ALBERT

Description: GRC is supporting JSC by developing LIDS main interface seals Seal development and testing is occurring at both sub-scale and full-scale levels: a) Small-scale tests performed to define seal materials and evaluate exposure to space environments. b) Medium-scale testing: 1) Permits evaluation of candidate seal designs at faster pace than for full-scale seals. 2) Leak rates and loads can be scaled up to full-scale for indication of seal performance. c) Full-scale test rigs used for seal development and flight qualification tests and to assess on-orbit anomalies if needed. GRC responsible for delivering flight hardware seals to JSC approx.2013 for integration into LIDS flight units.

Description: Modeling Materials: a) Hyperelastic model used for room temperature and higher, but has limitations at predicting response at different compressive rates and at low temperatures. b) Viscoelastic model is rarely used, and needs more research and application. Test and Characterization of Materials: a) Better material characterization using biaxial tension vs simple compression testing modes is debatable. b) Testing at high and low temperature is challenging.

Description: The EcoTurn Class K production prototypes have passed all AAR qualification tests and received conditional approval. The accelerated life test on the second set of seals is in progress. Due to the performance of the first set, no problems are expected.The seal has demonstrated superior performance over the HDL seal in the test lab with virtually zero torque and excellent contamination exclusion and grease retention.

Description: NASA has established 6 Themes for Exploration: 1) USE THE MOON: Reduce risks and cost and increase productivity of future missions by testing technologies, systems, and operations in a planetary environment other than the Earth. 2) PURSUE SCIENTIFIC: Engage in scientific investigations of the Moon (solar system processes), on the Moon (use the unique environment), and from the Moon (to study other celestial phenomena). 3) EXTEND PERMANENT HUMAN PRESENCE: Develop the capabilities and infrastructure required to expand the number of people, the duration, the self-sufficiency, and the degree of non-governmental activity. 4) EXPAND EARTH S ECONOMIC SPHERE: Create new markets based on lunar activity that will return economic, technological, and quality-of-life benefits. 5) ENHANCE GLOBAL SECURTIY: Provide a challenging, shared, and peaceful global vision that unites nations in pursuit of common objectives. 6) ENGAGE, INSPIRE: Excite the public about space, encourage students to pursue careers in high technology fields, ensure that individuals enter the workforce with the scientific and technical knowledge necessary to sustain exploration.

Description: Must use earth's most abundant natural resources - Biomass, Solar, Arid land (43%), Seawater (97%) with nutrients (80%) plus brackish waters and nutrients resolve environmental triangle of conflicts energy-food-freshwater and ultrafine particulate hazards. Requires Paradigm Shift - Develop and Use Solar* for energy; Biomass for aviation and hybrid-electric-compressed air mobility fueling with transition to hydrogen long term.

Description: Non-metallic brush seals are ultra-low flow sealing elements ideal for low pressure differentials (〈30 psid) and low temperature (typically 〈300 degF) applications. The compliant bristle pack of a non-metallic brush seal is advantageous in terms of sealing capability during transients. However, if not designed properly, the bristle pack compliance can be detrimental to the performance of the seal. GE GLobal Research has investigated the stiffness and heat generation properties of non-metallic brush seals made from Kevlar and Carbon Fiber. The presentation will review the progress made on the design points of the seals, as well as highlight some current commercial applications of the technology.

Description: The baseline non-contacting finger seal is a NASA patented design. The primary difference between it and Gul Aroras design patented by AlliedSignal is that there are no lift pads on the high pressure fingers. The baseline non-contacting finger seal is comprised of a back plate, aft spacer, aft (or low pressure) finger element, forward (or high pressure) finger element, forward spacer, and front plate. The components are held together with 20 flat head screws. A typical seal would have a back plate of approximately the same thickness as the front plate and would be riveted together. The thicker back plate allows use of threaded fasteners so that different finger elements can be tested without having to replace all the individual seal components. The finger elements are essentially washers made of thin sheet stock with multiple curved slots machined around the inner diameter to form the fingers. They are clocked so that the fingers of one cover the slots of the other. The aft finger element fingers have axial extensions or "lift pads" at the seal id that are concentric to the rotor. The fingers act as cantilever beams and flex in response to rotor dynamic motion and radial growth of the rotor due to centrifugal or thermal forces.

Description: NASA Glenn is currently performing seal research supporting both advanced turbine engine development and advanced space vehicle/propulsion system development. Studies have shown that decreasing parasitic leakage by applying advanced seals will increase turbine engine performance and decrease operating costs. Studies have also shown that higher temperature, long life seals are critical in meeting next generation space vehicle and propulsion system goals in the areas of performance, reusability, safety, and cost. Advanced docking system seals need to be very robust resisting space environmental effects while exhibiting very low leakage and low compression and adhesion forces. NASA Glenn is developing seal technology and providing technical consultation for the Agencys key aero- and space technology development programs.

Description: The industry is requiring seals to operate at higher and higher temperatures. Traditional static seal designs and materials experience stress relaxation, losing their ability to maintain contact with moving flanges. Ultra High Temperature seal development program is a multiphase program with incremental increases in seal operating temperatures.

Description: NASA GRC supporting design, development, and implementation of numerous seal systems for the Orion CEV: a) HS-to-BS interface. b) Compression pad. HS-to-BS Interface Seal System: a) design has evolved as a result of changes with the CEV TPS. b) Seal system is currently under development/evaluation. Coupon level tests, Arc jet tests, and Validation test development. Compression Pad: a) Finalizing design options. b) Evaluating material candidates.

Description: In the seal literature you can find many attempts by various researchers to adapt film riding seals to the gas turbine engine. None have been successful, potential distortion of the sealing faces is the primary reason. There is a film riding device that does accommodate distortion and is in service in aircraft applications, namely the foil bearing. More specifically a foil thrust bearing. These are not intended to be seals, and they do not accommodate large axial movement between shaft & static structure. By combining the 2 a unique type of face seal has been created. It functions like a normal face seal. The foil thrust bearing replaces the normal primary sealing surface. The compliance of the foil bearing allows the foils to track distortion of the mating seal ring. The foil seal has several perceived advantages over existing hydrodynamic designs, enumerated in the chart. Materials and design methodology needed for this application already exist. Also the load capacity requirements for the foil bearing are low since it only needs to support itself and overcome friction forces at the antirotation keys.

Description: The effect of hoop stresses in reducing cylindrical roller bearing fatigue life was determined for various classes of inner-ring interference fit. Calculations were performed for up to 7 fit classes for each of 10 bearing sizes. The hoop stresses were superimposed on the Hertzian principal stresses created by the applied radial load to calculate roller bearing fatigue life. A method was developed through a series of equations to calculate the life reduction for cylindrical roller bearings. All calculated lives are for zero initial internal clearance. Any reduction in bearing clearance due to interference fit would be compensated by increasing the initial (unmounted) clearance. Results are presented as tables and charts of life factors for bearings with light, moderate, and heavy loads and interference fits ranging from extremely light to extremely heavy for bearing accuracy class RBEC-5 (ISO class 5). Interference fits on the inner ring of a cylindrical roller bearing can significantly reduce bearing fatigue life. In general, life factors are smaller (lower life) for bearings running under light load where the unfactored life is highest. The various bearing series within a particular bore size had almost identical interference-fit life factors for a particular fit. The tightest fit at the high end of the tolerance band produces a life factor of approximately 0.40 for an inner-race maximum Hertz stress of 1200 MPa (175 ksi) and a life factor of 0.60 for an inner-race maximum Hertz stress of 2200 MPa (320 ksi). Interference fits also impact the maximum Hertz stress-life relation.

Description: Data mining is defined as the discovery of useful, possibly unexpected, patterns and relationships in data using statistical and non-statistical techniques in order to develop schemes for decision and policy making. Data mining can be used to discover the sources and causes of problems in complex systems. In addition, data mining can support simulation strategies by finding the different constants and parameters to be used in the development of simulation models. This paper introduces a framework for data mining and its application to complex problems. To further explain some of the concepts outlined in this paper, the potential application to the NASA Shuttle Reinforced Carbon-Carbon structures and genetic programming is used as an illustration.

Description: In order for ceramics to be fully utilized as components for high-temperature and structural applications, joining and integration methods are needed. Such methods will allow for the fabrication the complex shapes and also allow for insertion of the ceramic component into a system that may have different adjacent materials. Monolithic silicon carbide (SiC) is a ceramic material of focus due to its high temperature strength and stability. Titanium foils were used as an interlayer to form diffusion bonds between chemical vapor deposited (CVD) SiC ceramics with the aid of hot pressing. The influence of such variables as interlayer thickness and processing time were investigated to see which conditions contributed to bonds that were well adhered and crack free. Optical microscopy, scanning electron microscopy, and electron microprobe analysis were used to characterize the bonds and to identify the reaction formed phases.

