Capabilities Briefingp g

2010

Engineering Division

• Advanced Materials Research and Characterization

132 Engineering Employees

BS

• Electromechanical Systems Design and integration

• Environment and Energy Research

MS

Technical Support

ResearchPhD

• 4 Locations in Alabama– Birmingham (2), Huntsville,

and Wilsonville

• Durham, North Carolina

Systems Development DepartmentSystems Development Department

Electro-Mechanical SystemsElectro Mechanical Systems• Design, Modeling, Fabrication,

Integration, Test and LRIP Production CapabilitiesCapabilities

• Stabilized Platforms– EO/IR Seekers– Scanning Mirror Assemblies– Gimbals--- 5” to 33”; 2, 3, or 4 axes

• Servo Controller Electronics Design

Imaging Systems and Targeting• Visible and IR image processing• Real-time contrast enhancement• Cueing• Video trackers

– VME-based CCAs– PC-based

HDTV Vid T k– HDTV Video Tracker• Inertial pointing and target geo-location

extraction

Systems Integration - podsSystems Integration pods• Aircraft integration

– Experience on multiple platformsplatforms

– Fixed/rotary wing– Low-speed/supersonic

Turnkey systems– Turnkey systems– User-configurable payloads

• Sensor IntegrationMechanical Packaging– Mechanical Packaging

– Electronics Development/Support

Systems Integration –Large Multi axis TurretsLarge Multi-axis Turrets

• Multi-sensors compatibility• Readily configured for various payloads• Large collection apertures• Longer focal length lens capability

Airborne Imaging and g gRecording System (AIRS)

• System design and developmenty g p• Pre/post mission support• New sensor package development• Can be used for persistent surveillance• Geo location extraction• Geo-location extraction

WB57

Various Payloads for AIRSWAVE Tsunami

WAVE II

NEHI-ORANGE

ATOMMSNCAM

Sample Imagery 50K’ Alt.

Sample Imagery 50K’ Alt.

Mechanics and Materials ResearchMechanics and Materials Research

Mechanical, Thermal, and Physical Properties CharacterizationProperties Characterization

• Mechanical and Subscale Structural TestingCryo ( 260°C) to Elevated (3030°C) Temps– Cryo (-260°C) to Elevated (3030°C) Temps

• Thermal Properties and Analysis Testingp y g– Cryo (-260°C) to Elevated (3030°C) Temps

• Physical Properties• Physical Properties– Permeability, Porosity, Chemistry, Microscopy, Moisture

Properties, Density, etc.

• Non-Destructive Evaluation– Radiography CT Ultrasonics Resistivity Eddy CurrentRadiography, CT, Ultrasonics, Resistivity, Eddy Current

Mechanics and Materials Research

• Missile Defense• Aero Propulsion• Composite Flight Hardware• Test Technology Development

Mechanics and Materials Research• Hypersonic Vehicles -

Prompt Global Strike– Ground testing– Ground testing– Material characterization– Aero-Thermal modeling

• NASA’s Heavy Lift Programs– Builds on our Shuttle program

legacy– Advanced propulsion and

heatshield materials

Ground Testing for Hypersonics

● Supports AF, Navy and Army in Ground Test Evaluations of Candidate Materials and Shapes

● Thermal Protection Materials Ground Test Experience / Improvements AEDC arcs HEAT-HR, -H1, -H2, -H3

AEDC Tunnels A B 9 and DET- AEDC Tunnels A, B, 9 and DET- AEDC Ballistic Range- NASA-Ames IHF and AHF Arcs- Boeing LCAT Arc

Double-sided wedge in H1 (side view)

g- USAF LHMEL Laser

● Post-Test Analyses- define sample boundary conditionsdefine sample boundary conditions- evaluate material ablative/thermal

performance

Strain Field Visualization

• Non-contact method of measuring shape & strain on surface of materialp

• Obtain strain distribution instead of only single value

• Visualize how strain changes with increased load, temperature, etc.

Hypersonic VehiclesHypersonic Vehicles

Large Structures Testing

• Facilities– 10’x10’x12’ high load frameg– multi-axis servo-hydraulic– 100+ channels data

acquisitionacquisition

• Test Engineering– SLT planning and

di ticoordination– Test fixture design and

fabrication– Specimen prep and

instrumentation– Data reduction and reporting

Environment and Energy

Environment and EnergyNorth Carolina OverviewNorth Carolina Overview

• Established in 1991• ~50 Staff

– Engineers (BS to PhD)– Scientists and chemists– Scientists and chemists– Technicians & mechanics– Administrative staff

• Facilities– 42,000 ft2 of office, R&D prototyping, & lab space– Technology field deployment/performance verification teams Technology field deployment/performance verification teams

and equipment

• ClientsI d t t t h l i l t & d l– Industry, government, technology implementers & developers

