfacial adhesion strength. One technique commonly used to improve coating adhesion or durability is the use of bond coats that are interleaved between a coating and a substrate with vastly different coefficients of thermal expansion. An example of this remedy is the use of bondcoats for ceramic thermal barrier coatings on metallic turbine components (ref. 2). Prior collaborative research between the NASA Glenn Research Center and the Allison Advanced Development Company (AADC) demonstrated that bond coats sandwiched between PMCs and high-quality plasma-sprayed, erosion-resistant coatings substantially improved the erosion resistance of PMCs (ref. 3). One unresolved problem in this earlier collaboration was that there was no easy, accurate way to measure the coating erosion wear scar. Coating wear was determined by both profilometry and optical microscopy. Both techniques are time consuming. Wear measurement by optical microscopy requires sample destruction and does not provide a comprehensive measure of the entire wear volume. An even more subtle, yet critical, problem is that these erosion coatings contain two or more materials with different densities. Therefore, simply measuring specimen mass loss before and after erosion will not provide an accurate gauge for coating and/or substrate volume loss. By using a noncontact technique called scanning optical interferometry, which was recently developed at Glenn, researchers can accurately determine the wear performance of erosion-coated PMCs while preserving the sample. An example of this interferometry technique is shown in the preceding figure for an erosion-coated inlet guide vane from a Rolls Royce AE3007 regional gas turbine jet engine. Erosion was conducted with coated and uncoated PMC vanes, with the abrasive material moving at a velocity of 229 m/s at impingement angles of 20 and 90 degrees. The coatings for PMCs remarkably reduced the erosion volume loss by a factor of approximately 10. Currently, several erosion coatings for PMCs are being compared and downselected for engine testing at Rolls Royce.

Description: A system directly measuring the transmission error between the meshing spur or helical gears was installed at the NASA Glenn Research Center and made operational in August 2001. This system employs light beams directed by lenses and prisms through gratings mounted on the two gear shafts. The amount of light that passes through both gratings is directly proportional to the transmission error of the gears. The device is capable of resolution better than 0.1 mm (one thousandth the thickness of a human hair). The measured transmission error can be displayed in a "map" that shows how the transmission error varies with the gear rotation or it can be converted to spectra to show the components at the meshing frequencies. Accurate transmission error data will help researchers better understand the mechanisms that cause gear noise and vibration and will lead to The Design Unit at the University of Newcastle in England specifically designed the new system for NASA. It is the only device in the United States that can measure dynamic transmission error at high rotational speeds. The new system will be used to develop new techniques to reduce dynamic transmission error along with the resulting noise and vibration of aeronautical transmissions.

Description: The Structural Mechanics and Dynamics Branch at the NASA Glenn Research Center has developed a three-axis high-temperature magnetic bearing suspension rig to enhance the safety of the bearing system up to 1000 F. This test rig can accommodate thrust and radial bearings up to a 22.84 cm (9 in.) diameter with a maximum axial loading of 22.25 kN (5000 lb) and a maximum radial loading up to 4.45 kN (1000 lb). The test facility was set up to test magnetic bearings under high-temperature (1100 F) and high-speed (20,000 rpm) conditions. The magnetic bearing is located at the center of gravity of the rotor between two high-temperature grease-packed mechanical ball bearings. The drive-end duplex angular contact ball bearing, which is in full contact, acts as a moment release and provides axial stability. The outboard end ball bearing has a 0.015-in. radial clearance between the rotor to act as a backup bearing and to compensate for axial thermal expansion. There is a 0.020-in. radial air gap between the stator pole and the rotor. The stator was wrapped with three 1-kW band heaters to create a localized hot section; the mechanical ball bearings were outside this section. Eight threaded rods supported the stator. These incorporated a plunger and Bellville washers to compensate for radial thermal expansion and provide rotor-to-stator alignment. The stator was instrumented with thermocouples and a current sensor for each coil. Eight air-cooled position sensors were mounted outside the hot section to monitor the rotor. Another sensor monitored this rotation of the outboard backup bearing. Ground fault circuit interrupts were incorporated into all power amplifier loops for personnel safety. All instrumentation was monitored and recorded on a LabView-based data acquisition system. Currently, this 12-pole heteropolar magnetic bearing has 13 thermal cycles and over 26 hr of operation at 1000 F.

