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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.

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NASA NTRS2002

Design Through Manufacturing: The Solid Model-Finite Element Analysis Interface

State-of-the-art computer aided design (CAD) presently affords engineers the opportunity to create solid models of machine parts reflecting every detail of the finished product. Ideally, in the aerospace industry, these models should fulfill two very important functions: (1) provide numerical. control information for automated manufacturing of precision parts, and (2) enable analysts to easily evaluate the stress levels (using finite element analysis - FEA) for all structurally significant parts used in aircraft and space vehicles. Today's state-of-the-art CAD programs perform function (1) very well, providing an excellent model for precision manufacturing. But they do not provide a straightforward and simple means of automating the translation from CAD to FEA models, especially for aircraft-type structures. Presently, the process of preparing CAD models for FEA consumes a great deal of the analyst's time.

Rubin, Carol↗
NASA NTRS2002

Surface Enhancement Improves Crack Resistance

The low plasticity burnishing (LPB) process produces a deep layer of surface compression in a quick and affordable manner to produce metal surfaces free of scratches, nicks, and gouges. The process, designed for easy inclusion in the manufacturing environment, can be performed with conventional Computer Numerical Control machine tools. This allows parts to be processed during manufacturing, rather than as a post process in a separate facility. A smooth, free-rolling spherical ball suspended in a fluid allows for single-point contact. The ball comes into mechanical contact only with the surface to be burnished, and can be moved in any direction. LPB can be applied to all types of carbon and alloy steel, stainless steel, cast iron, aluminum, titanium, and nickel- based super alloys. In addition to improving a surface's resistance to fatigue and damage, treatment stops the growth of shallow cracks. The LPB process is used on the leading edges of turbine blades to improve resistance to foreign object damage and crack growth. This means significant savings for aircraft owners, since maintenance requirements to inspect for fatigue damage, replace parts, and remove corrosion damage increase the cost of operation.

Source record↗
NASA NTRS2003

Design Through Manufacturing: The Solid Model - Finite Element Analysis Interface

State-of-the-art computer aided design (CAD) presently affords engineers the opportunity to create solid models of machine parts which reflect every detail of the finished product. Ideally, these models should fulfill two very important functions: (1) they must provide numerical control information for automated manufacturing of precision parts, and (2) they must enable analysts to easily evaluate the stress levels (using finite element analysis - FEA) for all structurally significant parts used in space missions. Today's state-of-the-art CAD programs perform function (1) very well, providing an excellent model for precision manufacturing. But they do not provide a straightforward and simple means of automating the translation from CAD to FEA models, especially for aircraft-type structures. The research performed during the fellowship period investigated the transition process from the solid CAD model to the FEA stress analysis model with the final goal of creating an automatic interface between the two. During the period of the fellowship a detailed multi-year program for the development of such an interface was created. The ultimate goal of this program will be the development of a fully parameterized automatic ProE/FEA translator for parts and assemblies, with the incorporation of data base management into the solution, and ultimately including computational fluid dynamics and thermal modeling in the interface.

Rubin, Carol↗
NASA NTRS2003

Prompt and Precise Prototyping

For Sanders Design International, Inc., of Wilton, New Hampshire, every passing second between the concept and realization of a product is essential to succeed in the rapid prototyping industry where amongst heavy competition, faster time-to-market means more business. To separate itself from its rivals, Sanders Design aligned with NASA's Marshall Space Flight Center to develop what it considers to be the most accurate rapid prototyping machine for fabrication of extremely precise tooling prototypes. The company's Rapid ToolMaker System has revolutionized production of high quality, small-to-medium sized prototype patterns and tooling molds with an exactness that surpasses that of computer numerically-controlled (CNC) machining devices. Created with funding and support from Marshall under a Small Business Innovation Research (SBIR) contract, the Rapid ToolMaker is a dual-use technology with applications in both commercial and military aerospace fields. The advanced technology provides cost savings in the design and manufacturing of automotive, electronic, and medical parts, as well as in other areas of consumer interest, such as jewelry and toys. For aerospace applications, the Rapid ToolMaker enables fabrication of high-quality turbine and compressor blades for jet engines on unmanned air vehicles, aircraft, and missiles.