Description: Impact tests were conducted on uncoated 2D and 2.5D MI SiC/SiC composite specimens at room temperature and 1316 C in air. The specimens were analyzed before and after impact using optical microscopy, pulsed thermography (PT) and computed tomography (CT). Preliminary results indicate the following. Both 2-D and 2.5D composites show increase in surface and volumetric damages with increasing impact velocity. However, 2-D composites are prone to delamination cracks. In both 2D and 2.5D composites, the magnitude of impact damage at a fixed impact velocity is slightly greater at room temperature than at 1315 C. At a fixed projectile velocity and test temperature, the depth of penetration of the projectile into the substrate is significantly lower in 2.5D composites than in 2D composites. Fiber architecture plays a significant role controlling impact damage in MI SiC/SiC composites.

Description: Material flammability is an important factor in determining the pressure and composition (fraction of oxygen and nitrogen) of the atmosphere in the habitable volume of exploration vehicles and habitats. The method chosen in this work to quantify the flammability of a material is by its ease of ignition. The ignition delay time was defined as the time it takes a combustible material to ignite after it has been exposed to an external heat flux. Previous work in the Forced Ignition and Spread Test (FIST) apparatus has shown that the ignition delay in the currently proposed space exploration atmosphere (approximately 58.6 kPa and32% oxygen concentration) is reduced by 27% compared to the standard atmosphere used in the Space Shuttle and Space Station. In order to determine whether there is a safer environment in terms of material flammability, a series of piloted ignition delay tests using polymethylmethacrylate (PMMA) was conducted in the FIST apparatus to extend the work over a range of possible exploration atmospheres. The exploration atmospheres considered were the normoxic equivalents, i.e. reduced pressure conditions with a constant partial pressure of oxygen. The ignition delay time was seen to decrease as the pressure was reduced along the normoxic curve. The minimum ignition delay observed in the normoxic equivalent environments was nearly 30% lower than in standard atmospheric conditions. The ignition delay in the proposed exploration atmosphere is only slightly larger than this minimum. Interms of material flammability, normoxic environments with a higher pressure relative to the proposed pressure would be desired.

Description: Under contract to the Department of Energy (DOE), Lockheed Martin Space Systems Company (LMSSC) has been developing the Advanced Stirling Radioisotope Generator (ASRG). The use of Stirling technology introduces a four-fold increase in conversion efficiency over Radioisotope Thermoelectric Generators (RTGs), and thus the ASRG in an attractive power system option for future science missions. In August of 2008, the ASRG engineering unit (EU) was delivered to NASA Glenn Research Center (GRC). The engineering unit design resembles that of a flight unit, with the exception of electrical heating in place of a radioisotope source. Prior to delivery, GRC personnel prepared a test station continuous, unattended operation of the engineering unit. This test station is capable of autonomously monitoring the unit's safe operation and recording. , .. , .... performance data. Generator parameters recorded include temperatures, electrical power output, and thelmal power input. Convertor specific parameters are also recorded such as alternator voltage, current, piston amplitude, and frequency. Since November 2008, the ASRG EU has accumulated over 4,000 hours of operation. Initial operation was conducted using the AC bus control method in lieu of the LMSSC active power factor connecting controller. Operation on the LMSSC controller began in February 2009. This paper discusses the entirety of ASRG EU operation thus far, as well as baseline performance data at GRC and LMSSC, and comparison of performance using each control method.

Description: It is known that polymer films can degrade in space due to exposure to the environment, but the magnitude of the mechanical property degradation and the degree to which the different environmental factors play a role in it is not well understood. This paper describes the results of an experiment flown on the Materials International Space Station Experiment (MISSE) 5 to determine the change in tensile strength and % elongation of some typical polymer films exposed in a nadir facing environment on the International Space Station and where possible compare to similar ram and wake facing experiments flown on MISSE 1 to get a better indication of the role the different environments play in mechanical property change.

Description: Nano-fibers are used to reinforce polymer matrices to enhance the matrix dependent properties that are subsequently used in conventional structural composites. A quasi isotropic configuration is used in arranging like nano-fibers through the thickness to ascertain equiaxial enhanced matrix behavior. The nano-fiber volume ratios are used to obtain the enhanced matrix strength properties for 0.01,0.03, and 0.05 nano-fiber volume rates. These enhanced nano-fiber matrices are used with conventional fiber volume ratios of 0.3 and 0.5 to obtain the composite properties. Results show that nano-fiber enhanced matrices of higher than 0.3 nano-fiber volume ratio are degrading the composite properties.

Description: While the low thermal conductivities of silica aerogels have made them of interest to the aerospace community as lightweight thermal insulation, the application of conformal polymer coatings to these gels increases their strength significantly, making them potentially useful as structural materials as well. In this work we perform multiscale computer simulations to investigate the tensile and compressive strain behavior of silica and polymer-coated silica aerogels. Aerogels are made up of clusters of interconnected particles of amorphous silica of less than bulk density. We simulate gel nanostructure using a Diffusion Limited Cluster Aggregation (DLCA) procedure, which produces aggregates that exhibit fractal dimensions similar to those observed in real aerogels. We have previously found that model gels obtained via DLCA exhibited stress-strain curves characteristic of the experimentally observed brittle failure. However, the strain energetics near the expected point of failure were not consistent with such failure. This shortcoming may be due to the fact that the DLCA process produces model gels that are lacking in closed-loop substructures, compared with real gels. Our model gels therefore contain an excess of dangling strands, which tend to unravel under tensile strain, producing non-brittle failure. To address this problem, we have incorporated a modification to the DLCA algorithm that specifically produces closed loops in the model gels. We obtain the strain energetics of interparticle connections via atomistic molecular statics, and abstract the collective energy of the atomic bonds into a Morse potential scaled to describe gel particle interactions. Polymer coatings are similarly described. We apply repeated small uniaxial strains to DLCA clusters, and allow relaxation of the center eighty percent of the cluster between strains. The simulations produce energetics and stress-strain curves for looped and nonlooped clusters, for a variety of densities and interaction parameters.

Description: Phenolic Impregnated Carbon Ablator was the heatshield material for the Stardust probe and is also a candidate heatshield material for the Orion Crew Module. As part of the heatshield qualification for Orion, physical and thermal properties were measured for newly manufactured material, included emissivity, heat capacity, thermal conductivity, elemental composition, and thermal decomposition rates. Based on these properties, an ablation and thermal-response model was developed for temperatures up to 3500 K and pressures up to 100 kPa. The model includes orthotropic and pressure-dependent thermal conductivity. In this work, model validation is accomplished by comparison of predictions with data from many arcjet tests conducted over a range of stagnation heat flux and pressure from 107 Watts per square centimeter at 2.3 kPa to 1100 Watts per square centimeter at 84 kPa. Over the entire range of test conditions, model predictions compare well with measured recession, maximum surface temperatures, and in depth temperatures.

Description: An overview of rotary wing evolution and innovations over the last 20 years was presented. This overview is provided from a drive system perspective. Examples of technology innovations that have changed and advanced drive systems of rotary wing vehicles will be provided. These innovations include full 6-axis CNC gear manufacture, face gear development to aerospace standards, health and usage monitoring, and gear geometry and bearing improvements. Also, an overview of current state-of-the-art activities being conducted at NASA Glenn is presented with a short look to fixed and rotary wing aircraft and systems needed for the future.

Description: Ceramic thermal and environmental barrier coatings (TEBC) for SiC-based ceramics will play an increasingly important role in future gas turbine engines because of their ability to effectively protect the engine components and further raise engine temperatures. However, the coating long-term durability remains a major concern with the ever-increasing temperature, strength and stability requirements in engine high heat-flux combustion environments, especially for highly-loaded rotating turbine components. Advanced TEBC systems, including nano-composite based HfO2-aluminosilicate and rare earth silicate coatings are being developed and tested for higher temperature capable SiC/SiC ceramic matrix composite (CMC) turbine blade applications. This paper will emphasize coating composite and multilayer design approach and the resulting performance and durability in simulated engine high heat-flux, high stress and high pressure combustion environments. The advances in the environmental barrier coating development showed promise for future rotating CMC blade applications.

Description: Ceramic matrix composites (CMC) are suitable for high temperature structural applications such as turbine airfoils and hypersonic thermal protection systems due to their low density high thermal conductivity. The employment of these materials in such applications is limited by the ability to accurately monitor and predict damage evolution. Current nondestructive methods such as ultrasound, x-ray, and thermal imaging are limited in their ability to quantify small scale, transverse, in-plane, matrix cracks developed over long-time creep and fatigue conditions. CMC is a multifunctional material in which the damage is coupled with the material s electrical resistance, providing the possibility of real-time information about the damage state through monitoring of resistance. Here, resistance measurement of SiC/SiC composites under mechanical load at both room temperature monotonic and high temperature creep conditions, coupled with a modal acoustic emission technique, can relate the effects of temperature, strain, matrix cracks, fiber breaks, and oxidation to the change in electrical resistance. A multiscale model can in turn be developed for life prediction of in-service composites, based on electrical resistance methods. Results of tensile mechanical testing of SiC/SiC composites at room and high temperatures will be discussed. Data relating electrical resistivity to composite constituent content, fiber architecture, temperature, matrix crack formation, and oxidation will be explained, along with progress in modeling such properties.