Description: The Oil-Free Turbine Engine Technology Project team successfully demonstrated a foil-air bearing designed for the core rotor shaft of a turbine engine. The bearings were subjected to test conditions representative of the engine core environment through a combination of high speeds, sustained loads, and elevated temperatures. The operational test envelope was defined during conceptual design studies completed earlier this year by bearing manufacturer Mohawk Innovative Technologies and the turbine engine company Williams International. The prototype journal foil-air bearings were tested at the NASA Glenn Research Center. Glenn is working with Williams and Mohawk to create a revolution in turbomachinery by developing the world's first Oil-Free turbine aircraft engine. NASA's General Aviation Propulsion project and Williams International recently developed the FJX-2 turbofan engine that is being commercialized as the EJ-22. This core bearing milestone is a first step toward a future version of the EJ-22 that will take advantage of recent advances in foil-air bearings by eliminating the need for oil lubrication systems and rolling element bearings. Oil-Free technology can reduce engine weight by 15 percent and let engines operate at very high speeds, yielding power density improvements of 20 percent, and reducing engine maintenance costs. In addition, with NASA coating technology, engines can operate at temperatures up to 1200 F. Although the project is still a couple of years from a full engine test of the bearings, this milestone shows that the bearing design exceeds the expected environment, thus providing confidence that an Oil-Free turbine aircraft engine will be attained. The Oil-Free Turbomachinery Project is supported through the Aeropropulsion Base Research Program.

Description: General Aviation will benefit from turbine engines that are both fuel-efficient and reliable. Current engines fall short of their potential to achieve these attributes. The reason is compressor surge, which is a flow stability problem that develops when the compressor is subjected to conditions that are outside of its operating range. Compressor surge can occur when fuel flow to the engine is increased, temporarily back pressuring the compressor and pushing it past its stability limit, or when the compressor is subjected to inlet flow-field distortions that may occur during takeoff and landing. Compressor surge can result in the loss of an aircraft. As a result, engine designers include a margin of safety between the operating line of the engine and the stability limit line of the compressor. Unfortunately, the most efficient operating line for the compressor is usually closer to its stability limit line than it is to the line that provides an adequate margin of safety. A wider stable flow range will permit operation along the most efficient operating line of the compressor, improving the specific fuel consumption of the engine and reducing emissions. The NASA Glenn Research Center is working to extend the stable flow range of the compressor. Significant extension has been achieved in axial compressors by injecting air upstream of the compressor blade rows. Recently, the technique was successfully applied to a 4:1 pressure ratio centrifugal compressor by injecting streams of air into the diffuser. Both steady and controlled unsteady injection were used to inject air through the diffuser shroud surface and extend the range. Future work will evaluate the effect of air injection through the diffuser hub surface and diffuser vanes with the goal of maximizing the range extension while minimizing the amount of injected air that is required.

