Tag: Engineering

Southern Research continues decades-long support of veterans and national defense

Posted on November 10, 2017

In the nation’s 99^th year of officially commemorating U.S. veterans, Southern Research employees pay tribute to the sacrifices made by brave military men and women to secure and preserve freedom.

Over the past 70 years, the Birmingham-based research organization has supported national defense and protected warfighters serving around the globe through work in materials research and systems engineering. Research for the Department of Defense has been a key component of Southern Research’s engineering work, according to President and CEO Art Tipton, Ph.D.

Since the late 1950s, when Southern Research began work on the High Temperature Materials Characterization Laboratory, it has assisted the U.S. Department of Defense in all branches of the military. Some of the earliest programs for the DoD involved developing high-temperature reentry materials for missile systems reentering Earth’s atmosphere.

Through the decades, the work has included a diverse variety of efforts such as ballistic missile system development, hypersonic vehicle materials and structures analysis, and airborne sensors and stabilized gimbal systems.

“Veterans Day is a special one for Southern Research given the former service members we employ and the highly specialized work we do with the Department of Defense,” Tipton said. “Developing programs that protect the warfighter and keep our country safe from harm help make our mission more significant. And with pride and admiration, we celebrate those who served in defense of our great nation.”

Tipton acknowledged the many service men and women who have given and who presently give their time, talent and efforts toward Southern Research’s mission. Southern Research is supported by 25 staff members who are U.S. veterans.

“These individuals make our pursuit even more meaningful,” Tipton said.

Two such individuals are Maj. Gen. (Retired) N. Lee S. Price, who serves on Southern Research’s board of directors, and Chief Master Sgt. John C. McCullough, export control specialist for Southern Research.

McCullough has served in the Alabama Air National Guard for 32 years, including 24 years with the civil engineers. He was mobilized in support of Operation Noble Eagle, as well as campaigns Southern Watch and Iraqi Freedom.

Price entered the Army as a Private First Class in 1975, when only 2 percent of the Army workforce was female. In 2014, when she retired as major general, only seven women had exceeded her in the Army ranks. During her nearly four decades of service, she supported the nation’s operators across the globe in multiple combat zones. She was recently recognized by the Birmingham Business Journal as one of the Veterans of Influence.

“Price’s contributions to the Southern Research board are invaluable,” Tipton said. “Beyond her specific technical expertise, her combined focus on people and processes have helped us broadly. And her lessons in leadership have benefited me personally.”

Southern Research Oxmoor campus marks 25th anniversary milestone

Posted on October 24, 2017

Southern Research hosted a special event to mark the 25^th anniversary of the opening of its Oxmoor campus, where the organization’s staff have tackled complex technical challenges in support of the space program, critical defense systems, and important energy issues.

The event took place Oct. 25 at the facility at 757 Tom Martin Drive off Lakeshore Parkway in Birmingham.

“The opening of the Oxmoor campus represented a milestone for Southern Research because the facility has provided our team with a unique expansion space to help advance important programs in aerospace and defense,” said Art Tipton, Ph.D., the organization’s president and CEO. “And with expansion, it has been a great center for our growing energy and environment focus.”

“The work conducted by Southern Research at the Oxmoor campus has always focused on making discoveries that propel science and technical knowledge forward,” he added. “That mission is going to continue well into the future.”

Largely designed by Southern Research engineers, the Oxmoor facility was set up for flexible lab space to meet the changing demands of the staff’s work. Its labs are packed with one-of-a-kind instruments and devices invented by Southern Research engineers for tasks such as testing materials in extreme environments like those encountered by spacecraft.

In 2016, the organization’s Energy & Environment division moved to the Oxmoor campus, where it is conducting research on solar panels and next-generation energy storage systems, and operating a new economic development-focused initiative called The Prosperity Fund.

IMPORTANT CONTRIBUTIONS

Southern Research officially opened the Oxmoor facility on Oct. 9, 1992, after a dedication ceremony attended by Gov. Guy Hunt and community leaders. “It is most gratifying to see first-hand evidence of Alabama’s growing prominence in high-technology research and development,” Hunt said in his speech.

Visitors entering the main lab on a tour that day saw a giant replica of the Space Shuttle, reflecting Southern Research’s deep involvement in the NASA program.

With activities centered at the Oxmoor facility, Southern Research remains one of the few organizations in the world where the thermal and mechanical properties of materials are routinely studied at temperatures reaching into thousands of degrees.

“One thing that makes this facility unique is that we have been able to assemble under one roof some of the world’s top experts in advanced materials under extreme environments,” said Michael D. Johns, vice president of the Engineering division.

“The facility is full of one-of-a-kind extreme environment test facilities that simulate everything from cryogenic exposure of space telescopes to the extreme heat of earth atmospheric reentry.”