Source record↗
NASA NTRS2004

"Hot Spots" of Land Atmosphere Coupling

Previous estimates of land-atmosphere interaction (the impact of soil moisture on precipitation) have been limited by a severe paucity of relevant observational data and by the model-dependence of the various computational estimates. To counter this limitation, a dozen climate modeling groups have recently performed the same highly-controlled numerical experiment as part of a coordinated intercomparison project. This allows, for the first time ever, a superior multi-model approach to the estimation of the regions on the globe where precipitation is affected by soil moisture anomalies during Northern Hemisphere summer. Such estimation has many potential benefits; it can contribute, for example, to seasonal rainfall prediction efforts.

Koster, Randal D.↗
NASA NTRS2002

Comparison Made of Operating Characteristics of Spiral Bevel Gears Manufactured Using Different Methods

Spiral bevel gears are important components on all current rotorcraft drive systems. These components are required to operate at high speeds, high loads, and for an extremely large number of load cycles. In this application, spiral bevel gears are used to redirect the shaft from the horizontal gas turbine engine to the vertical rotor. Because of the high expense of manufacturing these gears, methods that can achieve the same level of performance at reduced cost are highly desirable to aerospace gear manufacturers. Gears manufactured for aerospace applications use high-quality materials and are manufactured to tight tolerances. Special manufacturing machine tools and computer numerically controlled coordinate measurement systems have enabled rotorcraft drive system manufacturers to produce extremely high-quality gears during their normal production. Because of low production rates for rotorcraft, these gears are manufactured in small batches, and thus are unable to benefit from the economics of high production numbers as in other industries. In this investigation, two different manufacturing methods, face-milled and face-hobbed, were used to fabricate spiral bevel gears. For face-milled spiral bevel gears, grinding of the contacting surfaces is the final manufacturing step. At least two different specialty machines are needed to generate the teeth for face-milled spiral bevel gears. For face-hobbed gears, hard cutting is the final manufacturing process. The same machine is used to rough cut and finish cut the gears. This study compared the operational behavior of face-milled spiral bevel gears with that of face-hobbed spiral bevel gears. Test hardware was manufactured to fit within NASA Glenn Research Center's Spiral Bevel Test Facility and to aerospace quality standards. Tests were conducted for stress, vibration, and noise. A comparison of the results attained indicated that the face-hobbed gears had a lower alternating stress level with a more even distribution of loading across the teeth, and slightly reduced levels of vibration and noise. Results of this study show that the face-hobbed method is a viable and lower-cost alternative for producing aerospace-quality spiral-bevel gears.

Handschuh, Robert F.↗
NASA NTRS1999

Advanced stitching head for making stitches in a textile article having variable thickness

A stitching head for a computer numerically controlled stitching machine includes a thread tensioning mechanism for automatically adjusting thread tension according to the thickness of the material being stitched. The stitching head also includes a mechanism for automatically adjusting thread path geometry according to the thickness of the material being stitched.

Thrash, Patrick J.↗
NASA NTRS2008

Single-Mode WGM Resonators Fabricated by Diamond Turning

A diamond turning process has made possible a significant advance in the art of whispering-gallery-mode (WGM) optical resonators. By use of this process, it is possible to fashion crystalline materials into WGM resonators that have ultrahigh resonance quality factors (high Q values), are compact (ranging in size from millimeters down to tens of microns), and support single electromagnetic modes. This development combines and extends the developments reported in "Few- Mode Whispering-Gallery-Mode Resonators" (NPO-41256), NASA Tech Briefs, Vol. 30, No. 1 (January 2006), page 16a and "Fabrication of Submillimeter Axisymmetric Optical Components" (NPO-42056), NASA Tech Briefs, Vol. 31, No. 5 (May 2007), page 10a. To recapitulate from the first cited prior article: A WGM resonator of this special type consists of a rod, made of a suitable transparent material, from which protrudes a thin circumferential belt of the same material. The belt is integral with the rest of the rod and acts as a circumferential waveguide. If the depth and width of the belt are made appropriately small, then the belt acts as though it were the core of a single-mode optical fiber: the belt and the rod material adjacent to it support a single, circumferentially propagating mode or family of modes. To recapitulate from the second cited prior article: A major step in the fabrication of a WGM resonator of this special type is diamond turning or computer numerically controlled machining of a rod of a suitable transparent crystalline material on an ultrahigh-precision lathe. During the rotation of a spindle in which the rod is mounted, a diamond tool is used to cut the rod. A computer program is used to control stepping motors that move the diamond tool, thereby controlling the shape cut by the tool. Because the shape can be controlled via software, it is possible to choose a shape designed to optimize a resonator spectrum, including, if desired, to limit the resonator to supporting a single mode. After diamond turning, a resonator can be polished to increase its Q. By virtue of its largely automated, computer-controlled nature, the process is suitable for mass production of nominally identical single-mode WGM resonators. In a demonstration of the capabilities afforded by this development, a number of WGM resonators of various designs were fabricated side by side on the surface of a single CaF2 rod (see figure).