Environment and Energy - North Carolina

• Technology Development & Deployment Support– Prototype & pilot advanced

energy & fuel mfg. technology– Manage commercial demo's of

energy & transport technologies Pilot Plant Commercial Demonstration

– 3rd party performance testing– Technical feasibility assessment

Assessment of technology deployment strategies

Lab Proto-typing

Pilot Plant Optimiz-ation

Demonstration

– Assessment of technology deployment strategies

• Industries and Technology Areas – Advanced energy and transportation devices: bioenergy,

biofuels, waste-to-energy, distributed power, co-gen... – Fossil fuel production and distribution: coal, oil, gas– Greenhouse gas mitigation, criteria pollutant mitigationGreenhouse gas mitigation, criteria pollutant mitigation

Recent Energy Technology Research & Development Effortsp

• Biomass to clean diesel, alcohol, or sugar using two biorefinery pilot plants (thermochemical, hydrolysis)y p p ( , y y )

• New biomass/coal feeder for advanced low CO2power production facilitiesp p

• Advanced hot syngas cleaning reactor for use on biomass gasifiersg

• CO2 & MSW to boiler fuel with molten metal gasification

Clean Energy Technology Development Center (Durham, NC)

Recent Small-Scale Technology Deployment EffortsDeployment Efforts

• Five different fuel cells: a private home two commercial sites two waste sitestwo commercial sites, two waste sites

• New fuels and additives for mine vehicles and locomotivesvehicles and locomotives

• Two farm manure waste-to-energy systems coupled to microturbines y p& advanced engines

• Geothermal water heater at a l bcommercial businesses

• Zero emission natural gas wellhead gas sweetening unitgas sweetening unit

Recent Moderate-Scale Technology Deployment EffortsDeployment Efforts

• Project Description – Plan for and install a system to capture and

utilize extremely low energy landfill methane gas to produce power, eliminate flaring and reduce emissions

– Perform independent third party performance verification of the integrated system (technology and economic performance)

– Client: DoD, Fort Benning, GA

• Technology Description• Technology Description– Flex-Microturbine®, a unique power plant

that generates electricity from gases with h t t t f 15 BTU bi f t heat contents of 15 BTU per cubic foot.

Recent Moderate-Scale Technology Deployment EffortsDeployment Efforts

• Project Description – Plan for and install a solar driven chiller to

provide cooling and hot water for a food service operation

– Perform independent third party performance verification of the integrated system (technology and economic performance)

– Client: DoD, Parris Island, SC

• Technology Description– Integrated hot water solar panels

and high efficiency adsorption chiller system

NYSERDA Clean Diesel Technology Field Demonstration Program

• Provide assessments of the in-use performanceof commercially available diesel retrofit control t h l i t d ffi i t di l technologies to expand energy-efficient diesel emission control technology options for off-road applications in New York State. pp

Environment and Energy – Alabama Operationsp

Power Systems Research Group• Combustion Research Facility and Lab-Scale Gasifier• Catalyst Test Facility & Development Lab• Catalyst Test Facility & Development Lab• Fossil Fuels, Biomass, and Flyash Analyses

Environmental Services Group● Precipitator, Baghouse, Scrubber Evaluations● SCR Studies, Analytical Services, Electrical Resistivity● Water/Wastewater Analysis and Remediation

National Carbon Capture Center (Wilsonville)CO C t R h (P d P t C b ti )• CO2 Capture Research (Pre- and Post-Combustion)

• Hot-Gas Cleanup Research• On-Site Analytical Support

Biomass Testing for Co-Firing and Coal Replacement

• New and potential regulations have • New and potential regulations have increased interests in biomass for power generation.

• Canadian utilities required to convert from coal to 100% biomass or shut down plants.

• Ability to store, mill, and burn fuel and control alkali metals are critical issues being addressed.

j i h d d• Projects with EPRI, OPG, Vendors, and other utilities.