In addition to the Space Shuttle, Southern Research engineers have made significant contributions to the development of spacecraft technology for NASA programs such as the James Webb Space Telescope and the Chandra X-ray Observatory, Johns said.

Other important work at the Oxmoor center has focused on the development of flight systems capable of traveling more than six times the speed of sound, and the creation of an airborne high-altitude video system capable of recording high-definition images at great distances.

The system, called AIRS/DyNAMITE, was deployed on a NASA-sponsored mission to capture unprecedented images of the Sun and Mercury during this year’s total solar eclipse.

Johns said Southern Research engineers will participate in many critical programs in the future. These include developing technologies related to NASA’s planned missions to Mars and next-generation space telescopes. They’ll also be focusing on cyber security, additive manufacturing, and the modernization of the nation’s aging missile fleets, he added.

EXPANDING FOOTPRINT

Meanwhile, the Energy & Environment (E&E) division is expanding its footprint at the Oxmoor campus by moving into a 28,000-square-foot expansion of the site commissioned in 2012, according to Bill Grieco, Ph.D., the division’s vice president.

The Southeast Solar Research Center, located at the Oxmoor site, permits E&E researchers to assess the reliability and cost performance of solar panels under field and lab conditions. Southern Research’s key partners in the project are Southern Company, the Department of Energy, and the Electric Power Research Institute.

E&E also recently launched the Energy Storage Research Center to focus on the integration and testing of advanced energy storage technologies, which promise to bring major changes to industries ranging from automotive to electric utilities.

The Prosperity Fund, whose goals are to foster job creation and spur entrepreneurial activity in four central Alabama counties, is a new initiative for Southern Research’s E&E team. The work will set the stage for future job creation and business consulting opportunities with an initial focus on communities impacted by the loss of coal jobs, Grieco

Southern Research technology captures ‘spectacular’ eclipse imagery

Posted on August 24, 2017

Sophisticated telescopes developed by Southern Research captured unique images of the Sun’s outer atmosphere during Monday’s “Great American Eclipse,” and scientists are beginning a detailed examination of data described as “spectacular.”

The imagery was captured by two NASA high-altitude research aircraft as the total solar eclipse unfolded over the United States.

The goal of the eclipse mission, led by NASA and supported by Southern Research, was to gather visible and infrared images of the solar corona and collect extensive data on the temperature of Mercury’s surface.

“The visible and infrared data look spectacular,” said Southwest Research Institute Senior Research Scientist Amir Caspi, Ph.D., principal investigator of the project. “We’re already seeing some surprising features, and we are very excited to learn what the detailed analysis will reveal.”

Southern Research eclipse imagery — This is an infrared image of the sun captured by Southern Research-developed telescopes during the Aug. 21 total solar eclipse.

The Southern Research-developed stabilized telescopes with sensitive, high-speed, visible-light and infrared cameras flew aboard the NASA WB-57F research aircraft to observe the targets from 50,000 feet, providing a significant advantage over ground-based observations.

Birmingham-based Southern Research built the Airborne Imaging and Recording Systems (AIRS) onboard and worked with the scientific team to retrofit its DyNAMITE telescopes with solar filters and improved data recorders and operating software.

CRITICAL ROLE

Charlie Mallini, NASA’s WB-57 program manager, said he was delighted with the success of the eclipse mission and the performance of Southern Research’s technology on the flight.

“Without Southern Research the NASA’s WB-57 solar eclipse mission would not have occurred,” Mallini said. “Their diligent preparation and operation of the DyNAMITE sensor was critical to the mission’s success. They were a valuable member of NASA’s WB-57 solar eclipse mission team.”

Johanna Lewis, program manager of the AIRS/DyNAMITE system, said the mission represented an exciting moment for the Southern Research engineering team.

“Southern Research has been a proud supporter of the NASA WB-57 since 2003, and during that time we have supported hundreds of flights and data collections, but this was one of the most exciting,” Lewis said.

Southern Research not only provided the instruments to collect the unique imagery but also a key member of the high-altitude crew. Southern Research’s Don Darrow was the Sensor Equipment Operator (SEO) flying in the lead plane, so he was the first to acquire the solar eclipse in totality.

“The view of the eclipse from aboard the WB-57 was fantastic,” Darrow said. “I was able to see the eclipse from the sensors aboard the plane and then look up and see it directly with my own eyes. I had one of the best views of the eclipse on the planet. It was truly an awe inspiring flight.”

‘PHENOMENAL JOB’

Total solar eclipses are unique opportunities for scientists to study the hot atmosphere above the Sun’s visible surface. The faint light from the corona is usually overpowered by intense emissions from the Sun itself. During a total eclipse, however, the Moon blocks the glare from the bright solar disk and darkens the sky, allowing the weaker coronal emissions to be observed.

“This is the best observed eclipse ever,” said Dan Seaton, Ph.D., co-investigator of the project from the University of Colorado. “With the results from the WB-57s and complementary observations from space and other experiments on the ground we have an opportunity to answer some of the most fundamental questions about the nature of the corona.”