Grudinin, Ivan↗
NASA NTRS2007

Fabrication of Submillimeter Axisymmetric Optical Components

It is now possible to fashion transparent crystalline materials into axisymmetric optical components having diameters ranging from hundreds down to tens of micrometers, whereas previously, the smallest attainable diameter was 500 m. A major step in the fabrication process that makes this possible can be characterized as diamond turning or computer numerically controlled machining on an ultrahigh-precision lathe.

Grudinin, Ivan↗
NASA NTRS2007

Wide Tuning Capability for Spacecraft Transponders

A document presents additional information on the means of implementing a capability for wide tuning of microwave receiver and transmitter frequencies in the development reported in the immediately preceding article, VCO PLL Frequency Synthesizers for Spacecraft Transponders (NPO- 42909). The reference frequency for a PLL-based frequency synthesizer is derived from a numerically controlled oscillator (NCO) implemented in digital logic, such that almost any reference frequency can be derived from a fixed crystal reference oscillator with microhertz precision. The frequency of the NCO is adjusted to track the received signal, then used to create another NCO frequency used to synthesize the transmitted signal coherent with, and at a specified frequency ratio to, the received signal. The frequencies can be changed, even during operation, through suitable digital programming. The NCOs and the related tracking loops and coherent turnaround logic are implemented in a field-programmable gate array (FPGA). The interface between the analog microwave receiver and transmitter circuits and the FPGA includes analog-to-digital and digital-toanalog converters, the sampling rates of which are chosen to minimize spurious signals and otherwise optimize performance. Several mixers and filters are used to properly route various signals.

Lux, James↗
NASA NTRS2009

Construction of Low Dissipative High Order Well-Balanced Filter Schemes for Non-Equilibrium Flows

The goal of this paper is to generalize the well-balanced approach for non-equilibrium flow studied by Wang et al. [26] to a class of low dissipative high order shock-capturing filter schemes and to explore more advantages of well-balanced schemes in reacting flows. The class of filter schemes developed by Yee et al. [30], Sjoegreen & Yee [24] and Yee & Sjoegreen [35] consist of two steps, a full time step of spatially high order non-dissipative base scheme and an adaptive nonlinear filter containing shock-capturing dissipation. A good property of the filter scheme is that the base scheme and the filter are stand alone modules in designing. Therefore, the idea of designing a well-balanced filter scheme is straightforward, i.e., choosing a well-balanced base scheme with a well-balanced filter (both with high order). A typical class of these schemes shown in this paper is the high order central difference schemes/predictor-corrector (PC) schemes with a high order well-balanced WENO filter. The new filter scheme with the well-balanced property will gather the features of both filter methods and well-balanced properties: it can preserve certain steady state solutions exactly; it is able to capture small perturbations, e.g., turbulence fluctuations; it adaptively controls numerical dissipation. Thus it shows high accuracy, efficiency and stability in shock/turbulence interactions. Numerical examples containing 1D and 2D smooth problems, 1D stationary contact discontinuity problem and 1D turbulence/shock interactions are included to verify the improved accuracy, in addition to the well-balanced behavior.

Wang, Wei↗
NASA NTRS2011

Merging for Particle-Mesh Complex Particle Kinetic Modeling of the Multiple Plasma Beams

We suggest a merging procedure for the Particle-Mesh Complex Particle Kinetic (PMCPK) method in case of inter-penetrating flow (multiple plasma beams). We examine the standard particle-in-cell (PIC) and the PMCPK methods in the case of particle acceleration by shock surfing for a wide range of the control numerical parameters. The plasma dynamics is described by a hybrid (particle-ion-fluid-electron) model. Note that one may need a mesh if modeling with the computation of an electromagnetic field. Our calculations use specified, time-independent electromagnetic fields for the shock, rather than self-consistently generated fields. While a particle-mesh method is a well-verified approach, the CPK method seems to be a good approach for multiscale modeling that includes multiple regions with various particle/fluid plasma behavior. However, the CPK method is still in need of a verification for studying the basic plasma phenomena: particle heating and acceleration by collisionless shocks, magnetic field reconnection, beam dynamics, etc.