Description: Light-weight, creep-resistant silicon nitride ceramics possess excellent high-temperature strength and are projected to significantly raise engine efficiency and performance when used as turbine components in the next-generation turbo-shaft engines without the extensive cooling that is needed for metallic parts. One key aspect of Si3N4 utilization in such applications is its joining response to diverse materials. In an ongoing research program, the joining and integration of Si3N4 ceramics with metallic, ceramic, and composite materials using braze interlayers with the liquidus temperature in the range 750-1240C is being explored. In this paper, the self-joining behavior of Kyocera Si3N4 and St. Gobain Si3N4 using a ductile Cu-based active braze (Cu-ABA) containing Ti will be presented. Joint microstructure, composition, hardness, and strength as revealed by optical microscopy, scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), Knoop microhardness test, and offset compression shear test will be presented. Additionally, microstructure, composition, and joint strength of Si3N4/Inconel 625 joints made using Cu-ABA, will be presented. The results will be discussed with reference to the role of chemical reactions, wetting behavior, and residual stresses in joints.

Description: In a Stirling radioisotope system, heat must continually be removed from the General Purpose Heat Source (GPHS) modules to maintain the modules and surrounding insulation at acceptable temperatures. Normally, the Stirling convertor provides this cooling. If the converter stops in the current system, the insulation is designed to spoil, preventing damage to the GPHS, and also ending the mission. An alkali-metal Variable Conductance Heat Pipe (VCHP) has been designed to allow multiple stops and restarts of the Stirling convertor in an Advanced Stirling Radioisotope Generator (ASRG). When the Stirling convertor is turned off, the VCHP will activate when the temperatures rises 30 C above the setpoint temperature. A prototype VCHP with sodium as the working fluid was fabricated and tested in both gravity aided and against gravity conditions for a nominal heater head temperature of 790 C. The results show very good agreement with the predictions and validate the model. The gas front was located at the exit of the reservoir when heater head temperature was 790 C while cooling was ON, simulating an operating Advanced Stirling Converter (ASC). When cooling stopped, the temperature increased by 30 C, allowing the gas front to move past the radiator, which transferred the heat to the case. After resuming the cooling flow, the front returned at the initial location turning OFF the VCHP. The against gravity working conditions showed a colder reservoir and faster transients.

Description: High-temperature piezoelectrics are a key technology for aeronautics and aerospace applications such as fuel modulation to increase the engine efficiency and decrease emissions. The principal challenge for the insertion of piezoelectric materials is the limitation on upper use temperature which is due to low Curie-Temperature (TC) and increasing electrical conductivity. BiScO3-PbTiO3 (BS-PT) system is a promising candidate for improving the operating temperature for piezoelectric actuators due to its high TC (greater than 400 C). Bi2O3 was shown to be a good sintering aid for liquid phase sintering resulting in reduced grain size and increased resistivity. Zr doped and liquid phase sintered BS-PT ceramics exhibited saturated and square hysteresis loops with enhanced remenant polarization (37 microC per square centimeter) and coercive field (14 kV/cm). BS-PT doped with Mn showed enhanced field induced strain (0.27% at 50kV/cm). All the numbers indicated in parenthesis were collected at 100 C.

Description: Robust multilayer insulation systems have long been a goal of many research projects. Such insulation systems must provide some degree of structural support and also mechanical integrity during loss of vacuum scenarios while continuing to provide insulative value to the vessel. Aerogel composite blankets can be the best insulation materials in ambient pressure environments; in high vacuum, the thermal performance of aerogel improves by about one order of magnitude. Standard multilayer insulation (MU) is typically 50% worse at ambient pressure and at soft vacuum, but as much as two or three orders of magnitude better at high vacuum. Different combinations of aerogel and multilayer insulation systems have been tested at Cryogenics Test Laboratory of NASA Kennedy Space Center. Analysis performed at Oak Ridge National Laboratory showed an importance to the relative location of the MU and aerogel blankets. Apparent thermal conductivity testing under cryogenic-vacuum conditions was performed to verify the analytical conclusion. Tests results are shown to be in agreement with the analysis which indicated that the best performance is obtained with aerogel layers located in the middle of the blanket insulation system.

Description: No abstract available

Description: Recent testing in a cylindrical, comparative cryostat at the Cryogenics Test Laboratory has focused on various seam concepts for multilayer insulation systems. Three main types of seams were investigated: straight overlap, fold-over, and roll wrapped. Each blanket was comprised of 40 layer pairs of reflector and spacer materials. The total thickness was approximately 12.5-mm, giving an average layer density of 32 layers per centimeter. The blankets were tested at high vacuum, soft vacuum, and no vacuum using liquid nitrogen to maintain the cold boundary temperature at 77 K. Test results show that all three seam concepts are all close in thermal performance; however the fold-over method provides the lowest heat flux. For the first series of tests, seams were located 120 degrees around the circumference of the cryostat from the previous seam. This technique appears to have lessened the degradation of the blanket due to the seams. In a follow-on test, a 20 layer blanket was tested in a roll wrapped configuration and then cut down the side of the cylinder, taped together, and re-tested. This test result shows the thermal performance impact of having the seams all in one location versus having the seams clocked around the vessel. This experimental investigation indicates that the method of joining the seams in multilayer insulation systems is not as critical as the quality of the installation process.

Description: Aerogel blanket materials for use in thermal insulation systems are now commercially available and implemented by industry. Prototype aerogel blanket materials were presented at the Cryogenic Engineering Conference in 1997 and by 2004 had progressed to full commercial production by Aspen Aerogels. Today, this new technology material is providing superior energy efficiencies and enabling new design approaches for more cost effective cryogenic systems. Aerogel processing technology and methods are continuing to improve, offering a tailor-able array of product formulations for many different thermal and environmental requirements. Many different varieties and combinations of aerogel blankets have been characterized using insulation test cryostats at the Cryogenics Test Laboratory of NASA Kennedy Space Center. Detailed thermal conductivity data for a select group of materials are presented for engineering use. Heat transfer evaluations for the entire vacuum pressure range, including ambient conditions, are given. Examples of current cryogenic applications of aerogel blanket insulation are also given. KEYWORDS: Cryogenic tanks, thermal insulation, composite materials, aerogel, thermal conductivity, liquid nitrogen boil-off

Description: RTM Resins based on a-ODPA and a-BPDA with kinked diamines exhibit low-melt viscosity (approximately 10 poise). Composites made from a-ODPA resins (T(sub g) = 265-330 C) by RTM display good mechanical properties at 288 C (550 F), but soften at 315 C (600 F). Composites of RTM370 based on a-BPDA retain excellent mechanical properties at 315 C, exceeding BMI-5270-1 capability.

Description: A 20-year life cycle cost analysis was performed to compare the operational life cycle cost, processing/turnaround timelines, and operations manpower inspection/repair/refurbishment requirements for corrosion protection of the Kennedy Space Center launch pad flame deflector associated with the existing cast-in-place materials and a newer advanced refractory ceramic material. The analysis compared the estimated costs of(1) continuing to use of the current refractory material without any changes; (2) completely reconstructing the flame trench using the current refractory material; and (3) completely reconstructing the flame trench with a new high-performance refractory material. Cost estimates were based on an analysis of the amount of damage that occurs after each launch and an estimate of the average repair cost. Alternative 3 was found to save $32M compared to alternative 1 and $17M compared to alternative 2 over a 20-year life cycle.

Description: Preferential oriented multiwalled carbon nanotubes were prepared by the injection chemical vapor deposition (CVD) method using either cyclopentadienyliron dicarbonyl dimer or cyclooctatetraene iron tricarbonyl as the iron catalyst source. The catalyst precursors were dissolved in toluene as the carrier solvent for the injections. The concentration of the catalyst was found to influence both the growth (i.e., MWNT orientation) of the nanotubes, as well as the amount of iron in the deposited material. As deposited, the multiwalled carbon nanotubes contained as little as 2.8% iron by weight. The material was deposited onto tantalum foil and fused silica substrates. The nanotubes were characterized by scanning electron microscopy, transmission electron microscopy, Raman spectroscopy and thermogravimetric analysis. This synthetic route provides a simple and scalable method to deposit MWNTs with a low defect density, low metal content and a preferred orientation. Subsequently, a small start-up was founded to commercialize the deposition equipment. The contrast between the research and entrepreneurial environments will be discussed.