The eclipse also provided an opportunity to study Mercury, which is notoriously difficult to image because of its proximity to the Sun. Using infrared in near darkness through very little atmosphere, the team received data enabling it for the first time to estimate the surface temperatures over the planet’s night side.

“The pilots, instrument operators, and engineers did a phenomenal job getting us exactly the data we asked for,” Caspi said. “Achieving this quality of measurement required an enormous effort and precise timing, and everyone hit their mark exactly. I am honored to be part of such an exceptionally talented and professional team, and grateful for everyone’s dedication and hard work.”

Southern Research specialist to collect solar eclipse data from stratosphere

Posted on July 25, 2017

When a total solar eclipse unfolds over the United States on Aug. 21, Southern Research communications engineer Donald Darrow will have a front row seat for the spectacular event some 50,000 feet above Earth.

Darrow will be aboard one of two NASA WB-57 high-altitude research planes flying in the stratosphere that day on a groundbreaking mission to capture the clearest views ever produced of the Sun’s outer atmosphere and the first thermal images revealing temperature shifts on the surface of Mercury.

“It certainly will be an exciting mission,” Darrow said. “I’m going to have the best view of probably anyone on the planet.”

Darrow is serving as the lead special equipment operator, or SEO, on the mission. His job is to operate a unique instrument developed by Southern Research called AIRS/DyNAMITE, which functions like an airborne telescope with special capabilities.

Southern Research solar eclipse — Southern Research’s Donald Darrow will operate the AIRS instrument on a NASA WB-57 aircraft during the total solar eclipse on Aug. 21.

The system is mounted on both of the WB-57 planes flying on the eclipse mission.

From nearly 10 miles above Earth, the AIRS/DyNAMITE’S high-speed, visible-light and infrared cameras will provide scientists with highly precise observations of the solar corona and the Sun’s nearest planetary neighbor.

The mission is being directed by Texas-based Southwest Research Institute, which brought in Southern Research to outfit the instruments with solar filters, new data recorders, and other upgrades. Darrow is flying on the WB-57 through Southern Research’s work with NASA’s Johnson Space Center in Houston.

Darrow has served as an SEO on WB-57 missions involving the AIRS/DyNAMITE equipment for around five years. The instrument, developed for the Space Shuttle program in 2004, has been deployed on a wide range of missions, from rocket launches to aircraft test flights.

“It’s a phenomenal asset, and everybody we show it to is very impressed by its capabilities, both by its versatility and by the resolution of its images,” Darrow said.

THE MISSION

On Aug. 21, Darrow’s day will be a long one.

It will start early that morning in Houston with three hours of equipment checks, briefings and other preparations. The flight to Carbondale, Illinois, the site picked to make observations because that’s where the total eclipse will last the longest, and back to Houston will take about six hours. After that, there will be debriefings and data transmission chores.

High above Carbondale, the two WB-57 aircraft will take turns collecting data on the eclipse for a combined total of around eight minutes. The fast-moving planes will be able to chase the moon’s shadow, giving Darrow and the other equipment operator additional time to make observations.

In addition, the AIRS/DyNAMITE instruments on the planes will capture thermal images of Mercury’s surface that could allow scientists to calculate temperatures on the planet’s entire night side for the first time.

Johanna Lewis, director of the Program Management Office in Southern Research’s Engineering Division, has worked with a SR team making modifications to the AIRS/DyNAMITE instruments to prepare them for the mission.

She said the long flight for Darrow will boil down to a few eventful minutes on Aug. 21.

“There may be millions of people on the ground watching exactly what he’s doing,” Lewis said. “He’s going to be involved in so much activity during a few minutes — tracking, making sure everything is in focus, making sure the system is operating just the way he wants, because he’s not going to get another chance to go around and do it again.”

While Darrow agreed that the mission promises to be a taxing one, the former Marine said he is confident it will go smoothly.

“This mission is very similar to our rocket launches in that we don’t get a second shot. If we miss this, we miss it,” he said. “When we are doing mapping, or something similar to that, we can always come back around for another pass.

“This time, it has go perfectly and smoothly. Otherwise, we don’t get the science.”

Darrow said he’s looking forward to seeing the scientific discoveries that come from the mission’s unprecedented look at the first total solar eclipse to track across the entire continental U.S. since 1918.

“We expect that within a few weeks of the data being delivered that we will have some preliminary observations about its quality and utility,” he said.

Southern Research technology to provide unique look at solar eclipse

Posted on July 18, 2017

A high-definition imaging system developed by Southern Research and deployed on NASA aircraft flying nearly 10 miles above Earth will give scientists a unique look at the Sun’s corona during a rare total eclipse taking place over the United States in August.

