SEARCH · Search NASA

Results for “Manufacturing Techniques”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 181 records · Page 10

All sources NASA NTRS DOE OSTI

NASA NTRS1984

Unidirectional fibers and polyurethane elastomer matrix based composites synthesis and properties

A study of the properties and manufacturing techniques for long-fiber reinforced elastomeric composites for flexible and damping structural materials is presented. Attention is given to the usage of polyurethane in the matrix to obtain plastic elastomeric matrices and vitreous transition temperatures which vary from -80 C to 10 C, as well as assure good fiber adhesion. Various polyurethane formulations synthesized from diisocyanate prepolymers are examined in terms of mechanical and thermal properties. The principal reinforcing fiber selected is a unidirectional glass cloth.

Chakar, A.↗

NASA NTRS1985

Manufacturing and producibility technology

Activities of the manufacturing/producibility working group within the Advanced High-Pressure O2/H2 Technology Program are summarized. The objectives of the M/P working group are: to develop and evaluate process and manufacturing techniques for advanced propulsion hardware design and selected materials; and to optimize the producibility of (SSME) components and assemblies by improved performance, increased life, greater reliability, and/or reduced cost. The technologies being developed include: plasma arc, laser, and inertia welding; combustion chamber and turbine blade coatings; coating processes; high performance alloy electroforming; and process control technology.

Hankins, J. D.↗

NASA NTRS1985

Bearings working group

The service life of the Space Shuttle Main Engine (SSME) turbomachinery bearings was a predominant factor in engine durability and maintenance problems. Recent data has indicated that bearing life is about one order of magnitude lower than the goal of seven and one-half hours particularly those in the High Pressure Oxidizer Turbopump (HPOTP). Bearing technology, primarily cryogenic turbomachinery bearing technology, is expanded by exploring the life and performance effects of design changes; design concept changes; materials changes; manufacturing technique changes; and lubrication system changes. Each variation is assessed against the current bearing design in full scale cryogenic tests.

Source record↗

NASA NTRS1984

Graphite/epoxy composite stiffened panel fabrication development

This report describes the manufacturing development procedures used to fabricate a series of carbon/epoxy panels with integrally molded stiffeners. Panel size was started at 6 inches by 18 inches and one stiffener and increased to 30 inches by 60 inches and six integral stiffeners. Stiffener concepts were optimized for minimum weight (or mass) to carry stress levels from 1500 lbs/inch to 25,000 lbs/inch compression load. Designs were created and manufactured with a stiffener configuration of integrally molded hat, J, I, sine wave I, solid blade, and honeycomb blade shapes. Successful and unsuccessful detail methods of tooling, lay-up methods, and bagging methods are documented. Recommendations are made for the best state-of-the-art manufacturing technique developed for type of stiffener construction.

Palmer, R. J.↗

NASA NTRS1985

National space transportation systems planning

In the fall of 1984, the DOD and NASA had been asked to identify launch vehicle technologies which could be made available for use in 1995 to 2010. The results of the studies of the two groups were integrated, and a consumer report, dated December 1984, was forwarded to the President. Aspects of mission planning and analysis are discussed along with a combined mission model, future launch system requirements, a launch vehicle planning background, Shuttle derivative vehicle program options, payload modularization, launch vehicle technology implications, a new engine program for the mid-1990's. Future launch systems goals are to achieve an order of magnitude reduction in future launch cost and meet the lift requirements and launch rates. Attention is given to an advanced cryogenic engine, advanced LOX/hydrocarbon engine, advanced power systems, aerodynamics/flight mechanics, reentry/recovery systems, avionics/software, advanced manufacturing techniques, autonomous ground and mission operations, advanced structures/materials, and air breathing propulsion.

Lucas, W. R.↗

NASA NTRS1986

Lessons learned from the DC-10 carbon-epoxy rudder program

With the DC-10 carbon-epoxy rudder, the Douglas Aircraft Company achieved one of the greatest percentage weight savings associated with composite structures. Apart from minor damage from lightning strikes, the 15 rudders put into service have experienced virtually trouble-free operation for about a decade. This paper explains why a multirib, postbuckled skin design was used for the DC-10 composite rudder, how it was justified, and how it would have compared with more conventional sandwich design concepts. Special attention is devoted to the reasons why, for such postbuckled designs, it is better to allow the skin to wrinkle and unload itself than to reinforce it and make it resist buckling until some higher load level is attained. With minor changes in the manufacturing technique, this design concept is ideal for the control surfaces on many aircraft. The paper includes suggestions on how to make even better composite control surfaces in the future.