Description: This paper describes the effort by the Texas Engineering Experiment Station (TEES) and Honeywell for NASA to design and test a pre-flight prototype pump for use in the Extra-vehicular activity (EVA) portable life support subsystem (PLSS). Major design decisions were driven by the need to reduce the pump s mass, power, and volume compared to the existing PLSS pump. In addition, the pump must accommodate a much wider range of abnormal conditions than the existing pump, including vapor/gas bubbles and increased pressure drop when employed to cool two suits simultaneously. A positive displacement, external gear type pump was selected because it offers the most compact and highest efficiency solution over the required range of flow rates and pressure drops. An additional benefit of selecting a gear pump design is that it is self priming and capable of ingesting non-condensable gas without becoming air locked. The chosen pump design consists of a 28 V DC, brushless, sealless, permanent magnet motor driven, external gear pump that utilizes a Honeywell development that eliminates the need for magnetic coupling. Although the planned flight unit will use a sensorless motor with custom designed controller, the pre-flight prototype to be provided for this project incorporates Hall effect sensors, allowing an interface with a readily available commercial motor controller. This design approach reduced the cost of this project and gives NASA more flexibility in future PLSS laboratory testing. The pump design was based on existing Honeywell designs, but incorporated features specifically for the PLSS application, including all of the key features of the flight pump. Testing at TEES verified that the pump meets the design requirements for range of flow rates, pressure drop, power consumption, working fluid temperature, operating time, gas ingestion , and restart capability under both ambient and vacuum conditions. The pump operated between 40 and 240 lbm/hr flowrate, 35 to 100 F pump temperature range, and 5 to 10 psid pressure rise. Power consumption of the pump controller at the nominal operating point in both ambient and vacuum conditions was 9.5 W, which was less than the 12 W predicted. Gas ingestion capabilities were tested by injecting 100 cc of air into the fluid line; the pump operated normally throughout this test. The test results contained a number of anomalies, specifically power increases and a few flow stoppages, that prompted TEES and Honeywell to disassemble and inspect the pump. Inspection indicated contamination in the pump and fit issues may have played roles in the observed anomalies. Testing following reassembly indicated that the performance of the pump 1) matched both the predicted performance values, 2) the performance values measured prior to disassembly, and 3) was free of the anomalies noted in the pre-disassembly testing.

Description: Described is a device having an anti-reflection surface. The device comprises a silicon substrate with a plurality of silicon spikes formed on the substrate. A first metallic layer is formed on the silicon spikes to form the anti-reflection surface. The device further includes an aperture that extends through the substrate. A second metallic layer is formed on the substrate. The second metallic layer includes a hole that is aligned with the aperture. A spacer is attached with the silicon substrate to provide a gap between an attached sensor apparatus. Therefore, operating as a Micro-sun sensor, light entering the hole passes through the aperture to be sensed by the sensor apparatus. Additionally, light reflected by the sensor apparatus toward the first side of the silicon substrate is absorbed by the first metallic layer and silicon spikes and is thereby prevented from being reflected back toward the sensor apparatus.

Description: No abstract available

Description: This Technical Memorandum examines the effects of heat and absorbed moisture on the open hole compression strength of carbon/epoxy laminates with the material and layup intended for the Ares I composite interstage. The knockdown due to temperature, amount of moisture absorbed, and the interaction between these two are examined. Results show that temperature is much more critical than the amount of moisture absorbed. The environmental knockdown factor was found to be low for this material and layup and thus obtaining a statistically significant number for this value needs to be weighed against a program s cost and schedule since basis values, damage tolerance, and safety factors all contribute much more to the overall knockdown factor.

Description: Self-healing cable apparatus and methods disclosed. The self-healing cable has a central core surrounded by an adaptive cover that can extend over the entire length of the self-healing cable or just one or more portions of the self-healing cable. The adaptive cover includes an axially and/or radially compressible-expandable (C/E) foam layer that maintains its properties over a wide range of environmental conditions. A tape layer surrounds the C/E layer and is applied so that it surrounds and axially and/or radially compresses the C/E layer. When the self-healing cable is subjected to a damaging force that causes a breach in the outer jacket and the tape layer, the corresponding localized axially and/or radially compressed portion of the C/E foam layer expands into the breach to form a corresponding localized self-healed region. The self-healing cable is manufacturable with present-day commercial self-healing cable manufacturing tools.

Description: An ion flux is directed to a carbon nanotube to permanently shape, straighten and/or bend the carbon nanotube into a desired configuration. Such carbon nanotubes have many properties that make them ideal as probes for Scanning Probe Microscopy and many other applications.

Description: SiC stability and recession rates were modeled in hydrogen/oxygen combustion environments for the Integrated High Payoff Rocket Propulsion Technology (IHPRPT) program. The IHPRPT program is a government and industry program to improve U.S. rocket propulsion systems. Within this program SiC-based ceramic matrix composites are being considered for transpiration cooled injector faceplates or rocket engine thrust chamber liners. Material testing under conditions representative of these environments was conducted at the NASA Glenn Research Center, Cell 22. For the study described herein, SiC degradation was modeled under these Cell 22 test conditions for comparison to actual test results: molar mixture ratio, MR (O2:H2) = 6, material temperatures to 1700 C, combustion gas pressures between 0.34 and 2.10 atm, and gas velocities between 8,000 and 12,000 fps. Recession was calculated assuming rates were controlled by volatility of thermally grown silica limited by gas boundary layer transport. Assumptions for use of this model were explored, including the presence of silica on the SiC surface, laminar gas boundary layer limited volatility, and accuracy of thermochemical data for volatile Si-O-H species. Recession rates were calculated as a function of temperature. It was found that at 1700 C, the highest temperature considered, the calculated recession rates were negligible, about 200 m/h, relative to the expected lifetime of the material. Results compared favorably to testing observations. Other mechanisms contributing to SiC recession are briefly described including consumption of underlying carbon and pitting. A simple expression for liquid flow on the material surface was developed from a one-dimensional treatment of the Navier-Stokes Equation. This relationship is useful to determine under which conditions glassy coatings or thermally grown silica would flow on the material surface, removing protective layers by shear forces. The velocity of liquid flow was found to depend on the gas velocity, the viscosity of gas and liquid, as well as the thickness of the gas boundary layer and the liquid layer. Calculated flow rates of a borosilicate glass coating compared well to flow rates observed for this coating tested on a SiC panel in Cell 22.

Description: A method and apparatus wherein phase changes in a material can dampen vibrational energy, dampen noise and facilitate heat transfer. One embodiment includes a method for damping vibrational energy in a body. The method comprises attaching a material to the body, wherein the material comprises a substrate, a shape memory alloy layer, and a plurality of temperature change elements. The method further comprises sensing vibrations in the body. In addition, the method comprises indicating to at least a portion of the temperature change elements to provide a temperature change in the shape memory alloy layer, wherein the temperature change is sufficient to provide a phase change in at least a portion of the shape memory alloy layer, and further wherein the phase change consumes a sufficient amount of kinetic energy to dampen at least a portion of the vibrational energy in the body. In other embodiments, the shape memory alloy layer is a thin film. Additional embodiments include a sensor connected to the material.

Description: The presence of a honeycomb core in a multi-wall shielding configuration for protection against micrometeoroid and orbital debris (MMOD) particle impacts at hypervelocity is generally considered to be detrimental as the cell walls act to restrict fragment cloud expansion, creating a more concentrated load on the shield rear wall. However, mission requirements often prevent the inclusion of a dedicated MMOD shield, and as such, structural honeycomb sandwich panels are amongst the most prevalent shield types. Open cell metallic foams are a relatively new material with novel mechanical and thermal properties that have shown promising results in preliminary hypervelocity impact shielding evaluations. In this study, an ISS-representative MMOD shielding configuration has been modified to evaluate the potential performance enhancement gained through the substitution of honeycomb for open cell foam. The baseline shielding configuration consists of a double mesh outer layer, two honeycomb sandwich panels, and an aluminum rear wall. In the modified configuration the two honeycomb cores are replaced by open-cell foam. To compensate for the heavier core material, facesheets have been removed from the second sandwich panel in the modified configuration. A total of 19 tests on the double layer honeycomb and double layer foam configurations are reported. For comparable mechanical and thermal performance, the foam modifications were shown to provide a 15% improvement in critical projectile diameter at low velocities (i.e. 3 km/s) and a 3% increase at high velocities (i.e. 7 km/s) for normal impact. With increasing obliquity, the performance enhancement was predicted to increase, up to a 29% improvement at 60 (low velocity). Ballistic limit equations have been developed for the new configuration, and consider the mass of each individual shield component in order to maintain validity in the event of minor configuration modifications. Previously identified weaknesses of open cell foams for hypervelocity impact shielding such as large projectile diameters, low velocities, and high degrees of impact obliquity have all been investigated, and found to be negligible for the double-layer configuration.

Description: A radiation detector assembly has a semiconductor detector array substrate of CdZnTe or CdTe, having a plurality of detector cell pads on a first surface thereof, the pads having a contact metallization and a solder barrier metallization. An interposer card has planar dimensions no larger than planar dimensions of the semiconductor detector array substrate, a plurality of interconnect pads on a first surface thereof, at least one readout semiconductor chip and at least one connector on a second surface thereof, each having planar dimensions no larger than the planar dimensions of the interposer card. Solder columns extend from contacts on the interposer first surface to the plurality of pads on the semiconductor detector array substrate first surface, the solder columns having at least one solder having a melting point or liquidus less than 120 degrees C. An encapsulant is disposed between the interposer circuit card first surface and the semiconductor detector array substrate first surface, encapsulating the solder columns, the encapsulant curing at a temperature no greater than 120 degrees C.

Description: In accordance with an embodiment of the invention, an article is disclosed. The article comprises a gas turbine engine component substrate comprising a silicon material; and an environmental barrier coating overlying the substrate, wherein the environmental barrier coating comprises cerium oxide, and the cerium oxide reduces formation of silicate glass on the substrate upon exposure to corrodant sulfates.