As a bonus, Southern Research’s Airborne Imaging and Recording System, or AIRS, will provide highly detailed observations of Mercury’s surface and could uncover the first solid evidence of the existence of vulcanoids, a belt of asteroids believed to be circling the Sun.

To capture this data, Southern Research and its AIRS/DyNAMITE technology are supporting the Southwest Research Institute (SwRI), which won a NASA contract to carry out the mission during the Aug. 21 eclipse.

AIRS/DyNAMITE turrets will be mounted on two NASA WB-57 research aircraft, which will fly at 50,000 feet and collect high-resolution video and infrared data throughout the first total solar eclipse occurring over the length of the entire continental U.S. in 99 years.

“NASA is providing the WB-57 aircraft, Southern Research is providing the unique on-board sensors, and Southwest Research Institute is conducting the science,” said Johanna Lewis, director of the Program Management Office in SR’s Engineering Division.

“Southern Research will be handling the data collection, and we will be making sure that Southwest Research Institute is getting the best data that we can provide on Mercury and the Sun,” she added.

UNPRECEDENTED OBSERVATIONS

The total eclipse will unfold over 14 states, from Oregon to South Carolina, as the moon’s shadow completely blocks the Sun, turning day into night for a few minutes. For scientists, the event is a chance to get a close look at the otherwise hidden solar corona, as well as planets and stars normally obscured by the Sun’s blinding light.

SwRI says the mission will provide the clearest images ever of the Sun’s outer atmosphere and the first thermal images of surface temperature variations on Mercury.

“This airborne platform provides us with higher-quality, higher-speed images than are achievable from current or previous space-borne instruments,” said Amir Caspi, Ph.D., principal investigator of the project and a senior research scientist in SwRI’s Boulder, Colorado, office.

“We hope to better understand what causes the corona and why it’s so hot. It’s millions of degrees Celsius, hundreds of times hotter than the visible surface below,” he added. “The corona is the source of electromagnetic storms here at Earth, which can damage satellites, cause power grid blackouts, and disrupt communication and GPS signals, so it’s important to better understand it.”

‘EYES IN THE SKY’

Southern Research AIRS — Three NASA AIRS/DyNAMITE-equipped WB-57 aircraft fly over Houston.

Lewis and John Wiseman, Ph.D., a senior project leader in Southern Research’s Engineering Division, traveled to NASA’s Johnson Space Center in Houston this month for test flights of one of the WB-57 aircraft with an AIRS/DyNAMITE instrument modified for the mission.

“The system provides a means of tracking events you might not be able to get elsewhere, with simultaneous mid-wave infrared and visible light data,” said Wiseman, one of the instrument’s inventors. “It’s configurable, and we have had a number of payloads in it, so it’s very versatile.”

Southern Research developed the technology in partnership with NASA, which was looking for a system to capture HD video of the July 26, 2005, launch of the Space Shuttle’s “Return to Flight” mission after the Columbia mishap. Acting as “eyes in the sky” for NASA, the system, from a distance of 20 miles, captured full-motion video of the shuttle’s lift-off and tracked it to 146,000 feet.

“It was developed as an experiment, and it was supposed to have about five to 10 flights,” Wiseman said.

Since then, the high-altitude video system has been used to monitor critical rocket launches, to collect data for science missions, and to assist the Department of Defense on security missions. In the past six years alone, the AIRS/DyNAMITE technology has flown on nearly 500 flights.

EXTENDED VIEW OF ECLIPSE

On Aug. 21, the twin WB-57 aircraft flying in the stratosphere over Carbondale, Illinois, will tag-team the total eclipse, gathering exceptionally accurate measurements of the solar corona to better understand how energy moves throughout the Sun’s atmosphere, according to NASA.

From a vantage point high above the clouds and Earth’s weather systems, the AIRS/DyNAMITE-equipped planes will get a clear view of the eclipse and collect data during totality for around eight minutes. That’s far longer than the 2 minutes and 40 seconds available to ground stations monitoring the event.

In addition, the instruments will be in position to make unprecedented observations of Mercury’s surface in infrared light, which can be otherwise hindered by radiation from the Sun. Scientists hope these measurements will give new information about how Mercury’s surface temperature changes as its day turns to night, shedding light on its surface composition, NASA says.

“Because Mercury is so close to the Sun, it’s very difficult to perform direct observations. When the moon is going into eclipse over the Sun, we will have a rare opportunity to collect Mercury infrared data,” Lewis said.

There’s even more to this mission. While the Sun’s bright light is blocked, AIRS’ HD cameras will search the skies for evidence of vulcanoids, a hypothetical band of asteroids traveling around the Sun in Mercury’s atmosphere. That’s important because vulcanoids could provide insights about the creation of the planets and the solar system’s earliest period.

“Most people have never heard of vulcanoids before. This will be an unique opportunity for them to look for these things that scientists theorize are there, but nobody has ever proven,” Lewis said. “If we provided the instrument that proves they were there, that would be a major accomplishment.”