Hart-Smith, L. J.↗

NASA NTRS1988

Small gas turbine engine technology

Performance of small gas turbine engines in the 250 to 1,000 horsepower size range is significantly lower than that of large engines. Engines of this size are typically used in rotorcraft, commutercraft, general aviation, and cruise missile applications. Principal reasons for the lower efficiencies of a smaller engine are well known: component efficients are lower by as much as 8 to 10 percentage points because of size effects. Small engines are designed for lower cycle pressures and temperatures because of smaller blading and cooling limitations. The highly developed analytical and manufacturing techniques evolved for large engines are not directly transferrable to small engines. Thus, it was recognized that a focused effort addressing technologies for small engies was needed and could significantly impact their performance. Recently, in-house and contract studies were undertaken at the NASA Lewis Research Center to identify advanced engine cycle and component requirements for substantial performance improvement of small gas turbines for projected year 2000 applications. The results of both in-house research and contract studies are presented. In summary, projected fuel savings of 22 to 42 percent could be obtained. Accompanying direct operating cost reductions of 11 to 17 percent, depending on fuel cost, were also estimated. High payoff technologies are identified for all engine applications, and recent results of experimental research to evolve the high payoff technologies are described.

Niedzwiecki, Richard W.↗

NASA NTRS1988

Large-Scale Advanced Prop-Fan (LAP)

In recent years, considerable attention has been directed toward improving aircraft fuel efficiency. Analytical studies and research with wind tunnel models have demonstrated that the high inherent efficiency of low speed turboprop propulsion systems may now be extended to the Mach .8 flight regime of today's commercial airliners. This can be accomplished with a propeller, employing a large number of thin highly swept blades. The term Prop-Fan has been coined to describe such a propulsion system. In 1983 the NASA-Lewis Research Center contracted with Hamilton Standard to design, build and test a near full scale Prop-Fan, designated the Large Scale Advanced Prop-Fan (LAP). This report provides a detailed description of the LAP program. The assumptions and analytical procedures used in the design of Prop-Fan system components are discussed in detail. The manufacturing techniques used in the fabrication of the Prop-Fan are presented. Each of the tests run during the course of the program are also discussed and the major conclusions derived from them stated.

Degeorge, C. L.↗

NASA NTRS1988

It's time to reinvent the general aviation airplane

Current designs for general aviation airplanes have become obsolete, and avenues for major redesign must be considered. New designs should incorporate recent advances in electronics, aerodynamics, structures, materials, and propulsion. Future airplanes should be optimized to operate satisfactorily in a positive air traffic control environment, to afford safety and comfort for point-to-point transportation, and to take advantage of automated manufacturing techniques and high production rates. These requirements have broad implications for airplane design and flying qualities, leading to a concept for the Modern Equipment General Aviation (MEGA) airplane. Synergistic improvements in design, production, and operation can provide a much needed fresh start for the general aviation industry and the traveling public. In this investigation a small four place airplane is taken as the reference, although the proposed philosophy applies across the entire spectrum of general aviation.

Stengel, Robert F.↗

NASA NTRS1986

Overview of advanced components for fiber optic systems

The basic operating principles and potential performance of several state-of-the-art fiber-optic devices are illustrated with diagrams and briefly characterized. Technologies examined include high-birefringence polarization-maintaining fibers and directional couplers, single-mode fiber polarizers and cut-off polarizers, optical-fiber modulators with radially poled piezoactive polymer (PVF2) jackets, and piezoelectric-squeezer polarization modulators. The need for improved manufacturing techniques to make such fiber-optic devices cost-competitive with their thin-film integrated-optics analogs is indicated.

Depaula, Ramon P.↗

NASA NTRS1991

An evaluation of bearings operating in a cryogenic environment with silicon nitride rolling elements

The bearings used in the space shuttle main engine (SSME) high pressure oxidizer turbopump (HPOTP) do not meet the expected life goals that were set for them. In an effort to improve their performance, many solutions are being studied. New bearing materials are being developed, better manufacturing techniques are being investigated, and improved cage materials for better lubrication are being tested. The focus is on the replacement of steel balls with ones made of silicon nitride in 57-mm HPOTP bearings. The bearings were then installed in a test rig and run at near turbopump operating conditions. The results from this test series are encouraging, with silicon nitride showing good wear resistance and thermal stability.

Gibson, H. G.↗

NASA NTRS1991

Optimization and performance of Space Station Freedom solar cells

High efficiency, large area and low cost solar cells are the drivers for Space Station solar array designs. The manufacturing throughput, process complexity, yield of the cells, and array manufacturing technique determine the economics of the solar array design. The cell efficiency optimization of large area (8 x 8 m), dielectric wrapthrough contact solar cells are described. The results of the optimization are reported and the solar cell performance of limited production runs is reported.

Khemthong, S.↗

NASA NTRS1989

Advanced Launch System advanced development oxidizer turbopump program: Technical implementation plan

The Advanced Launch Systems (ALS) Advanced Development Oxidizer Turbopump Program has designed, fabricated and demonstrated a low cost, highly reliable oxidizer turbopump for the Space Transportation Engine that minimizes the recurring cost for the ALS engines. Pratt and Whitney's (P and W's) plan for integrating the analyses, testing, fabrication, and other program efforts is addressed. This plan offers a comprehensive description of the total effort required to design, fabricate, and test the ALS oxidizer turbopump. The proposed ALS oxidizer turbopump reduces turbopump costs over current designs by taking advantage of design simplicity and state-of-the-art materials and producibility features without compromising system reliability. This is accomplished by selecting turbopump operating conditions that are within known successful operating regions and by using proven manufacturing techniques.