Description: Thick film magnetic/insulating nanocomposite materials, with significantly reduced core loss, and their manufacture are described. The insulator coated magnetic nanocomposite comprises one or more magnetic components, and an insulating component. The magnetic component comprises nanometer scale particles (about 1 to about 100 nanometers) coated by a thin-layered insulating phase. While the intergrain interaction between the immediate neighboring magnetic nanoparticles separated by the insulating phase provides the desired soft magnetic properties, the insulating material provides high resistivity, which reduces eddy current loss.

Description: In accordance with the present invention, an integrated micro steam turbine power plant on-a-chip has been provided. The integrated micro steam turbine power plant on-a-chip of the present invention comprises a miniature electric power generation system fabricated using silicon microfabrication technology and lithographic patterning. The present invention converts heat to electricity by implementing a thermodynamic power cycle on a chip. The steam turbine power plant on-a-chip generally comprises a turbine, a pump, an electric generator, an evaporator, and a condenser. The turbine is formed by a rotatable, disk-shaped rotor having a plurality of rotor blades disposed thereon and a plurality of stator blades. The plurality of stator blades are interdigitated with the plurality of rotor blades to form the turbine. The generator is driven by the turbine and converts mechanical energy into electrical energy.

Description: A method of testing the electrical functionality of an optically controlled switch in a reconfigurable antenna is provided. The method includes configuring one or more conductive paths between one or more feed points and one or more test point with switches in the reconfigurable antenna. Applying one or more test signals to the one or more feed points. Monitoring the one or more test points in response to the one or more test signals and determining the functionality of the switch based upon the monitoring of the one or more test points.

Description: A precursor of a ceramic adhesive suitable for use in a vacuum, thermal, and microgravity environment. The precursor of the ceramic adhesive includes a silicon-based, preceramic polymer and at least one ceramic powder selected from the group consisting of aluminum oxide, aluminum nitride, boron carbide, boron oxide, boron nitride, hafnium boride, hafnium carbide, hafnium oxide, lithium aluminate, molybdenum silicide, niobium carbide, niobium nitride, silicon boride, silicon carbide, silicon oxide, silicon nitride, tin oxide, tantalum boride, tantalum carbide, tantalum oxide, tantalum nitride, titanium boride, titanium carbide, titanium oxide, titanium nitride, yttrium oxide, zirconium diboride, zirconium carbide, zirconium oxide, and zirconium silicate. Methods of forming the ceramic adhesive and of repairing a substrate in a vacuum and microgravity environment are also disclosed, as is a substrate repaired with the ceramic adhesive.

Description: The Lunar Roving Vehicle (LRV) was developed for NASA s Apollo program so astronauts could cover a greater range on the lunar surface, carry more science instruments, and return more soil and rock samples than by foot. Because of the unique lunar environment, the creation of flexible wheels was the most challenging and time consuming aspect of the LRV development. Wheels developed for previous lunar systems were not sufficient for use with this manned vehicle; therefore, several new designs were created and tested. Based on criteria set by NASA, the choices were narrowed down to two: the wire mesh wheel developed by General Motors (GM), and the hoop spring wheel developed by the Bendix Corporation. Each of these underwent intensive mechanical, material, and terramechanical analyses, and in the end, the wire mesh wheel was chosen for the LRV. Though the wire mesh wheel was determined to be the best choice for its particular application, it may be insufficient towards achieving the objectives of future lunar missions that could require higher tractive capability, increased weight capacity, or extended life. Therefore lessons learned from the original LRV wheel development and suggestions for future Moon wheel projects are offered.

Description: A pulse detonation engine comprises a primary air inlet; a primary air plenum located in fluid communication with the primary air inlet; a secondary air inlet; a secondary air plenum located in fluid communication with the secondary air inlet, wherein the secondary air plenum is substantially isolated from the primary air plenum; a pulse detonation combustor comprising a pulse detonation chamber, wherein the pulse detonation chamber is located downstream of and in fluid communication with the primary air plenum; a coaxial liner surrounding the pulse detonation combustor defining a cooling plenum, wherein the cooling plenum is in fluid communication with the secondary air plenum; an axial turbine assembly located downstream of and in fluid communication with the pulse detonation combustor and the cooling plenum; and a housing encasing the primary air plenum, the secondary air plenum, the pulse detonation combustor, the coaxial liner, and the axial turbine assembly.

Description: A nonlinearly stacked low noise turbofan stator vane having a characteristic curve that is characterized by a nonlinear sweep and a nonlinear lean is provided. The stator is in an axial fan or compressor turbomachinery stage that is comprised of a collection of vanes whose highly three-dimensional shape is selected to reduce rotor-stator and rotor-strut interaction noise while maintaining the aerodynamic and mechanical performance of the vane. The nonlinearly stacked low noise turbofan stator vane reduces noise associated with the fan stage of turbomachinery to improve environmental compatibility.

Description: A thin nearly wireless adaptive optical device capable of dynamically modulating the shape of a mirror in real time to compensate for atmospheric distortions and/or variations along an optical material is provided. The device includes an optical layer, a substrate, at least one electronic circuit layer with nearly wireless architecture, an array of actuators, power electronic switches, a reactive force element, and a digital controller. Actuators are aligned so that each axis of expansion and contraction intersects both substrate and reactive force element. Electronics layer with nearly wireless architecture, power electronic switches, and digital controller are provided within a thin-film substrate. The size and weight of the adaptive optical device is solely dominated by the size of the actuator elements rather than by the power distribution system.

Description: Damage tolerance consists of analysis and experimentation working together. Impact damage is usually of most concern for laminated composites. Once impacted, the residual compression strength is usually of most interest. Other properties may be of more interest than compression (application dependent). A damage tolerance program is application specific (not everyone is building aircraft). The "Building Block Approach" is suggested for damage tolerance. Advantage can be taken of the excellent fatigue resistance of damaged laminates to save time and costs.

Description: Following the tragedy of the Orbiter Columbia (STS-107) on February 1, 2003, a major effort commenced to develop a better understanding of debris impacts and their effect on the space shuttle subsystems. An initiative to develop and validate physics-based computer models to predict damage from such impacts was a fundamental component of this effort. To develop the models it was necessary to physically characterize reinforced carbon-carbon (RCC) along with ice and foam debris materials, which could shed on ascent and impact the orbiter RCC leading edges. The validated models enabled the launch system community to use the impact analysis software LS-DYNA (Livermore Software Technology Corp.) to predict damage by potential and actual impact events on the orbiter leading edge and nose cap thermal protection systems. Validation of the material models was done through a three-level approach: Level 1--fundamental tests to obtain independent static and dynamic constitutive model properties of materials of interest, Level 2--subcomponent impact tests to provide highly controlled impact test data for the correlation and validation of the models, and Level 3--full-scale orbiter leading-edge impact tests to establish the final level of confidence for the analysis methodology. This report discusses the Level 2 test program conducted in the NASA Glenn Research Center (GRC) Ballistic Impact Laboratory with ice projectile impact tests on flat RCC panels, and presents the data observed. The Level 2 testing consisted of 54 impact tests in the NASA GRC Ballistic Impact Laboratory on 6- by 6-in. and 6- by 12-in. flat plates of RCC and evaluated three types of debris projectiles: Single-crystal, polycrystal, and "soft" ice. These impact tests helped determine the level of damage generated in the RCC flat plates by each projectile and validated the use of the ice and RCC models for use in LS-DYNA.

Description: This project is a subtask of a multi-center project to advance the state-of-the-art by developing NDE techniques that are capable of evaluating stress rupture (SR) degradation in Kevlar/epoxy (K/Ep) composite overwrapped pressure vessels (COPVs), and damage progression in carbon/epoxy (C/Ep) COPVs. In this subtask, acoustic emission (AE) data acquired during intermittent load hold tensile testing of K/Ep and C/Ep composite tow materials-of-construction used in COPV fabrication were analyzed to monitor progressive damage during the approach to tensile failure. Insight into the progressive damage of composite tow was gained by monitoring AE event rate, energy, source location, and frequency. Source location based on arrival time data was used to discern between significant AE attributable to microstructural damage and spurious AE attributable to background and grip noise. One of the significant findings was the observation of increasing violation of the Kaiser effect (Felicity ratio 〈 1.0) with damage accumulation.

Description: Cooling Flow Reduction: a) Focus on improving turbine hot gas path part cooling efficiency. b) Applicable to current metallic turbine components and synergistic with advanced materials. c) Address challenges of IGCC/hydrogen fuel environment (for example, possible cooling hole plugging). Leakage Flow Reduction: a) Focus on decreasing turbine parasitic leakages, i.e. between static-to-static, static-to-rotating turbine parts. b) Develop improved seal designs in a variety of important areas. Purge Flow Reduction: a) Focus on decreasing required flows to keep rotor disk cavities within temperature limits. b) Develop improved sealing at the cavity rims and modified flow geometries to minimize hot gas ingestion and aerodynamic impact.

Description: This DVD contains video showing the results of hypervelocity impact. One is showing a projectile impact on a Kevlar wrapped Aluminum bottle containing 3000 psi gaseous oxygen. One video show animations of a two stage light gas gun.

Description: The rollerjaw rock crusher melds the concepts of jaw crushing and roll crushing long employed in the mining and rock-crushing industries. Rollerjaw rock crushers have been proposed for inclusion in geological exploration missions on Mars, where they would be used to pulverize rock samples into powders in the tens of micrometer particle size range required for analysis by scientific instruments.