Description: Sensor indications during rocket engine operation are the primary means of assessing engine performance and health. Effective selection and location of sensors in the operating engine environment enables accurate real-time condition monitoring and rapid engine controller response to mitigate critical fault conditions. These capabilities are crucial to ensure crew safety and mission success. Effective sensor selection also facilitates postflight condition assessment, which contributes to efficient engine maintenance and reduced operating costs. Under the Next Generation Launch Technology program, the NASA Glenn Research Center, in partnership with Rocketdyne Propulsion and Power, has developed a model-based procedure for systematically selecting an optimal sensor suite for assessing rocket engine system health. This optimization process is termed the systematic sensor selection strategy. Engine health management (EHM) systems generally employ multiple diagnostic procedures including data validation, anomaly detection, fault-isolation, and information fusion. The effectiveness of each diagnostic component is affected by the quality, availability, and compatibility of sensor data. Therefore systematic sensor selection is an enabling technology for EHM. Information in three categories is required by the systematic sensor selection strategy. The first category consists of targeted engine fault information; including the description and estimated risk-reduction factor for each identified fault. Risk-reduction factors are used to define and rank the potential merit of timely fault diagnoses. The second category is composed of candidate sensor information; including type, location, and estimated variance in normal operation. The final category includes the definition of fault scenarios characteristic of each targeted engine fault. These scenarios are defined in terms of engine model hardware parameters. Values of these parameters define engine simulations that generate expected sensor values for targeted fault scenarios. Taken together, this information provides an efficient condensation of the engineering experience and engine flow physics needed for sensor selection. The systematic sensor selection strategy is composed of three primary algorithms. The core of the selection process is a genetic algorithm that iteratively improves a defined quality measure of selected sensor suites. A merit algorithm is employed to compute the quality measure for each test sensor suite presented by the selection process. The quality measure is based on the fidelity of fault detection and the level of fault source discrimination provided by the test sensor suite. An inverse engine model, whose function is to derive hardware performance parameters from sensor data, is an integral part of the merit algorithm. The final component is a statistical evaluation algorithm that characterizes the impact of interference effects, such as control-induced sensor variation and sensor noise, on the probability of fault detection and isolation for optimal and near-optimal sensor suites.

Description: A high-efficiency Stirling Radioisotope Generator (SRG) for use on potential NASA Space Science missions is being developed by the Department of Energy, Lockheed Martin, Stirling Technology Company, and the NASA Glenn Research Center. These missions may include providing spacecraft onboard electric power for deep space missions or power for unmanned Mars rovers. Glenn is also developing advanced technology for Stirling convertors, aimed at substantially improving the specific power and efficiency of the convertor and the overall power system. Performance and mass improvement goals have been established for second- and third-generation Stirling radioisotope power systems. Multiple efforts are underway to achieve these goals, both in house at Glenn and under various grants and contracts. These efforts include the development of a multidimensional Stirling computational fluid dynamics code, high-temperature materials, advanced controllers, an end-to-end system dynamics model, low-vibration techniques, advanced regenerators, and a lightweight convertor. Under a NASA grant, Cleveland State University (CSU) and its subcontractors, the University of Minnesota (UMN) and Gedeon Associates, have developed a twodimensional computer simulation of a CSUmod Stirling convertor. The CFD-ACE commercial software developed by CFD Research Corp. of Huntsville, Alabama, is being used. The CSUmod is a scaled version of the Stirling Technology Demonstrator Convertor (TDC), which was designed and fabricated by the Stirling Technology Company and is being tested by NASA. The schematic illustrates the structure of this model. Modeled are the fluid-flow and heat-transfer phenomena that occur in the expansion space, the heater, the regenerator, the cooler, the compression space, the surrounding walls, and the moving piston and displacer. In addition, the overall heat transfer, the indicated power, and the efficiency can be calculated. The CSUmod model is being converted to a two-dimensional model of the TDC at NASA Glenn. Validation of the multidimensional Stirling code is an important part of the grant effort. UMN has been generating data in an oscillating-flow test facility using two different test sections: a 90 turn and a cooler/regenerator/heater test section. CSU has created computational fluid dynamics models of both these test sections and has been making comparisons with the data, then improving their models to improve the agreement with the test data. CSU has also been using data available in the literature for code validation. UMN is now preparing to begin fabrication of a new 180 turn test section that will be more representative of certain portions of the Stirling engine geometry. Simulations to almost periodic steady state with the two-dimensional CSUmod model indicate that, to reach periodic steady state on a single 2-GHz desktop computer, 75 to 100 complete simulation cycles would be required and between 1 and 2 months of computer time. Therefore, Glenn has purchased the first 8 computers, of a 64-computer cluster, to be run in parallel to accelerate the simulation. On the basis of CFD Research Corp.'s experience with running the parallelized version of CFD-ACE on their clusters, we estimate that the complete 64-computer cluster will reduce simulation computing time by a factor of about 40. Plans are to continue development of these multidimensional Stirling codes and to use them to study the fluid-flow and heat-transfer phenomena that occur inside Stirling convertors. This is expected to lead to improved thermodynamic loss understanding, onedimensional design and performance codes, and engine performance.