Oxy-Firing for COfor CO22 MitigationMitigation● Retrofit for existing coal-fixed power

stations

● Minimized capital expenditure

● Staged-oxygen burners – moderate heat release, provide stable flame, and reduce NO

MAXON Corporation Oxy-Burner with flue-gas recycle at Southern Research

● Oxygen Introduced at burner

● Pure CO2 in exhaust stream

● CO2 – sequestration technologiesFlue-gas recycle loop

● CO2 sequestration technologies

Capabilities with Sorbents and Catalysts• Sorbent/Catalyst Development• Sorbent/Catalyst Development

— Grinding, solution preparation, precipitation, precipitate recovery, and drying

— Activate catalysts by reduction in H CO etcActivate catalysts by reduction in H2, CO, etc

— Spray dryer for small-pilot-scale production

• Sorbent/Catalyst Characterization— PSD, surface area, porosity, pore-size distribution

— SEM/EDX

— TGA, DSC, and DTA for studies of reactivity

H t t i t l SEM t b — Hot-stage, environmental SEM to observe reactions on and in particles

• Sorbent/Catalyst Evaluation— Reactivity studies with controllable synthetic gas Reactivity studies with controllable synthetic gas

mixtures

— Real-time gas analysis by GCMS/FTIR/GC

— Injection of sulfur compounds, halides, and trace l d i imetals to study poisoning

Environmental Field Services• Field evaluation of NOx control, Hg oxidation, and SO3

formation.― Effect of SCR on mercury oxidation.― SO3 formation in boilers.SO3 formation in boilers.― Long-term baghouse monitoring program.

• Highly-regarded studies of fly ash properties.― First demonstration of method for recreating particle-size First demonstration of method for recreating particle size

distributions.

• Unique capabilities in scrubber mist eliminator evaluation using SRI-developed video droplet analyzer.

Vapor-Phase Mercury Measurement

QSISTM Probe and Gas Conditioning Systemg y

i dMercury Monitor and Spike Source

Water & Wastewater Treatment

1. Determination of the chemical and

Remediation Steps

physical constituents in effluents.2. Determination of problematic

constituents.3. Remediation strategies for the

identified problematic constituents.

– Bench, Bucket, Pilot and Full-scale testing

Water & Wastewater Treatment

• Remediation of Problematic Constituents

Capabilities at Southern Research

• Remediation of Problematic Constituents– Selenium– Mercury

Arsenic– Arsenic– Nitrogen forms– Biochemical oxygen demand

• Analytical Methods– Total inorganic analyses (ICP-ORS-MS)

Speciation of Selenium and Mercury– Speciation of Selenium and Mercury– Water Chemistry Parameters

Backup SlidesBackup Slides

Materials Characterization

• Materials Characterization is the core technology of Southern Research Engineering Division

• Key technical developments date to mid 1950’s– Gas Bearing Tensile (IR100)– 5500ºF (3030°C) furnace for general use – 6500°F (3590°C) furnace for special applications

• Developments driven by high temperature, brittle material applications– Reentry– Planetary reentry– Nuclear– Launch Vehicles– Aeropropulsion

Mechanical Property Measurements

• Full Range of Properties– Tension

C i– Compression– Shear– Flexure– Fatigue– Fatigue– Creep

• Cryogenic to 5500° F• Inert, Air, Environmental Conditioning etc.Inert, Air, Environmental Conditioning etc.• >40 Facilities, • Hundreds of Set-ups

– Extensive experience in testing composites, brittle materials Extensive experience in testing composites, brittle materials and other materials with unusual behaviors

– Development of tests techniques appropriate for these materials and environments

Mechanical Property Measurements

• Specialized Testing Capabilities– Gas Bearing Tension, Compression and Torsion (to 5500°F) – Cryogenic Tension and Compression (-440° in Dev.)– High Temperature Ring Tests (to 5000°F)

• Tension• Compression• Compression

– Oxidative Fatigue (Cryogenic to 3000°+)– Yarn/Fiber/Wire Tensile/Creep tests (to 5500°F)– Microyield (f/°T)– Tensile/Compressive Creep in Air (to 3000°F)– Thermal Stress Testing – Biaxial Flexure and Torsion

R i d Th l G h ( d i )– Restrained Thermal Growth (coupon and ring)– Rail, Saddle and Iosepescu shear

Thermal Property Measurements

• Thermal Conductivity Testing– Comparative Rod Apparatus - Cryo to

2000° F

Thermal Conductivity of a Fiber ReinforcedCeramic Matrix Composite

– Radial Inflow Apparatus - 1500 to 5000° F

– Pulse Laser Thermal Diffusivity - RT to 3000° FModified C 177 Guarded Hot Plate

rmal

Con

duct

ivity

Inplane

Through Thickness

– Modified C-177 Guarded Hot Plate

• Thermal Analysis Testing– Nietze 404 DSC - RT to 2600°

Adi b i C l i

0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400

The

r– Adiabatic Calorimetry – Ice Calorimetry – TA DSC– TA DMA

TA TGA Temperature, °C– TA TGA– SRI TGA - RT to 2000° (3600°/min),

O2, Multi - gm samples

Thermal Property Measurement CapabilitiesThermal Property Measurement Capabilities

Specialized Testing Capabilities

• Cryocoolers for cryogenic y y gproperties

• Thermal conductivity under load.