Description: A theoretical investigation of the factors controlling the stress rupture life of the National Aeronautics and Space Administration's (NASA) composite overwrapped pressure vessels (COPVs) continues. Kevlar (DuPont) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However due to the presence of a load sharing liner, the manufacturing induced residual stresses and the complex mechanical response, the state of actual fiber stress in flight hardware and test articles is not clearly known. This paper is a companion to a previously reported experimental investigation and develops a theoretical framework necessary to design full-scale pathfinder experiments and accurately interpret the experimentally observed deformation and failure mechanisms leading up to static burst in COPVs. The fundamental mechanical response of COPVs is described using linear elasticity and thin shell theory and discussed in comparison to existing experimental observations. These comparisons reveal discrepancies between physical data and the current analytical results and suggest that the vessel s residual stress state and the spatial stress distribution as a function of pressure may be completely different from predictions based upon existing linear elastic analyses. The 3D elasticity of transversely isotropic spherical shells demonstrates that an overly compliant transverse stiffness relative to membrane stiffness can account for some of this by shifting a thin shell problem well into the realm of thick shell response. The use of calibration procedures are demonstrated as calibrated thin shell model results and finite element results are shown to be in good agreement with the experimental results. The successes reported here have lead to continuing work with full scale testing of larger NASA COPV hardware.

Description: Results: From the testing we were able to determine all the cracks within the test range were detectable or better with developer. Many of the indications after development lost their linearity and gave circular indications. Our tests were performed in a laboratory and our procedure would be difficult in an industrial setting. Conclusions: The "V" did not significantly affect our ability to detect the POD cracks with fluorescent penetrant. Conduct same experiment with more cracks. The 0.025 and 0.050 POD specimens are clean and documented with the SEM. Conduct water-wash fluorescent penetrant test at EAFB. The poppet cracks are tighter than the POD specimen cracks. Flight FCV poppets: 0.01 mils (0.3 microns) Langley fatigue cracked poppets: 0.02 mils (0.5 microns) POD specimen (post 5 mils): 0.05 mils (1.4 microns) We could not detect cracks in Langley fatigue-cracked poppets with fluorescent penetrant. Investigate inability of penetrant to wet the poppet surface.

Description: The NASA Engineering and Safety Center (NESC) has been conducting an independent technical assessment to address safety concerns related to the known stress rupture failure mode of filament wound pressure vessels in use on Shuttle and the International Space Station. The Shuttle s Kevlar-49 (DuPont) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar-49 filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However due to the presence of load sharing liners and the complex manufacturing procedures, the state of actual fiber stress in flight hardware and test articles is not clearly known. Indeed nonconservative life predictions have been made where stress rupture data and lifing procedures have ignored the contribution of the liner in favor of applied pressure as the controlling load parameter. With the aid of analytical and finite element results, this paper examines the fundamental mechanical response of composite overwrapped pressure vessels including the influence of elastic plastic liners and degraded/creeping overwrap properties. Graphical methods are presented describing the non-linear relationship of applied pressure to Kevlar-49 fiber stress/strain during manufacturing, operations and burst loadings. These are applied to experimental measurements made on a variety of vessel systems to demonstrate the correct calibration of fiber stress as a function of pressure. Applying this analysis to the actual qualification burst data for Shuttle flight hardware revealed that the nominal fiber stress at burst was in some cases 23 percent lower than what had previously been used to predict stress rupture life. These results motivate a detailed discussion of the appropriate stress rupture lifing philosophy for COPVs including the correct transference of stress rupture life data between dissimilar vessels and test articles.

Description: A document discusses self-deployable, rigidized structures that are ultra-lightweight and have gas barrier properties, space durability, and high impact resistance. Developed here are microcellular-foamed sandwich structures made from nanocomposite shape memory polymers (SMPs) with Cold-Hibernated Elastic Memory (CHEM) deployed technique for space structural components including space habitats. This type of foam sandwich also does not suffer from the toxicity problems of conventional foams, and has higher mechanical properties than those processed with conventional techniques. This design can be compacted into a very small volume for launch. Once deployed, the microcellular structure can use the heat from the Sun to recover 98 to 100 percent of its shape.

Description: Triaxial braid composite materials are beginning to be used in fan cases for commercial gas turbine engines. The primary benefit for the use of composite materials is reduced weight and the associated reduction in fuel consumption. However, there are also cost benefits in some applications. This paper presents a description of the braided composite materials and discusses aspects of the braiding process that can be utilized for efficient fabrication of composite cases. The paper also presents an approach that was developed for evaluating the braided composite materials and composite fan cases in a ballistic impact laboratory. Impact of composite panels with a soft projectile is used for materials evaluation. Impact of composite fan cases with fan blades or blade-like projectiles is used to evaluate containment capability. A post-impact structural load test is used to evaluate the capability of the impacted fan case to survive dynamic loads during engine spool down. Validation of these new test methods is demonstrated by comparison with results of engine blade-out tests.

Description: Many epoxy systems under consideration for composite pressure vessels are composed of toughened epoxy resins. In this work, epoxy blends containing both rigid aromatic and flexible aliphatic components were prepared, to model toughened systems, and determine the optimum route of silicate addition. Compositions were chosen such that both glassy and rubbery resins were obtained at room temperature. The physical properties of the nanocomposites varied with T(g) and silicate placement, however, nanocomposite T(g)s were observed which exceeded that of the base resin by greater than 10 C. The tensile strength of the glassy resin remained constant or decreased on the dispersion of clay while that of the rubbery material doubled. Selectively placing the clay in the aliphatic component of the rubbery blend resulted in a greater than 100% increase in material toughness.

Description: A method of monitoring the health of selected solder joints, called SJ-BIST, has been developed by Ridgetop Group Inc. under a Small Business Innovative Research (SBIR) contract. The primary goal of this research program is to test and validate this method in a flight environment using realistically seeded faults in selected solder joints. An additional objective is to gather environmental data for future development of physics-based and data-driven prognostics algorithms. A test board is being designed using a Xilinx FPGA. These boards will be tested both in flight and on the ground using a shaker table and an altitude chamber.

Description: Acoustic emission (AE) data acquired during intermittent load hold tensile testing of epoxy impregnated Kevlar(Registeres TradeMark) 49 (K/Ep) composite strands were analyzed to monitor progressive damage during the approach to tensile failure. Insight into the progressive damage of K/Ep strands was gained by monitoring AE event rate and energy. Source location based on energy attenuation and arrival time data was used to discern between significant AE attributable to microstructural damage and spurious AE attributable to noise. One of the significant findings was the observation of increasing violation of the Kaiser effect (Felicity ratio 〈 1.0) with damage accumulation. The efficacy of three different intermittent load hold stress schedules that allowed the Felicity ratio to be determined analytically is discussed.

Description: An electroactive sensing or actuating material comprises a composite made from a polymer with polarizable moieties and an effective amount of carbon nanotubes incorporated in the polymer for a predetermined electromechanical operation of the composite when such composite is affected by an external stimulus. In another embodiment, the composite comprises a, third component of micro -sized to nano-sized particles of an electroactive ceramic that is also incorporated in the polymer matrix. The method for making the three-phase composite comprises either incorporating the carbon nanotubes in the polymer matrix before incorporation of the particles of ceramic or mixing the carbon nanotubes and particles of ceramic together in a solution before incorporation in the polymer matrix.

Description: Method and system for processing waste from human activities, including solids, liquids and vapors. A fluid-impermeable bag, lined with a liquid-impermeable but vapor-permeable membrane, defining an inner bag, is provided. A vacuum force is provided to extract vapors so that the waste is moved toward a selected region in the inner bag, extracted vapors, including the waste vapors and vaporized portions of the waste liquids are transported across the membrane, and most or all of the solids remain within the liner. Extracted vapors are filtered, and sanitized components thereof are isolated and optionally stored. The solids remaining within the liner are optionally dried and isolated for ultimate disposal.

Description: The present invention is directed to the effective dispersion of carbon nanotubes (CNTs) into polymer matrices. The nanocomposites are prepared using polymer matrices and exhibit a unique combination of properties, most notably, high retention of optical transparency in the visible range (i.e., 400-800 nm), electrical conductivity, and high thermal stability. By appropriate selection of the matrix resin, additional properties such as vacuum ultraviolet radiation resistance, atomic oxygen resistance, high glass transition (T(sub g)) temperatures, and excellent toughness can be attained. The resulting nanocomposites can be used to fabricate or formulate a variety of articles such as coatings on a variety of substrates, films, foams, fibers, threads, adhesives and fiber coated prepreg. The properties of the nanocomposites can be adjusted hy selection of the polymer matrix and CNT to fabricate articles that possess high optical transparency and antistatic behavior.

Description: A gearing system using modular gear bearing components. Each component is composed of a core, one or more modules attached to the core and two or more fastening modules rigidly attaching the modules to the core. The modules, which are attached to the core, may consist of gears, rollers or gear bearing components. The core orientation affects the orientation of the modules attached to the core. This is achieved via the keying arrangement of the core and the component modules that attach to the core. Such an arrangement will also facilitate the phase tuning of gear modules with respect to the core and other gear modules attached to the core.