FLYING WITH THE WB-57

Southern Research will play another important role in the eclipse mission. A Houston-based SR communications engineer, Donald Darrow, will serve as the special equipment operator in the back seat of one of the WB-57 aircraft, operating the AIRS/DyNAMITE instrument during the flight.

Lewis said a Southern Research team on the ground at NASA’s Johnson Space Center will assist Darrow on the mission.

“We can be another set of eyes, seeing what he’s seeing. If we see there are any adjustments he needs to make – open the camera’s iris more, sharpen the focus – we can call that up to him,” she said. “We’ll be doing the same for the other back-seater when it’s his turn.”

To make sure the scientists at SwRI’s Colorado labs get the data they need, the AIRS/DyNAMITE equipment flying on the mission have received modifications including software upgrades and a filter to protect the visible light camera. In addition, new video recorders that capture a full range of data have been added.

“This is one of the most exciting missions for this technology,” Wiseman said.

Southern Research taps Mark Patterson for aerospace business development role

Posted on July 11, 2017

Mark Patterson, an engineer and innovator with broad experience across a sweeping range of technology disciplines, has joined Southern Research’s Engineering Division to lead business development efforts focusing on the aerospace industry.

Over a 30-year career, Patterson, Ph.D., has made significant technical contributions to fields as diverse as advanced materials and climate change research. He has been heavily involved in all aspects of R&D projects and worked with key government agencies and major defense contractors.

For Southern Research, Patterson will concentrate on identifying new business opportunities and potential collaborations for the organization’s engineering team.

Mark Patterson Southern Research — Mark Patterson, left, discusses Southern Research’s AIRS technology with engineer John Wiseman, one of the developers, in the Systems Development Integration Lab.

The Engineering Division’s areas of specialization include high-temperature testing of materials, non-destructive evaluation technologies, mechanical testing of components in extreme conditions, and the development of complex sensing devices.

“Mark brings a richly diverse background that is highly relevant to our specialized technical areas at Southern Research,” said Michael Johns, vice president of Engineering at the Birmingham-based non-profit organization.

“With his wide-ranging expertise, Mark can help us build on fields where we are already industry leaders and pinpoint new opportunities in disciplines where we can grow to become leaders,” he added.

DIVERSE CAREER

Patterson has considerable experience in research and development activities, having managed $60 million in projects spanning the complete R&D lifecycle, from funding acquisition to technology development and product delivery.

He has directed efforts involving an array of different technologies – sensors, advanced materials, ceramics, additive manufacturing, autonomous systems, and mineral extraction, among others. He’s also been involved in efforts focusing on climate change, artificial bone implants, nuclear waste, energy, environment, and counter terrorism.

In addition, Patterson introduced new manufacturing techniques for advanced ceramic materials and devised methods to fabricate transparent armor, infrared windows and domes, and machine tool inserts. He also supported pioneering robotics operations that used autonomous platforms to collect climate change data from volcanoes and glacial lakes, as well as through atmospheric profiles.

He has given numerous presentations at national and international conferences, published more than 80 papers, and holds four patents. He served as the technical secretariat for a U.S. Department of Defense handbook on ceramic matrix composites, a revolutionary lightweight material capable of withstanding extreme temperatures, and worked as a consultant to the Defense Advanced Research Projects Agency (DARPA).

EQUIPPED FOR GROWTH

Southern Research engineering — Mark Patterson has been named director of business development-aerospace for Southern Research’s Engineering Division.

Patterson said Southern Research’s longstanding partnerships with NASA, defense agencies and aerospace companies, along with an extensive set of technical capabilities, mean the Engineering Division is well positioned for growth opportunities.

“In aerospace engineering, there are several areas where Southern Research can have a significant footprint in the future. Obviously, we’re well established in high-temperature testing of materials, and we will maintain world leadership in that,” Patterson said.

“I’d like to see Southern Research continue our development in advanced additive manufacturing technologies,” he added. “The development and use of additive manufacturing is going to require new qualification protocols and test methods, and we are well positioned to become world leaders in this area.”

Patterson has previously worked with the Birmingham-based organization’s Materials Research Department, which has made important contributions to the nation’s space program and to defense projects.

“Mark has ties to Southern Research. Over the years, he has collaborated on various projects with the Materials Research Department,” said Jim Tucker, the department’s director. “We have had the pleasure of working with Mark for over 20 years. His insight into complex technical problems is well known in the industry and will be of great value to Southern Research.”

Patterson has previously worked in research and technology roles for small businesses, Advanced Ceramics Research and Hydronalix, in Arizona; the University of Arizona, as director of research initiatives; and defense contractor BAE Systems, where he focused on unmanned aerial vehicles and advanced ceramics.

Patterson holds a doctorate in materials science from the University of Cambridge in England, a master’s degree in materials science from Queens University in Canada, and a bachelor’s in mining engineering/mineral processing from Camborne School of Mines at England’s Exeter University.