Description: The insulating properties of thermal barrier coatings (TBCs) provide highly beneficial thermal protection to turbine engine components by reducing the temperature sustained by those components. Therefore, measuring the temperature beneath the TBC is critical for determining whether the TBC is performing its insulating function. Currently, noncontact temperature measurements are performed by infrared pyrometry, which unfortunately measures the TBC surface temperature rather than the temperature of the underlying component. To remedy this problem, the NASA Glenn Research Center, under the Information Rich Test Instrumentation Project, developed a technique to measure the temperature beneath the TBC by incorporating a thin phosphor layer beneath the TBC. By performing fluorescence decay-time measurements on light emission from this phosphor layer, Glenn successfully measured temperatures from the phosphor layer up to 1100 C. This is the first successful demonstration of temperature measurements that penetrate beneath the TBC. Thermographic phosphors have a history of providing noncontact surface temperature measurements. Conventionally, a thermographic phosphor is applied to the material surface and temperature measurements are performed by exciting the phosphor with ultraviolet light and then measuring the temperature-dependent decay time of the phosphor emission at a longer wavelength. The innovative feature of the new approach is to take advantage of the relative transparency of the TBC (composed of yttria-stabilized zirconia) in order to excite and measure the phosphor emission beneath the TBC. The primary obstacle to achieving depth-penetrating temperature measurements is that the TBCs are completely opaque to the ultraviolet light usually employed to excite the phosphor. The strategy that Glenn pursued was to select a thermographic phosphor that could be excited and emit at wavelengths that could be transmitted through the TBC. The phosphor that was selected was yttria doped with europia (Y2O3:Eu), which has a minor excitation peak at 532 nm (green) and an emission peak at 611 nm (red)--both are wavelengths that exhibit significant transmission through the TBC. The measurements were performed on specimens consisting of a 25- m-thick phosphor layer beneath a 100- m-thick TBC. The 532-nm (green) excitation light was provided by a frequency-doubled YAG:Nd (yttrium-aluminum-garnet:neodymium) laser, and the fluorescence decay time measurements were acquired with a modified Raman microscope. The preceding graph compares the intensity of the phosphor emission of the phosphor layer above the TBC versus that of the phosphor layer beneath the TBC. Although there was considerable attenuation of the phosphor signal (a factor of 30), the phosphor emission at the reduced intensity was more than sufficient to perform fluorescence decay time measurements. The following graph shows the fluorescence lifetime temperature dependency for the Y2O3:Eu phosphor layers both above and below the TBC. These curves show an excellent match and indicate that, despite the attenuation due to the overlying TBC, the phosphor layer beneath the TBC still functions as an effective temperature indicator.

Description: The High Resolution Airborne Wideband Camera (HAWC) and the Submillimeter And Far Infrared Experiment (SAFIRE) will use identical Adiabatic Demagnetization Refrigerators (ADR) to cool their bolometer detectors to 200mK and 100mK, respectively. In order to minimize thermal loads on the salt pill, a Kevlar@ suspension system is used to hold it in place. An innovative, kinematic suspension system is presented. The suspension system is unique in that it consists or two parts that can be assembled and tensioned offline, and later bolted onto the salt pill. The resulting assembly constrains each degree of freedom only once, yielding a kinematic, tensile structure.

Description: Forgings of nickel base superalloy were formed under several different strain rates and forging temperatures. Samples were taken from each forging condition to find the ASTM grain size, and the as large as grain (ALA). The specimens were mounted in bakelite, polished, etched and then optical microscopy was used to determine grain size. The specimens ASTM grain sizes from each forging condition were plotted against strain rate, forging temperature, and presoak time. Grain sizes increased with increasing forging temperature. Grain sizes also increased with decreasing strain rates and increasing forging presoak time. The ALA had been determined from each forging condition using the ASTM standard method. Each ALA was compared with the ASTM grain size of each forging condition to determine if the grain sizes were uniform or not. The forging condition of a strain rate of .03/sec and supersolvus heat treatment produced non uniform grains indicated by critical grain growth. Other anomalies are noted as well.