Description: A gear bearing having a first gear and a second gear, each having a plurality of teeth. Each gear operates on two non-parallel surfaces of the opposing gear teeth to perform both gear and bearing functions simultaneously. The gears are moving at substantially the same speed at their contact points. The gears may be roller gear bearings or phase-shifted gear bearings, and may be arranged in a planet/sun system or used as a transmission. One preferred embodiment discloses and describes an anti-backlash feature to counter ''dead zones'' in the gear bearing movement.

Description: A RF MEMS switch comprising a crossbeam of SiC, supported by at least one leg above a substrate and above a plurality of transmission lines forming a CPW. Bias is provided by at least one layer of metal disposed on a top surface of the SiC crossbeam, such as a layer of chromium followed by a layer of gold, and extending beyond the switch to a biasing pad on the substrate. The switch utilizes stress and conductivity-controlled non-metallic thin cantilevers or bridges, thereby improving the RF characteristics and operational reliability of the switch. The switch can be fabricated with conventional silicon integrated circuit (IC) processing techniques. The design of the switch is very versatile and can be implemented in many transmission line mediums.

Description: The present invention is directed to the effective dispersion of carbon nanotubes (CNTs) into polymer matrices. The nanocomposites are prepared using polymer matrices and exhibit a unique combination of properties, most notably, high retention of optical transparency in the visible range (i.e., 400 800 nm), electrical conductivity, and high thermal stability. By appropriate selection of the matrix resin, additional properties such as vacuum ultraviolet radiation resistance, atomic oxygen resistance, high glass transition (T.sub.g) temperatures, and excellent toughness can be attained. The resulting nanocomposites can be used to fabricate or formulate a variety of articles such as coatings on a variety of substrates, films, foams, fibers, threads, adhesives and fiber coated prepreg. The properties of the nanocomposites can be adjusted by selection of the polymer matrix and CNT to fabricate articles that possess high optical transparency and antistatic behavior.

Description: The Overarching Mission of NASA's Aeronautics Research Mission Directorate (ARMD) is: To advance U.S. technological leadership in aeronautics in partnership with industry, academia, and other government agencies that conduct aeronautics-related research. ARMD supports the Agency's goal of developing a balanced overall program of science, exploration, and aeronautics, and ARMD's research plans also directly support the National Aeronautics R&D Policy and accompanying Executive Order 131419.

Description: An actuator for moving a load has a frame forming a race between two surfaces thereof, at least two elements joined together by at least one flexible member, the elements and the at least one flexible member being disposed between the two surfaces of the frame that forms a race, one of the elements further joined to the load by a portion of the at least one flexible member, wherein when an element comes into contact with a surface of the frame it will stick thereto absent a repelling force, and moving means disposed to selectively attract or repel a corresponding element towards or away from one or the other of the two surfaces of the frame that forms the race. The actuator effects movement of the load in a direction towards or away from the elements, by changing a position of at least one of the elements on a surface of the frame that forms the race.

Description: A method of fabricating a metal/composite hybrid laminate is provided. One or more layered arrangements are stacked on a solid base to form a layered structure. Each layered arrangement is defined by a fibrous material and a perforated metal sheet. A resin in its liquid state is introduced along a portion of the layered structure while a differential pressure is applied across the laminate structure until the resin permeates the fibrous material of each layered arrangement and fills perforations in each perforated metal sheet. The resin is cured thereby yielding a metal/composite hybrid laminate.

Description: Using a remarkable fabric originally developed to protect Apollo astronauts, Birdair Inc. of Amherst, New York, has crafted highly durable, safe, environmentally friendly, and architecturally stunning tensile membrane roofs for over 900 landmark structures around the world. Travelers in airports, sports fans at stadiums, and shoppers in malls have all experienced the benefits of the Teflon-coated fiberglass fabric that has enabled Birdair to grow from a small company established in its founder?s kitchen in 1955 to a multimillion-dollar specialty contractor today.

Description: An electroactive material comprises multiple layers of electroactive composite with each layer having unique dielectric, electrical and mechanical properties that define an electromechanical operation thereof when affected by an external stimulus. For example, each layer can be (i) a 2-phase composite made from a polymer with polarizable moieties and an effective amount of carbon nanotubes incorporated in the polymer for a predetermined electromechanical operation, or (ii) a 3-phase composite having the elements of the 2-phase composite and further including a third component of micro-sized to nano-sized particles of an electroactive ceramic incorporated in the polymer matrix.

Description: Method and system for functionalizing a collection of carbon nanotubes (CNTs). A selected precursor gas (e.g., H2 or F2 or CnHm) is irradiated to provide a cold plasma of selected target species particles, such as atomic H or F, in a first chamber. The target species particles are d irected toward an array of CNTs located in a second chamber while suppressing transport of ultraviolet radiation to the second chamber. A CNT array is functionalized with the target species particles, at or below room temperature, to a point of saturation, in an exposure time interval no longer than about 30 sec. *Discrimination against non-target species is provided by (i) use of a target species having a lifetime that is much greater than a lifetime of a non-target species and/or (2) use of an applied magnetic field to discriminate between charged particle trajectories for target species and for non-target species.

Description: A thin-film electrode for a bio-nanobattery is produced by consecutively depositing arrays of a ferritin protein on a substrate, employing a spin self-assembly procedure. By this procedure, a first ferritin layer is first formed on the substrate, followed by building a second, oppositely-charged ferritin layer on the top of the first ferritin layer to form a bilayer structure. Oppositely-charged ferritin layers are subsequently deposited on top of each other until a desired number of bilayer structures is produced. An ordered, uniform, stable and robust, thin-film electrode material of enhanced packing density is presented, which provides optimal charge density for the bio-nanobattery.

Description: A resilient, flexible, pressure-activated, high-temperature seal is adapted to be interposed between high and low pressure regions to provide sealing between opposing surfaces of adjacent relatively movable structures. The seal comprises at least one C-shaped sheet element. The C-shaped element design enables the seal to be pressure-activated to provide a radially outward biasing force, responsive to a seal-activating pressure differential acting across the seal thereby increasing resiliency. A centrally-located, resilient core structure provides load bearing and insulating properties. In an exemplary embodiment where at least two seal elements are used, each layer has a cutout slot pattern and the remaining strip material pattern. The slots provide flexibility to the seal, enabling the seal to be manually contoured to seal around corners and curves. The strip material of each layer covers the slots in each adjacent layer to minimize leakage through the slots. Attached barrier strips can block interface leakage between the seal and the opposing surfaces.

Description: A thermal test overview of the Constellation Environmental Qualification and Acceptance Test Requirement (CEQATR) is presented. The contents include: 1) CEQATR Thermal Test Overview; 2) CxP Environments; 3) CEQATR Table 1.2-1; 4) Levels of Assembly; 5) Definitions for Levels of Assembly; 6) Hardware Applicability; 7) CEQATR Thermal-Related Definitions; 8) Requirements for unit-level thermal testing; 9) Requirements for major assembly level thermal testing; 10) General thermal testing requirements; 11) General thermal cycle, thermal vacuum profiles; 12) Test tolerances; 13) Vacuum vs Ambient; 14) Thermal Gradient; 15) Sequence of Testing; 16) Alternative Strategies; 17) Protoflight; 18) Halt/Hass; 19) Humidity; and 20) Tailoring.

Description: A test methodology currently employed for large engines was extended to quantify the ballistic containment capability of a small turboshaft engine compressor case. The approach involved impacting the inside of a compressor case with a compressor blade. A gas gun propelled the blade into the case at energy levels representative of failed compressor blades. The test target was a full compressor case. The aft flange was rigidly attached to a test stand and the forward flange was attached to a main frame to provide accurate boundary conditions. A window machined in the case allowed the projectile to pass through and impact the case wall from the inside with the orientation, direction and speed that would occur in a blade-out event. High-peed, digital-video cameras provided accurate velocity and orientation data. Calibrated cameras and digital image correlation software generated full field displacement and strain information at the back side of the impact point.

Description: No abstract available

Description: Foil gas bearings under development for rotorcraft-sized, hot core engine applications have been susceptible to damage from the slow acceleration and rates typically encountered during the pre-ignition stage in conventional engines. Recent laboratory failures have been assumed to be directly linked to operating foil bearings below their lift-off speed while following conventional startup procedures for the engines. In each instance, the continuous sliding contact between the foils and shaft was believed to thermally overload the bearing and cause the engines to fail. These failures highlight the need to characterize required acceleration rates and minimum operating speeds for these applications. In this report, startup experiments were conducted with a large, rotorcraft engine sized foil bearing under moderate load and acceleration rates to identify the proper start procedures needed to avoid bearing failure. The results showed that a bearing under a 39.4 kPa static load can withstand a modest acceleration rate of 500 rpm/s and excessive loitering below the bearing lift-off speed provided an adequate solid lubricant is present.

Description: Cooperative product development projects in the aerospace and defense industry are held hostage to high cost and risk due to poor alignment of collaborative design tools and processes. This impasse can be broken if companies will jointly develop implementation approaches and practices in support of high value working arrangements. The current tools can be used to better advantage in many situations and there is reason for optimism that tool vendors will provide significant support.