Ferlita, F.↗

NASA NTRS1989

Current developments in optical engineering and commercial optics; Proceedings of the Meeting, San Diego, CA, Aug. 7-11, 1989

Various papers on current developments in optical engineering and commercial optics are presented. Individual topics addressed include: large optics fabrication technology drivers and new manufacturing techniques, new technology for beryllium mirror production, design examples of hybrid refractive-diffractive lenses, optical sensor designs for detecting cracks in optical materials, retroreflector field-of-view properties for open and solid cube corners, correction of misalignment-dependent aberrations of the HST via phase retrieval, basic radiometry review for seeker test set, radiation effects on visible optical elements, and nonlinear simulation of efficiency for large-orbit nonwiggler FELs.

Fischer, Robert E.↗

NASA NTRS1990

Design, Evaluation and Experimental Effort Toward Development of a High Strain Composite Wing for Navy Aircraft

This design development effort addressed significant technical issues concerning the use and benefits of high strain composite wing structures (Epsilon(sub ult) = 6000 micro-in/in) for future Navy aircraft. These issues were concerned primarily with the structural integrity and durability of the innovative design concepts and manufacturing techniques which permitted a 50 percent increase in design ultimate strain level (while maintaining the same fiber/resin system) as well as damage tolerance and survivability requirements. An extensive test effort consisting of a progressive series of coupon and major element tests was an integral part of this development effort, and culminated in the design, fabrication and test of a major full-scale wing box component. The successful completion of the tests demonstrated the structural integrity, durability and benefits of the design. Low energy impact testing followed by fatigue cycling verified the damage tolerance concepts incorporated within the structure. Finally, live fire ballistic testing confirmed the survivability of the design. The potential benefits of combining newer/emerging composite materials and new or previously developed high strain wing design to maximize structural efficiency and reduce fabrication costs was the subject of subsequent preliminary design and experimental evaluation effort.

Bruno, Joseph↗

NASA NTRS1992

STME - Streamlining the engine of change

The key to the success of the NASA Space Transportation Main Engine (STME) is its enhanced reliability and reduced costs, rather than enhanced performance and reduced weight. Reliability and cost improvements derive from the design of an engine with fewer components, wider operating margins, conventional materials, and innovative manufacturing techniques; this is exemplified by the STME's combustion chamber, in which the structural jacket and all minifolds are cast as a single piece. 'Platelet' technology is under active consideration as a basis for the nozzle design. The use of hydrostatic bearings in both the turbine and pump ends of the STME turbopump will eliminate bearing-life limitations.

Smelser, Jerry W.↗

NASA NTRS1992

Process comparison study. MSFC Center Director's Discretionary Fund (CDDF)

A process comparison study was conducted using four different advanced manufacturing techniques to fabricate a composite solid rocket booster systems tunnel cover. Costs and labor hours were tracked to provide the comparison between the processes. A relative structural comparison of the components is also included. The processes utilized included filament winding, pultrusion, automated tape laying, and thermoplastic thermoforming. The hand layup technique is also compared. Of the four advanced processes evaluated, the thermoformed thermoplastic component resulted in the least total cost. The automated tape laying and filament winding techniques closely followed the thermoplastic component in terms of total cost; and, these techniques show the most promise for high quality components and lower production costs. The pultruded component, with its expensive tooling and material requirements, was by far the most expensive process evaluated, although the results obtained would not be representative of large production runs.

Golden, T.↗

NASA NTRS1993

NASA's Advanced solid rocket motor

The Advanced Solid Rocket Motor (ASRM) will not only bring increased safety, reliability and performance for the Space Shuttle Booster, it will enhance overall Shuttle safety by effectively eliminating 174 failure points in the Space Shuttle Main Engine throttling system and by reducing the exposure time to aborts due to main engine loss or shutdown. In some missions, the vulnerability time to Return-to-Launch Site aborts is halved. The ASRM uses case joints which will close or remain static under the effects of motor ignition and pressurization. The case itself is constructed of the weldable steel alloy HP 9-4-0.30, having very high strength and with superior fracture toughness and stress corrosion resistance. The internal insulation is strip-wound and is free of asbestos. The nozzle employs light weight ablative parts and is some 5,000 pounds lighter than the Shuttle motor used to date. The payload performance of the ASRM-powered Shuttle is 12,000 pounds higher than that provided by the present motor. This is of particular benefit for payloads delivered to higher inclinations and/or altitudes. The ASRM facility uses state-of-the-art manufacturing techniques, including continuous propellant mixing and direct casting.

Mitchell, Royce E.↗