Southern Research engineer John Koenig receives notable industry award

Posted on July 6, 2017

Southern Research engineer John Koenig was awarded the distinguished Thermal Conductivity Award by the governing board of the International Thermal Conductivity Conference (ITCC).

This award, established in 1970, honors outstanding researchers, educators, and industrialists who have contributed significantly to the field of thermophysics. The traveling award is engraved with the roster of past recipients’ names including giants in this discipline.

The nomination process is conducted by a committee of the board, and then selection is made upon due deliberation of the entire board. The awardee is nominated based on a variety of achievements that could include a singular key development such as a key theory or measurement method, a significant long-term involvement in thermal science or engineering activities, or the growth of the ITCC.

Koenig’s selection for the award was based on this process, taking into consideration his longstanding technical achievements, his organization of the 29th ITCC in Birmingham in 2007, and his service during two terms as chairman of the ITCC governing board.

Additionally, he has directed meaningful measurements in the field of thermophysical properties of materials, and his work has involved numerous government contracts with a high level of difficulty.

“I am honored to be selected by my peers to join this corps of notable men and women who have contributed so greatly to the thermal conductivity discipline,” Koenig said. “The ITCC and this award bring deserved recognition to a field that is integral to the defense and aerospace industries.”

Koenig’s career spanned 39 years at Southern Research, where he concentrated on materials research and development and led teams of engineers as director of materials research. He is currently a consultant to the Birmingham-based research organization, investigating methods to develop and test new advanced materials with multiple space applications.

“John’s career contributions to the thermal conductivity field have placed Southern Research on the map as a national leader in hypersonics, thermal properties characterization and evaluation of high-temperature materials for leading contractors like NASA and the Department of Defense,” said Mike Johns, vice president of Engineering at Southern Research.

“He continues to play a critical role in this industry and in guiding our Engineering team toward success.”

Last year, NASA honored Koenig for significant contributions to the nation’s space program.

Engineers put NASA inflatable heat shield materials through testing

Posted on April 27, 2017

Southern Research engineers conducted tests that advanced an experimental NASA technology designed to solve a tough challenge in landing people and cargo on Mars – slowing down a spacecraft entering the Red Planet’s thin atmosphere to permit a safe touchdown.

The Hypersonic Inflatable Aerodynamic Decelerator, or HIAD, is essentially a doughnut-shaped heat shield made of soft, flexible materials. The system is like a cone of inflatable inner tubes that’s packed tightly into a spacecraft and automatically deployed to use atmospheric drag to slow a fast-moving capsule during descent.

NASA HIAD — The HIAD’s main rings look like giant inner tubes. (Image: NASA)

The innovative HIAD system is being examined for possible uses such as manned missions to Mars and landing cargo weighing more than 20 metric tons on other worlds.

“NASA was able to land the Mars Rover, but that is a pretty small device,” said Jacques Cuneo, a Southern Research engineer involved in the testing of HIAD’s materials. “If humans ever go to Mars, we will need to land many things with lots of mass – structures, supplies and other vital items.

“NASA will need to land large payloads, and, right now, they just can’t do it.”

When it comes to Mars, NASA’s mission planners must contend with an atmosphere that is roughly 100 times thinner than Earth’s and composed mostly of carbon dioxide, which can float to the planet’s frigid surface as snowflakes.

FOLDING TESTS

Southern Research’s assigned task in HIAD’s development centered on a key question posed by NASA’S Langley Research Center in Hampton, Virginia, according to Cuneo.

The HIAD’s inflatable structure is fashioned from a fastened series of pressurized concentric tubes, or tori, that form an exceptionally strong cone-shaped shield. The tori’s braided synthetic fibers are 15 times stronger than steel, according to NASA.

But would packing the inflatable aeroshell’s flexible materials into the tight confines of a spacecraft threaten the system’s performance and doom the mission?

Southern Research Cuneo HIAD — Jacques Cuneo is a Southern Research engineer who worked on the tests of the HIAD materials.

“When they fold this complex item, when they crunch it down, there is no way for them to get a regular fold,” Cuneo said. “It’s going to end up crumpled, it’s going to have kinks. There is definite randomness in what happens.

“It’s not like a parachute where they nicely fold it up and pack it in every time,” he added. “After they fold HIAD up, they compress it, so there is going to be some damage. The question is whether it can withstand this damage.”

The Southern Research team designed an extensive series of tests to provide an answer.

The engineers conducted folding studies meant to generate a wide range of creases and folds in the flexible HIAD materials during the packing process. They then evaluated specimens of the materials in strength-retention and permeation tests.

“We were looking to see what kind of property retention it has and what kind of damage occurred while it was folded up,” Cuneo said. “We folded it up loosely, we folded it up tightly. We introduced a lot of different conditions to see how it was going to perform, and the material actually did really well.