Description: In this design, single-wall carbon nanotubes (SWNTs) have been coated in polymer molecules to create a new type of material that has low electrical conductivity, but still contains individual nanotubes, and small ropes of individual nanotubes, which are themselves good electrical conductors and serve as small conducting rods immersed in an electrically insulating matrix. The polymer is attached through weak chemical forces that are primarily non-covalent in nature, caused primarily through polarization rather than the sharing of valence electrons. Therefore, the electronic structure of the SWNT involved is substantially the same as that of free, individual (and small ropes of) SWNT. Their high conductivity makes the individual nanotubes extremely electrically polarizable, and materials containing these individual, highly polarizable molecules exhibit novel electrical properties including a high dielectric constant.

Description: Integrated multilayer insulation (IMLI) is being developed as an improved alternative to conventional multilayer insulation (MLI), which is more than 50 years old. A typical conventional MLI blanket comprises between 10 and 120 metallized polymer films separated by polyester nets. MLI is the best thermal- insulation material for use in a vacuum, and is the insulation material of choice for spacecraft and cryogenic systems. However, conventional MLI has several disadvantages: It is difficult or impossible to maintain the desired value of gap distance between the film layers (and consequently, it is difficult or impossible to ensure consistent performance), and fabrication and installation are labor-intensive and difficult. The development of IMLI is intended to overcome these disadvantages to some extent and to offer some additional advantages over conventional MLI. The main difference between IMLI and conventional MLI lies in the method of maintaining the gaps between the film layers. In IMLI, the film layers are separated by what its developers call a micro-molded discrete matrix, which can be loosely characterized as consisting of arrays of highly engineered, small, lightweight, polymer (typically, thermoplastic) frames attached to, and placed between, the film layers. The term "micro-molded" refers to both the smallness of the frames and the fact that they are fabricated in a process that forms precise small features, described below, that are essential to attainment of the desired properties. The term "discrete" refers to the nature of the matrix as consisting of separate frames, in contradistinction to a unitary frame spanning entire volume of an insulation blanket.

Description: An improved version of composite layer manufacturing (CLM) has been invented. CLM is a type of solid freeform fabrication (SFF) -- an automated process in which a three-dimensional object is built up, point-by-point, through extrusion of a matrix/fiber composite-material precursor. In CLM, the translation and the extrusion operation are such that the final size and shape of the fabricated object are as specified by a computer-aided design (CAD). Sometimes, in order to achieve the desired final shape,

Description: A material having useful thermoelectric properties was synthesized by combining indium-tin-oxide (ITO) with a NiCoCrAlY alloy/alumina cermet. This material had a very large Seebeck coefficient with electromotive-force-versustemperature behavior that is considered to be excellent with respect to utility in thermocouples and other thermoelectric devices. When deposited in thin-film form, ceramic thermocouples offer advantages over precious-metal (based, variously, on platinum or rhodium) thermocouples that are typically used in gas turbines. Ceramic thermocouples exhibit high melting temperatures, chemical stability at high temperatures, and little or no electromigration. Oxide ceramics also resist oxidation better than metal thermocouples, cost substantially less than precious-metal thermocouples, and, unlike precious-metal thermocouples, do not exert catalytic effects.

Description: A methodology for developing complex multifunctional materials that consist of or contain polymer/carbon-nanotube composites has been conceived. As used here, "multifunctional" signifies having additional and/or enhanced physical properties that polymers or polymer-matrix composites would not ordinarily be expected to have. Such properties include useful amounts of electrical conductivity, increased thermal conductivity, and/or increased strength. In the present methodology, these properties are imparted to a given composite through the choice and processing of its polymeric and CNT constituents.

Description: Moisture diffusion in multi-layer carbon composite structures is difficult to model using finite difference methods due to the discontinuity in concentrations between adjacent layers of differing materials. Applying a mass conserving approach at these boundaries proved to be effective at accurately predicting moisture uptake for a sample exposed to a fixed temperature and relative humidity. Details of the model developed are presented and compared with actual moisture uptake data gathered over 130 days from a graphite epoxy composite sandwich coupon with a Rohacell foam core.

Description: A method for designing gas turbine engine components using a coupled parametric analysis of part geometry and flow control is disclosed. Included are the steps of parametrically defining the geometry of the duct wall shape, parametrically defining one or more flow control actuators in the duct wall, measuring a plurality of performance parameters or metrics (e.g., flow characteristics) of the duct and comparing the results of the measurement with desired or target parameters, and selecting the optimal duct geometry and flow control for at least a portion of the duct, the selection process including evaluating the plurality of performance metrics in a pareto analysis. The use of this method in the design of inter-turbine transition ducts, serpentine ducts, inlets, diffusers, and similar components provides a design which reduces pressure losses and flow profile distortions.

Description: Carbon nanotube material having an outer diameter less than 10 nm and a number of walls less than ten are disclosed. Also disclosed are an electron field emission device including a substrate, an optionally layer of adhesion-promoting layer, and a layer of electron field emission material. The electron field emission material includes a carbon nanotube having a number of concentric graphene shells per tube of from two to ten, an outer diameter from 2 to 8 nm, and a nanotube length greater than 0.1 microns. One method to fabricate carbon nanotubes includes the steps of (a) producing a catalyst containing Fe and Mo supported on MgO powder, (b) using a mixture of hydrogen and carbon containing gas as precursors, and (c) heating the catalyst to a temperature above 950.degree. C. to produce a carbon nanotube. Another method of fabricating an electron field emission cathode includes the steps of (a) synthesizing electron field emission materials containing carbon nanotubes with a number of concentric graphene shells per tube from two to ten, an outer diameter of from 2 to 8 nm, and a length greater than 0.1 microns, (b) dispersing the electron field emission material in a suitable solvent, (c) depositing the electron field emission materials onto a substrate, and (d) annealing the substrate.

Description: A rotary phase separator system generally includes a step-shaped rotary drum separator (RDS) and a motor assembly. The aspect ratio of the stepped drum minimizes power for both the accumulating and pumping functions. The accumulator section of the RDS has a relatively small diameter to minimize power losses within an axial length to define significant volume for accumulation. The pumping section of the RDS has a larger diameter to increase pumping head but has a shorter axial length to minimize power losses. The motor assembly drives the RDS at a low speed for separating and accumulating and a higher speed for pumping.

Description: The present invention provides a method of removing silicon nitride at about the same removal rate as silicon dioxide by CMP. The method utilizes a polishing slurry that includes colloidal silica abrasive particles dispersed in water and additives that modulate the silicon dioxide and silicon nitride removal rates such that they are about the same. In one embodiment of the invention, the additive is lysine or lysine mono hydrochloride in combination with picolinic acid, which is effective at a pH of about 8. In another embodiment of the invention, the additive is arginine in combination with picolinic acid, which is effective at a pH of about 10.

Description: A method and system for spatial data manipulation input and distribution via an adaptive wireless transceiver. The method and system include a wireless transceiver for automatically and adaptively controlling wireless transmissions using a Waveform-DNA method. The wireless transceiver can operate simultaneously over both the short and long distances. The wireless transceiver is automatically adaptive and wireless devices can send and receive wireless digital and analog data from various sources rapidly in real-time via available networks and network services.

Description: Carbon fiber composites utilizing flattened, large tow yarns in woven or braided forms are being used in many aerospace applications. Their complex fiber architecture and large unit cell size present challenges in both understanding deformation processes and measuring reliable material properties. This report examines composites made using flattened 12k and 24k standard modulus carbon fiber yarns in a 0 /+60 /-60 triaxial braid architecture. Standard straight-sided tensile coupons are tested with the 0 axial braid fibers either parallel with or perpendicular to the applied tensile load (axial or transverse tensile test, respectively). Nonuniform surface strain resulting from the triaxial braid architecture is examined using photogrammetry. Local regions of high strain concentration are examined to identify where failure initiates and to determine the local strain at the time of initiation. Splitting within fiber bundles is the first failure mode observed at low to intermediate strains. For axial tensile tests splitting is primarily in the 60 bias fibers, which were oriented 60 to the applied load. At higher strains, out-of-plane deformation associated with localized delamination between fiber bundles or damage within fiber bundles is observed. For transverse tensile tests, the splitting is primarily in the 0 axial fibers, which were oriented transverse to the applied load. The initiation and accumulation of local damage causes the global transverse stress-strain curves to become nonlinear and causes failure to occur at a reduced ultimate strain. Extensive delamination at the specimen edges is also observed.

Description: The present invention relates to a conformal gripping device. In an embodiment of the present invention a conformal gripper device may be disclosed comprising a frame that includes an array of movable pins. The device may also include a roller locking and unlocking system within the frame. The system may comprise a pair of locking rollers for each row of gripper pins to facilitate locking and unlocking the array of gripper pins on a column-by-column basis. The system may also include a striker element that may force the locking rollers to roll along an angled roll surface to facilitate unlocking of the array of pins on a column-by-column basis. The system may further include an electromagnetic actuator or solenoid and permanent magnets to facilitate movement of the striker element and the locking rollers.