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The new devices and missions to achieve the aims of NASA's Science Mission Directorate (SMD) are creating increasingly demanding thermal environments and applications. In particular, the low conductance of metal-to-metal interfaces used in the thermal switches lengthen the cool-down phase and resource usage for spacecraft instruments. During this work, we developed and tested a vacuum-compatible, durable, heat-conduction interface that employs carbon nanotube (CNT) arrays directly anchored on the mating metal surfaces via microwave plasma-enhanced, chemical vapor deposition (PECVD). We demonstrated that CNT-based thermal interface materials have the potential to exceed the performance of currently available options for thermal switches and other applications.

This paper presents in-process monitoring and control based on a novel ultrasonic sensing technique. The developed ultrasonic system provides non-contact measurement of surface roughness, which is applicable to wet machining environments. The utility and robustness of the technique are demonstrated through applications to different processes and materials. In-process surface roughness monitoring capability of the system is also shown along with its potential to monitor flank wear conditions. The result of in-process surface roughness control implementation based on the developed technique shows the control scheme is able to maintain consistent surface roughness values regardless of the tool wear state.

A high fidelity, direct-interface, fusible heat sink for cooling astronauts during extravehicular activity was constructed and tested. The design includes special connectors that allow the coolant loop to be directly connected to the fusible material, in this case water. Aspects tested were start-up characteristics, cooling rate, and performance during simulated heat loads. A simplified math model was used to predict the effect of increasing the effective thermal conductivity on heat sink freezing rate. An experiment was designed to measure the effective thermal conductivity of a water/Aluminum foam system, and full gravity tests were conducted to compare the freezing rates of water and water/foam systems. This paper discusses the results of these efforts.

This paper describes research to analyze widespread fatigue damage in lap joints. The particular objective is to determine when large numbers of small cracks could degrade the joint strength to an unacceptable level. A deterministic model is described to compute fatigue crack growth and residual strength of riveted panels that contain multiple cracks. Fatigue crack growth tests conducted to evaluate the predictive model are summarized, and indicate good agreement between experimental and numerical results. Monte Carlo simulations are then performed to determine the influence of statistical variability on various analysis parameters.

Throughout the industry, organizations struggle with the task of implementing effective human factors programs aimed at reducing maintenance errors. Almost universally, many barriers have frustrated these efforts. In 1998 and 1999, the National Transportation Safety Board sponsored two workshops designed at identifying barriers to the implementation of human factors programs and to explore what was working and what was not working among the many industry efforts. This paper explores the findings of these workshops. In addition, it will report findings of Purdue University studies that reveal a rapid deterioration of even the most successful human factors programs. The research findings disclose several “disconnects” within most organizations which rapidly negate the positive effects of successful human factors and error management training and nullify many proactive human factors programs.

The formation of ice on aircraft is a highly dynamic process during which ice will expand and contract upon freezing and undergoing changes in temperature. Finite element analysis (FEA) simulations were performed investigating the stress/strain response of an idealized ice sample bonded to an acrylic substrate subjected to a uniform temperature change. The FEA predictions were used to guide the placement of strain gages on custom-built acrylic and aluminum specimens. Tee rosettes were placed in two configurations adjacent to thermocouple sensors. The specimens were then placed in icing conditions such that ice was grown on top of the specimen. It was hypothesized that the ice would expand on freezing and contract as the temperature of the interface returned to the equilibrium conditions.

Fatigue damage prediction approaches in both time and frequency domains have been developed to simulate the operational life of mechanical structures under random loads. Fatigue assessment of mechanical structures and components subjected to those random loads is increasingly being addressed by frequency domain approaches because of time and cost savings. Current frequency-based fatigue prediction methods focus on stationary random loadings (stationary Power Spectral Density), but many machine components, such as jet engines, rotating machines, and tracked vehicles are subjected to non-stationary PSD conditions under real service loadings. This paper describes a new fatigue damage modeling approach capable of predicting fatigue damage for structures exposed to non-stationary (evolutionary) PSD loading conditions where the PSD frequency content is time-varying.

NASA’s planned advanced space transportation vehicles will benefit from the use of integral/conformal cryogenic propellant tanks which will reduce the launch weight and lower the earth-to-orbit costs considerably. To implement the novel concept of integral/conformal tanks requires developing an equally novel concept in thermal protection materials. Providing insulation against reentry heating and preserving propellant mass can no longer be considered separate problems to be handled by separate materials. A new family of materials, Superthermal Insulation (STI), has been conceived and investigated by NASA’s Ames Research Center to simultaneously provide both thermal protection and cryogenic insulation in a single, integral material. The present paper presents the results of a series of proof-of-concept tests intended to characterize the thermal performance of STI over a range of operational conditions representative of those which will be encountered in use.

The objective of this study was to subject small female and large male cadavers to simulated rear impact, document soft-tissue injuries to the neck, determine the kinematics, forces and moments at the occipital condyles, and evaluate neck injury risks using peak force, peak tension and normalized tension-extension criteria. Five unembalmed intact human cadavers (four small females and one large male) were prepared using accelerometers and targets at the head, T1, iliac crest, and sacrum. The specimens were placed on a custom- designed seat without head restraint and subjected to rear impact using sled equipment. High-speed cameras were used for kinematic coverage. After the test, x-rays were obtained, computed tomography scans were taken, and anatomical sections were obtained using a cryomicrotome. Two female specimens were tested at 4.3 m/s (mean) and the other two were tested at 6.8 m/s (mean), and one large male specimen was subjected to 6.6 m/s velocity.

Driveline and suspension notched components of off-road ground vehicles often experience multiaxial fatigue failures along notch locations. Large nominal load histories may induce local elasto-plastic stress and strain responses at the critical notch locations. Fatigue life prediction of such notched components requires detailed knowledge of local stresses and strains at notch regions. The notched components that are often subject to multiaxial loadings in services, experience complex stress and strain responses. Fatigue life assessment of the components utilizing non-linear Finite Element Analysis (FEA) require unfeasibly inefficient computation times and large data. The lack of more efficient and effective methods of elasto-plastic stress-strain calculation may lead to the overdesign or earlier failures of the components or costly experiments and inefficient non-linear FEA.

The purpose of this study was to determine neck strength characteristics of children indirectly using scaling relationships through a caprine animal model. Because of the necessity to evaluate airbag designs for injury risk to the out- of-position child, a strong foundation of experimental data is needed to obtain appropriate tolerance values. Cadaver caprine cervical spines of different ages were tested mechanically in non-destructive bending and destructive tensile modes. Injuries induced in destructive testing such as endplate failure and ligament tears were consistent with clinical observations. Specimens demonstrated statistically significant increased strength characteristics with age. Scaling relationships were developed with respect to the adult specimens. For the tensile failure load the scaling percentages were 78%, 38%, 20%, and 12% for the twelve-, six-, three-, and one-year-old, respectively.