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Operational issues encountered by Apollo astronauts relating to lunar dust were catalogued, including material abrasion that resulted in scratches and wear on spacesuit components, ultimately impacting visibility, joint mobility and pressure retention. Standard methods are being developed to measure abrasive wear on candidate construction materials to be used for spacesuits, spacecraft, and robotics. Calibration tests were conducted using a standard diamond stylus scratch tip on the common spacecraft structure aluminum, Al 6061-T6. Custom tips were fabricated from terrestrial counterparts of lunar minerals for scratching Al 6061-T6 and comparing to standard diamond scratches. Considerations are offered for how to apply standards when selecting materials and developing dust mitigation strategies for lunar architecture elements.

The thick oxide layer of silicon-on-insulator (SOI) devices significantly reduces the junction leakage current at elevated temperatures compared to similar Si devices, resulting in an elevated maximum operating temperature. The maximum operating temperature, specified by manufacturers, of commercial SOI devices/circuits with conventional packaging is usually 225°C. It is important to understand the performance and de-ratings of these SOI circuits at temperatures above 225°C without the temperature limit imposed by commercial packaging technology. This work tested a low frequency square-wave oscillator based on an SOI 555 Timer with a special high temperature ceramic packaging technology from room temperature to 375°C. The timer die was attached to a 96% aluminum oxide substrate with high temperature durable gold (Au) thick-film metallization, and interconnected with Au wires.

A completely nondestructive means of r-value measurement is being developed. Unlike the modul-r method, it requires no specimen removal and has potential for on-line measure-ment. The method employs noncontacting ultrasonic transducers which generate waves propagating at three different angles relative to the sheet rolling direction. A prototype instrument based on these principles has been jointly developed by researchers at Ford Motor Company and National Institute of Standards and Technology (NIST). At present, there are correlations between ultrasonic and mechanical measurements of r̄. The ultrasonic measurements generally agree with mechanical measurements to 0.1 or better. A method based on metallurgical theories is being developed to use ultrasonic velocity measure-ments to predict not only r̄, but individual r values. To date, all measurements have been made on static sheet. We are currently developing a device to move sheet metal at controlled velocity.

Smoke detection experiments were conducted in the Microgravity Science Glovebox (MSG) on the International Space Station (ISS) during Expedition 15 in an experiment entitled Smoke Aerosol Measurement Experiment (SAME). The preliminary results from these experiments are presented. In order to simulate detection of a prefire overheated-material event, samples of five different materials were heated to temperatures below the ignition point. The smoke generation conditions were controlled to provide repeatable sample surface temperatures and air flow conditions. The smoke properties were measured using particulate aerosol diagnostics that measure different moments of the size distribution. These statistics were combined to determine the count mean diameter which can be used to describe the overall smoke distribution.

The calibration of yield functions for numerical sheet forming simulations is done using different experimental approaches such as the uniaxial tensile test, the bulge test, etc. How accurately the material behavior of dedicated aluminum, conventional and high strengths steel grades subjected to various loading conditions can be modeled is investigated using e.g. uniaxial tensile test data only. Different formulations of yield functions that are widely used in industry (e.g. Hill'48, Hosford'79, Hill'90) are considered. It is shown that tensile test data is insufficient to successfully calibrate yield functions for numerical sheet forming simulations especially for aluminum and pronounced anisotropic steel. The use of improved formulations of yield functions is emphasized.

We consider the heat transfer characteristics of an ideal concentric disk used in the Wiped-Film Rotating-Disk (WFRD) evaporator for the Vapor Phase Catalytic Ammonia Removal (VPCAR) water recovery system. A mathematical model is derived to predict the radial temperature distribution and its average over the surface of the disk as a function of system parameters. The model shows self-similarity of the temperature distribution and the existence of a dimensionless parameter S (ratio of heat flux to convection) that can be used as a criterion to optimize the thermal characteristics of the disk in order to approach uniform surface temperature. Comparison of the model to experimental data using global (infrared imager) and local (resistive temperature devices) measurements shows that agreement with the model depends on the ambient condition denoted by the local heat transfer coefficient.