Description: To be competitive on the today's market, cars have to be as light as possible while meeting the Noise, Vibration, and Harshness (NVH) requirements and conforming to Government-man dated crash survival regulations. The latter are difficult to meet because they involve very compute-intensive, nonlinear analysis, e.g., the code RADIOSS capable of simulation of the dynamics, and the geometrical and material nonlinearities of a thin-walled car structure in crash, would require over 12 days of elapsed time for a single design of a 390K elastic degrees of freedom model, if executed on a single processor of the state-of-the-art SGI Origin2000 computer. Of course, in optimization that crash analysis would have to be invoked many times. Needless to say, that has rendered such optimization intractable until now. The car finite element model is shown. The advent of computers that comprise large numbers of concurrently operating processors has created a new environment wherein the above optimization, and other engineering problems heretofore regarded as intractable may be solved. The procedure, shown, is a piecewise approximation based method and involves using a sensitivity based Taylor series approximation model for NVH and a polynomial response surface model for Crash. In that method the NVH constraints are evaluated using a finite element code (MSC/NASTRAN) that yields the constraint values and their derivatives with respect to design variables. The crash constraints are evaluated using the explicit code RADIOSS on the Origin 2000 operating on 256 processors simultaneously to generate data for a polynomial response surface in the design variable domain. The NVH constraints and their derivatives combined with the response surface for the crash constraints form an approximation to the system analysis (surrogate analysis) that enables a cycle of multidisciplinary optimization within move limits. In the inner loop, the NVH sensitivities are recomputed to update the NVH approximation model while keeping the Crash response surface constant. In every outer loop, the Crash response surface approximation is updated, including a gradual increase in the order of the response surface and the response surface extension in the direction of the search. In this optimization task, the NVH discipline has 30 design variables while the crash discipline has 20 design variables. A subset of these design variables (10) are common to both the NVH and crash disciplines. In order to construct a linear response surface for the Crash discipline constraints, a minimum of 21 design points would have to be analyzed using the RADIOSS code. On a single processor in Origin 2000 that amount of computing would require over 9 months! In this work, these runs were carried out concurrently on the Origin 2000 using multiple processors, ranging from 8 to 16, for each crash (RADIOSS) analysis. Another figure shows the wall time required for a single RADIOSS analysis using varying number of processors, as well as provides a comparison of 2 different common data placement procedures within the allotted memories for each analysis. The initial design is an infeasible design with NVH discipline Static Torsion constraint violations of over 10%. The final optimized design is a feasible design with a weight reduction of 15 kg compared to the initial design. This work demonstrates how advanced methodology for optimization combined with the technology of concurrent processing enables applications that until now were out of reach because of very long time-to-solution.