• Vacuum thermal response measurements

SPECIMENEDM GRAPHITEHEARTH GRAPHITE

10 INCHES

ELEMENT GRAPHITEZIRCAR (???)MIN KSTAINLESS STEELCOPPER

ATMOSPHERIC PRESSURE TOVACUUMTEMPERATURE OVER 3000 DEGREES (4500)

Thermal Property Measurements

• Thermal Expansion Facilities– NIST Quartz Dilatometers (Cryo to 1800° F)NIST Quartz Dilatometers (Cryo to 1800 F)– Horizontal Quartz Dilatometers (Cryo to 1800°

F)– Graphite Dilatometers (RT to 5000° F)– Optical Thermal Expansion (RT to 5000° F)

80

100

Q t Dil t t

Across Ply Thermal Expansion for Silica Phenolic

Optical Thermal Expansion (RT to 5000 F)– Precision Thermal Expansion (20 K to 400 K)– Ring Thermal Expansion (RT to 5000° F)

• Analog-20

0

20

40

60

herm

al E

xpan

sion

( x

0.00

1 in

/in ) TE-AP-03

Run: K534-153 Density: 1.7134 gm/cm³

TE-AP-04 Run: K534-154 Density: 1.7093 gm/cm³

Quartz Dilatometer

– Simulation Facility– LHMEL (USAF)– Quartz Lamps– Oxyacetylene Torch -100

-80

-60

-40

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Uni

t Th

Red symbols represent data measured after cooling to room temperature

• Total Normal EmmissivityTemperature ( °F )

Thermal Property Measurements

• Thermal Properties Testing

TGA d f Sili Ph li W i h L d D i i V T(-440° F to 5500° F)– Thermal Conductivity– Thermal Diffusivity– Thermal Expansion

TGA data for Silica Phenolic - Weight Lose and Derivative Versus Temperature

95

100

105

0.07

0.08

0.09

0.1

TGA-1

TGA-2

Heating Rate: 20°C/minEnvironment: Nitrogen

– Thermal Expansion– Specific Heat

• Thermal Analysis Testing– TGA 80

85

90

Wei

ght (

%)

0.03

0.04

0.05

0.06

1 - 81.37%2 - 81.36%TGA

– DSC• Analog Facilities• Thermal-optical

70

75

0 200 400 600 800 1000 1200

Temperature (°C)

0

0.01

0.02

p• Physical• Mass Flow

Radiant Facility II

• Infrared heat source by Research, Inc.• Up to 12 x 9” heated area• Up to fifteen 2000 W / 240 V bulbs• Water-cooled, polished aluminum reflector• Capable of temperature or flux control• Data logging with Agilent 34970A and Labview• Horizontal

New Ultrasonic Spectroscopy Technique

Rapidly Swept WaveE ti W f Di iti d Entire Waveform Digitized

FFT of Sweep Gives Flat Spectrum Bandwidth and Amplitude User Defined

Ultrasonic Spectroscopy

Attenuation as a Function of Frequency

Normalized Input Spectrum for 0.5 to 2.25 MHz Compared to Traditional Broadband Input Spectrum

140

160

Ultrasonic Spectroscopy Modes of Interaction

Dispersion/Defect InteractionResonance

60

80

100

120

Rel

ativ

e Am

plitu

de

SRI UltrasonicSpectroscopy

Traditional Broadband

0

20

40

0 0.5 1 1.5 2 2.5 3

Frequency (MHz)

Other Measurement Capabilities

• Permeability

p

– Ambient to 3500° F– High Pressure (incl.. H2)– Effect of loads

• Porosity• Porosity– Hg porosimetry– He Pycnometry– Liquid Absorption

Mi• Microscopy– SEM– Optical

• ChemistryChemistry– Resin Content– Wet chemistry as required

Non-destructive Characterization

2.5

1/16" THICK ALUMINIM SHEET• RadiographyC lli t d

1

1.5

2

MA

GN

ITU

DE

– Collimated• Computed tomography• Ultrasonics

Velocity0

0.5

0 2 4 6 8 10 12

FREQUENCY (MHz)

– Velocity– Pulse echo– Attenuation

• Electrical resistivity D f t d t ti• Electrical resistivity• Eddy current• Metrology

• Defect detection• Material identification• Material fingerprinting• Physical properties• Physical properties

Precision MetrologyPrecision Metrology

• Ordered ScannerMeasures Z height along an X Y grid– Measures Z height along an X-Y grid

– Specular & Diffuse– Multiple systems some using

confocal and some triangulation2 mil accuracy – 2 mil accuracy

• Portable CMM– 8 foot Ø measurement volume– 1 mil accuracy with hard point probe– 3 mil accuracy with laser line

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