This paper presents results from a smoke detection experiment entitled Smoke Aerosol Measurement Experiment (SAME) which was conducted in the Microgravity Science Glovebox on the International Space Station (ISS) during Expedition 15. Five different materials representative of those found in spacecraft were pyrolyzed at temperatures below the ignition point with conditions controlled to provide repeatable sample surface temperatures and air flow conditions. The sample materials were Teflon®, Kapton®, cellulose, silicone rubber and dibutylphthalate. The transport time from the smoke source to the detector was simulated by holding the smoke in an aging chamber for times ranging from 10 to1800 seconds. Smoke particle samples were collected on Transmission Electron Microscope (TEM) grids for post-flight analysis.

In order to study dust propagation and mitigation techniques, an inertial separation and gravitational settling experiment rig was constructed and used for experimental work in reduced gravity aircraft flights. The first experimental objective was to test dust filtration by a cyclone separator in lunar gravity. The second objective was to characterize dust flow and settling in lunar gravity in order to devise more comprehensive dust mitigation strategies. A settling channel provided a flow length over which particles settled out of the air flow stream. The experimental data provides particle quantity and size distribution, and a means of verifying numerical predictions.

The complex strain states that exist within a real metal stamping are likely to generate different surface morphologies when compared to the same level of plastic strain produced via single pass deformation. This study quantifies the surface morphology that develops when an as-received traditional plain carbon steel sheet is deformed under two different single-pass, in-plane stretching operations. Roughness measurements performed in the as-received condition with a high resolution scanning laser confocal microscope revealed that an initial surface roughness did not appear to influence the deformation generated with biaxial strain. However, the initial surface roughness could have affected the deformation generated with uniaxial strain. The roughness data were fitted to a probability density function (PDF) and resulted in a near-ideal Gaussian distribution of the surface profile heights.

The airworthiness authorities (FAA, JAA, Transport Canada) will be releasing a draft rule in the 2006 timeframe concerning the operation of aircraft in a Supercooled Large Droplet (SLD) environment aloft. The draft rule will require aircraft manufacturers to demonstrate that their aircraft can operate safely in an SLD environment for a period of time to facilitate a safe exit from the condition. It is anticipated that aircraft manufacturers will require a capability to demonstrate compliance with this rule via experimental means (icing tunnels or tankers) and by analytical means (ice prediction codes). Since existing icing research facilities and analytical codes were not developed to account for SLD conditions, current engineering tools are not adequate to support compliance activities in SLD conditions. Therefore, existing capabilities need to be augmented to include SLD conditions.

Prediction of springback has become a major focus in sheet metal forming. Validation of finite element codes that are being developed to predict springback require accurate property data and a more complete understanding of the residual stresses that are involved. To provide experimental data for these calculations, neutron and synchrotron X-ray diffraction measurements were carried out to determine the through-thickness distribution of axial and hoop (or tangential) residual stresses in deep-drawn steel and aluminum cups. The techniques are able to provide true spatial resolutions as low as 0.05 mm for a strain measurement on cups with ≤ 1 mm wall thickness. It was found that the stresses exhibit non-linear gradients through the thickness that also depend on the axial position.

In a recent preliminary report of the National Research Council, it is stated that U.S. manufacturers are increasingly coming to depend upon information technology--computers, communications, and complex systems that combine the two. As a first approximation, any information infrastructure for manufacturing will be based on distributed systems of fast, reliable, and relatively inexpensive computers linked by high-speed, high-bandwidth networks.

The history and current status of spacecraft smoke detection is discussed including a review of the state of understanding of the effect of gravity on the resultant smoke particle size. The results from a spacecraft experiment (Comparative Soot Diagnostics (CSD)) which measured microgravity smoke particle sizes are presented. Five different materials were tested producing smokes with different properties including solid aerosol smokes and liquid droplets aerosol smokes. The particulate size distribution for the solid particulate smokes increased substantially in microgravity and the results suggested a corresponding increase for the smokes consisting of a liquid aerosol. A planned follow on experiment that will resolve the issues raised by CSD is presented. Early results from this effort have provided the first measurements of the ambient aerosol environment on the ISS (International Space Station) and suggest that the ISS has very low ambient particle levels.