Description: The primary objective of this research is to support the design of liquid rocket systems for the Advanced Space Transportation System. Since the space launch systems in the near future are likely to rely on liquid rocket engines, increasing the efficiency and reliability of the engine components is an important task. One of the major problems in the liquid rocket engine is to understand fluid dynamics of fuel and oxidizer flows from the fuel tank to plume. Understanding the flow through the entire turbopump geometry through numerical simulation will be of significant value toward design. This will help to improve safety of future space missions. One of the milestones of this effort is to develop, apply and demonstrate the capability and accuracy of 3D CFD methods as efficient design analysis tools on high performance computer platforms. The development of the MPI and MLP versions of the INS3D code is currently underway. The serial version of INS3D code is a multidimensional incompressible Navier-Stokes solver based on overset grid technology. INS3D-MPI is based on the explicit massage-passing interface across processors and is primarily suited for distributed memory systems. INS3D-MLP is based on multi-level parallel method and is suitable for distributed-shared memory systems. For the entire turbopump simulations, moving boundary capability and an efficient time-accurate integration methods are build in the flow solver. To handle the geometric complexity and moving boundary problems, overset grid scheme is incorporated with the solver that new connectivity data will be obtained at each time step. The Chimera overlapped grid scheme allows subdomains move relative to each other, and provides a great flexibility when the boundary movement creates large displacements. The performance of the two time integration schemes for time-accurate computations is investigated. For an unsteady flow which requires small physical time step, the pressure projection method was found to be computationally efficient since it does not require any subiterations procedure. It was observed that the artificial compressibility method requires a fast convergence scheme at each physical time step in order to satisfy incompressibility condition. This was obtained by using a GMRES-ILU(0) solver in our computations. When a line-relaxation scheme was used, the time accuracy was degraded and time-accurate computations became very expensive. The current geometry for the LOX boost turbopump has various rotating and stationary components, such as inducer, stators, kicker, hydrolic turbine, where the flow is extremely unsteady. Figure 1 shows the geometry and computed surface pressure of the inducer. The inducer and the hydrolic turbine rotate in different rotational speed.

Description: This viewgraph presentation provides information on an experiment. Its objective is to experimentally determine unshrouded impeller performance sensitivity to tip clearance. The experiment included: Determining impeller efficiency at scaled operating conditions in water at MSFC's Pump Test Equipment (PTE) Facility; Testing unshrouded impeller at three different tip clearances; Testing each tip clearance configuration at on- and off-design conditions, and collecting unsteady- and steady-state data in each configuration; Determining impeller efficiency directly using drive line torquemeter and pump inlet and exit total pressure measurements.

Description: The application of active flow control technology to enhance turbomachinery system performance is being investigated at the NASA Glenn Research Center through experimental studies. Active flow control involves the use of sensors and actuators embedded within engine components to dynamically alter the internal flow path during off nominal operation in order to optimize engine performance and maintain stable operation. Modern compressors are already highly optimized components that must be designed to accommodate a broad range of operating conditions in a safe and efficient manner. Since overall engine performance is driven by compressor performance, advances in compressor technology that reduce weight and parts count, reduce fuel consumption, and lower maintenance costs will have a significant impact on the cost of aircraft ownership. Active flow control holds the promise of delivering such technology advances.

Description: Tests with robots and the high-fidelity Hubble Space Telescope mockup astronauts use to train for servicing missions have convinced NASA managers it may be possible to maintain and upgrade the orbiting observatory without sending a space shuttle to do the job. In a formal request last week, the agency gave bidders until July 16 to sub-mit proposals for a robotic mission to the space telescope before the end of 2007. At a minimum, the mission would attach a rocket motor to deorbit the telescope safely when its service life ends. In the best case, it would use state-of-the- art robotics to prolong its life on orbit and install new instruments. With the space shuttle off-limits for the job under strict post-Columbia safety policies set by Administrator Sean O'Keefe, NASA has designed a "straw- man" robotic mission that would use an Atlas V or Delta N to launch a 20,ooO-lb. "Hubble Robotic Vehicle" to service the telescope. There, a robotic arm would grapple it, much as the shuttle does.

Description: Robotic technology being developed out of necessity to keep the Hubble Space Telescope operating could also lead to new levels of man-machine team-work in deep-space exploration down the road-if it survives the near-term scramble for funding. Engineers here who have devoted their NASA careers to the concept of humans servicing the telescope in orbit are planning modifications to International Space Station (ISS) robots that would leave the humans on the ground. The work. forced by post-Columbia flight rules that killed a planned shuttle-servicing mission to Hubble, marks another step in the evolution of robot-partners for human space explorers. "Hubble has always been a pathfider for this agency," says Mike Weiss. Hubble deputy program manager technical. "When the space station was flown and assembled, Hubble was the pathfinder. not just for modularity, but for operations, for assembly techniques. Exploration is the next step. Things we're going to do on Hubble are going to be applied to exploration. It's not just putting a robot in space. It's operating a robot in space. It's adapting that robot to what needs to be done the next time you're up there."