“That gave NASA confidence that what they are doing makes sense, and that catastrophic damage was not going to result from the folding operation,” he added.

COMPRESSION TESTS

Last year, NASA put HIAD through a key field test. Engineers used a vacuum pump to compress a 9-foot diameter prototype of the inflatable heat shield into the tight confines of a spacecraft. They then checked the materials for leaks and damage.

After that successful test, NASA said its engineers will move forward with the development of a larger HIAD that can withstand the stress of being tightly packed in a rocket and the challenges experienced when it descends through the atmosphere of a planet such as Mars.

NASA inflatable heat-shield — The materials making up the HIAD system would be compressed into a compartment on a spacecraft. (Image: NASA)

Cuneo said the innovative technology holds promise as NASA contends with the challenges of landing large volumes of supplies, scientific instruments and equipment on worlds with thin atmospheres.

“HIAD has an excellent shot at being utilized down the road for these types of missions,” he said. “It might be Mars or a moon of Jupiter. The technology is there to utilize.”

NASA PARTNERSHIP

Birmingham-based Southern Research has a long history of collaboration with NASA, dating back to the early days of the Apollo program. As part of that work, engineers analyzed the thermal and mechanical properties of potential shield materials and developed mathematical models to predict their performance in re-entry conditions.

Southern Research conducted similar work for the Space Shuttle program, while also remedying a potentially catastrophic rocket nozzle problem and helping the NASA “Return to Flight” missions after the Columbia accident.

Today, the organization is involved in the Space Launch System, or SLS, the massive rocket NASA is developing for planned Mars missions.

“The unique talents of Southern Research’s engineers have contributed to many of NASA’s most significant projects over the decades, and that’s continuing today as the space agency plans epic missions to land astronauts on Mars,” said Michael D. Johns, the organization’s vice president of Engineering.

Southern Research contributes to unique Solar Probe Plus mission

Posted on March 27, 2017

When a NASA probe launching in mid-2018 approaches its final destination – the roiling upper atmosphere of the Sun – the spacecraft’s heat shield will encounter temperatures hot enough to melt steel.

Testing conducted by Southern Research engineers demonstrated that the carbon composite materials selected for the Solar Probe Plus’ thermal protection system will protect the craft and its instruments from the relentlessly brutal conditions.

“The probe is going to be getting pretty hot, pretty toasty, and it’s going to be hot for a while,” said Jacques Cuneo, a member of Southern Research’s

Solar Probe Plus heat shield — NASA expects the launch the Solar Probe Plus in summer 2018.

engineering team who worked on the project. “It’s not a transitory thing; it’s going to be baking for a while.”

The Johns Hopkins Applied Physics Laboratory in Maryland is managing the mission and building the spacecraft. The lab brought in the Southern Research team to conduct high-temperature evaluations of the heat shield materials – a task the Birmingham non-profit organization has been performing since the early days of NASA.

Making sure the Solar Probe Plus can handle the hazards of intense heat and radiation is crucial. Scientists have imagined a mission to the Sun since 1958, and data collected by this probe will yield important new insights about the sun’s atmosphere – known as the corona – and its role in producing fierce solar winds.

Scientists want a deeper understanding of solar activity so they are better able to predict space-weather events that can impact life on Earth and disrupt the operations of orbiting satellites.

“The talented engineers and technicians at Southern Research have made many important contributions to the nation’s space program over several decades,” said Michael D. Jones, vice president of Engineering. “Solar Probe Plus is an exciting mission, and we are proud to have been part of an endeavor that will advance scientific knowledge about the Sun.”

REVOLUTIONARY MISSION

The Solar Probe Plus will travel closer to the Sun than any previous spacecraft, approaching as close as 3.9 million miles as it hurtles past the star at 450,000 miles per hour. That will put the craft well within the orbit of Mercury, the planet nearest to the sun.

Over seven years, the probe will complete two dozen solar orbits, using seven gravity-assisted flybys of Venus to skirt continually closer to the Sun’s blazing corona.

So it can perform this revolutionary investigation, the spacecraft and its instruments will be protected from the heat by a 4.5-inch-thick carbon composite shield capable of withstanding temperatures climbing to more than 2,000 degrees Fahrenheit, according to the Applied Physics Laboratory.

“As you can imagine, the heat shield is a big article,” Cuneo said. “It’s made up of carbon-carbon sheets on the top and the bottom, and in the middle, there’s a rigid carbon foam.”

The Southern Research engineering team was asked to determine the mechanical and thermal properties of the heat shield materials. The carbon composite used in the sheets represented familiar ground for testing, thanks to Southern Research’s longstanding involvement in the space program.

The carbon foam, however, was different. Just figuring out how to the test the relatively brittle open-cell foam was technically challenging, Cuneo said. The issue: How can you measure strain when you can’t even touch the specimen?