Using a new fiber electrode technology, currently developed and produced by Bekaert Corporation (Bekaert), Electro Energy, Inc., (EEI) Mobile Energy Products Group (formerly, Eagle-Picher Technologies, LLC, Power Systems Department) in Colorado Springs, CO has demonstrated that it is feasible to manufacture flight weight nickel hydrogen cells having about twice the specific energy (80 vs. 40 watt-hr./kg) as state-of-the-art nickel hydrogen cells that are currently flown on geosynchronous communications satellites. Although lithium-ion battery technology has made large in-roads to replace the nickel alkaline technology (nickel-cadmium, nickel-metal hydride), the technology offered here competes with lithium-ion weight and offers alternatives not present in the lithium-ion chemistry such as: ability to undergo a continuous overcharge, reversal on discharge, and sustain rate capability sufficient to start automotive and aircraft engines at subzero temperatures.

Experimental procedures and results of a benchmark test for springback are reported and a complete suite of obtained data is provided for the validation of forming and springback simulation software. The test is usually referred as the Slit-Ring test where a cylindrical cup is first formed by deep drawing and then a ring is cut from the mid-section of the cup. The opening of the ring upon slitting releases the residual stresses in the formed cup and provides a valuable set of easy-to-measure, easy-to-characterize springback data. The test represents a realistic deep draw stamping operation with stretching and bending deformation, and is highly repeatable in a laboratory environment. In this study, six different automotive materials are evaluated.

Numerical solutions have been generated which simulate flow inside an aircraft engine flying at altitude through an ice crystal cloud. The geometry used for this study is the Honeywell Uncertified Research Engine (HURE) which was recently tested in the NASA Propulsion Systems Laboratory (PSL) in January 2018. The simulations were carried out at predicted operating points with a potential risk of ice accretion. The extent of the simulation is from upstream of the engine inlet to downstream past the strut in the core and bypass. The flow solution is produced using GlennHT, a NASA in-house code. A mixing plane approximation is used upstream and downstream of the fan. The use of the mixing plane allows for steady state solutions in the relative frame. The flow solution is then passed on to LEWICE3D for particle trajectory, impact and breakup prediction. The LEWICE3D code also uses a mixing plane approximation at the boundaries upstream and downstream of the fan.

Development of a high specific energy battery is one of the objectives of the lightweight nickel-hydrogen (Ni-H2) program at the NASA Glenn Research Center. The approach has been to improve the nickel electrode by continuing combined in-house and contract efforts to develop a lighter weight electrode for the nickel-hydrogen cell. Small fiber diameter nickel plaques are used as conductive supports for the nickel hydroxide active material. These plaques are commercial products and have an advantage of increased surface area available for the deposition of active material. Initial tests include activation and capacity measurements at five different discharge levels, C/2, 1.0C, 1.37C, 2.0C, and 2.74C. The electrodes are life cycle tested using a half-cell configuration at 40 and 80% depths-of-discharge (DOD) in a low-Earth-orbit regime. The electrodes that pass the initial tests are life cycle-tested in a boilerplate nickel-hydrogen cell before flightweight designs are built and tested.

Refractive secondary concentrators are being considered for solar thermal applications because of their ability to achieve maximum efficiency through the use of total internal reflection for the concentration and distribution of solar energy. A prototype refractive secondary concentrator was built based on ray tracing analysis to demonstrate this collection and distribution concept. The design included a conical secondary concentrator and a faceted extractor. The objective of this effort was to functionally evaluate the performance of the refractive secondary concentrator/extractor prototype and to compare the results with modeling. Most of the light was found to exit the refractive secondary concentrator through the extractor. In addition, the degree of attenuation encountered by the light as it passed through the refractive secondary concentrator was of interest.

NASA and the FAA conducted two flight campaigns to quantify onboard weather radar measurements with in-situ measurements of high concentrations of ice crystals found in deep convective storms. The ultimate goal of this research was to improve the understanding of high ice water content (HIWC) and develop onboard weather radar processing techniques to detect regions of HIWC ahead of an aircraft to enable tactical avoidance of the potentially hazardous conditions. Both HIWC RADAR campaigns utilized the NASA DC-8 Airborne Science Laboratory equipped with a Honeywell RDR-4000 weather radar and in-situ microphysical instruments to characterize the ice crystal clouds. The purpose of this paper is to summarize how these campaigns were conducted and highlight key results. The first campaign was conducted in August 2015 with a base of operations in Ft. Lauderdale, Florida.