“When you pressed on the foam, it would create dust. It wouldn’t actually break, it just kind of machined itself down,” Cuneo said. “Anything that generated compression was a real issue with the foam, so we developed a way to stiffen the ends by impregnating them.

“We were able to figure out how to grab and pull or torque a specimen, and develop ways to measure strain because you couldn’t mount anything on the specimens,” he added.

The Southern Research engineers generated a database of the carbon foam properties, and the material passed muster.

“The foam fit what they thought it was going to do – particularly at high temperatures, which is what they were concerned about — and it’s on track for launch,” Cuneo said.

In July 2016, NASA said the Solar Probe Plus is slated to launch during a 20-day window that opens on July 31, 2018. The spacecraft has passed NASA’s design review stage, meaning it is has moved to final assembly. Engineers at the Johns Hopkins Applied Physics Laboratory are now finishing assembly and installing spacecraft systems and science instruments.

Stuart Starrett tapped for Alabama Engineering Hall of Fame

Posted on February 16, 2017

Southern Research’s Stuart Starrett, who has made many significant contributions to the nation’s defense, aerospace and energy industries, is being inducted into the State of Alabama Engineering Hall of Fame at a ceremony this Saturday.

During a career that began in the 1960s, Starrett has built a formidable international reputation as an expert in the behavior of materials in extreme environments such as atmospheric reentry and rocket propulsion systems.

Starrett Southern Research — Stuart Starrett, who worked on key defense systems, is being inducted in the Alabama Engineering Hall of Fame.

Those who worked with Starrett say his technical insights were vital to the development of reentry nosetips for advanced defense systems, including the U.S. Navy’s C4 and D5 Submarine-Launched Ballistic Missiles and the Air Force’s Minuteman III Ballistic Missile.

“His efforts helped win the Cold War without much official recognition,” said John K. Shigley, Ph.D., of defense contractor Orbital ATK.

Added Keith Bowman, Ph.D., of the Air Force Research Laboratory at Wright-Patterson Air Force Base: “I equate what Stuart did for the nation’s defense to what the engineers working for NASA in the 1960s did for space exploration.”

They say Starrett also provided valuable insights into engineering challenges ranging from composite materials to hypersonic vehicles.

“What makes me proud is just being involved in programs that I thought were important to the U.S.A. and to national defense. That was sort of a mission for me, I guess,” Starrett said.

SOLVING COMPLEX CHALLENGES

Starrett joins Coultas “Colt” Pears, an innovator who led the development of Southern Research’s high-temperature materials laboratory, in the Alabama Engineering Hall of Fame. Southern Research and the high-temperature lab, renamed for Pears, have also been inducted into the Hall of Fame.

“Stuart’s technical excellence allowed Southern Research to become the leader in high-temperature materials. His quiet leadership also inspired those around him, leading to programs in aero-propulsion, reentry systems, heat shields, ground-based turbines, and nuclear power,” said Art Tipton, Ph.D., president and CEO.

“This honor is richly deserved, and recognizes the Stuart’s legacy of impressive technical expertise and his many achievements that have strengthened national defense,” he added.

Starrett, who received bachelor’s and master’s degrees in mechanical engineering from the Georgia Institute of Technology, joined Southern Research in 1965 as an associate engineer. He soon progressed to head the Solid Mechanics Section, then the Mechanics Division. In 1990, he was named Director of the Materials Research Department, a post he held for 16 years.

Officially in retirement, Starrett remains an active consultant on a variety of engineering projects.

“From the beginning, Stuart was able to use his love of mathematics to solve some of the most complex materials challenges of his day,” said Michael D. Johns, vice president of Southern Research’s Engineering division.

“He was a pioneer in the development and understanding of carbon-carbon composites, which are a foundational technology for human space flight, atmospheric reentry, and many other extreme-environment applications,” he added.

Johns said Starrett’s work helped to establish Southern Research’s high-temperature materials lab as one of the few locations in the world capable of conducting thermal and mechanical tests at temperatures ranging from 70 to 5,500 degrees Fahrenheit.

While much of his work has concentrated on U.S. Department of Defense projects, Starrett also used his extensive materials and engineering know-how to help solve challenges for the energy industry. For example, he was involved in the development of material systems for the filtration of hot gases from boilers to be used in the recovery of the energy in a gas turbine – a technology being deployed today.

Starrett has made many technical presentations, primarily in the U.S. but also overseas, and published scientific papers on a wide variety of topics related to materials research.

HALL OF FAME

The State of Alabama Engineering Hall of Fame is overseen by engineering colleges and schools at Auburn University, Alabama A&M University, the University of Alabama, Tuskegee University, University of Alabama at Birmingham, University of Alabama in Huntsville and the University of South Alabama.

Since its inception 30 years ago, the Engineering Hall of Fame has honored 168 individuals. Saturday’s induction ceremony will take place at the Renaissance Montgomery Hotel & Spa.

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