Lipatov, Alexander S.↗
NASA NTRS2014

All-Digital Baseband 65nm PLL/FPLL Clock Multiplier using 10-cell Library

PLLs for clock generation are essential for modern circuits, to generate specialized frequencies for many interfaces and high frequencies for chip internal operation. These circuits depend on analog circuits and careful tailoring for each new process, and making them fault tolerant is an incompletely solved problem. Until now, all digital PLLs have been restricted to sampled data DSP techniques and not available for the highest frequency baseband applications. This paper presents the design and preliminary evaluation of an all-digital baseband technique built entirely with an easily portable 10-cell digital library. The library is also described, as it aids in research and low volume design porting to new processes. The advantages of the digital approach are the wide variety of techniques available to give varying degrees of fault tolerance, and the simplicity of porting the design to new processes, even to exotic processes that may not have analog capability. The only tuning parameter is digital gate delay. An all-digital approach presents unique problems and standard analog loop stability design criteria cannot be directly used. Because of the quantization of frequency, there is effectively infinite gain for very small loop error feedback. The numerically controlled oscillator (NCO) based on a tapped delay line cannot be reliably updated while a pulse is active in the delay line, and ordinarily does not have enough frequency resolution for a low-jitter output.

Shuler, Robert L., Jr.↗
NASA NTRS2014

ALL-Digital Baseband 65nm PLL/FPLL Clock Multiplier Using 10-Cell Library

PLLs for clock generation are essential for modern circuits, to generate specialized frequencies for many interfaces and high frequencies for chip internal operation. These circuits depend on analog circuits and careful tailoring for each new process, and making them fault tolerant is an incompletely solved problem. Until now, all digital PLLs have been restricted to sampled data DSP techniques and not available for the highest frequency baseband applications. This paper presents the design and preliminary evaluation of an all-digital baseband technique built entirely with an easily portable 10-cell digital library. The library is also described, as it aids in research and low volume design porting to new processes. The advantages of the digital approach are the wide variety of techniques available to give varying degrees of fault tolerance, and the simplicity of porting the design to new processes, even to exotic processes that may not have analog capability. The only tuning parameter is digital gate delay. An all-digital approach presents unique problems and standard analog loop stability design criteria cannot be directly used. Because of the quantization of frequency, there is effectively infinite gain for very small loop error feedback. The numerically controlled oscillator (NCO) based on a tapped delay line cannot be reliably updated while a pulse is active in the delay line, and ordinarily does not have enough frequency resolution for a low-jitter output.

Schuler, Robert L., Jr.↗
NASA NTRS2016

Mechanical Prototyping and Manufacturing Internship

The internship was located at the Johnson Space Center (JSC) Innovation Design Center (IDC), which is a facility where the JSC workforce can meet and conduct hands-on innovative design, fabrication, evaluation, and testing of ideas and concepts relevant to NASA's mission. The tasks of the internship included mechanical prototyping design and manufacturing projects in service of research and development as well as assisting the users of the IDC in completing their manufacturing projects. The first project was to manufacture hatch mechanisms for a team in the Systems Engineering and Project Advancement Program (SETMAP) hexacopter competition. These mechanisms were intended to improve the performance of the servomotors and offer an access point that would also seal to prevent cross-contamination. I also assisted other teams as they were constructing and modifying their hexacopters. The success of this competition demonstrated a proof of concept for aerial reconnaissance and sample return to be potentially used in future NASA missions. I also worked with Dr. Kumar Krishen to prototype an improved thermos and a novel, portable solar array. Computer-aided design (CAD) software was used to model the parts for both of these projects. Then, 3D printing as well as conventional techniques were used to produce the parts. These prototypes were then subjected to trials to determine the success of the designs. The solar array is intended to work in a cluster that is easy to set up and take down and doesn't require powered servomechanisms. It could be used terrestrially in areas not serviced by power grids. Both projects improve planetary exploration capabilities to future astronauts. Other projects included manufacturing custom rail brackets for EG-2, assisting engineers working on underwater instrument and tool cases for the NEEMO project, and helping to create mock-up parts for Space Center Houston. The use of the IDC enabled efficient completion of these projects at significantly reduced cost. I acquired and improved manufacturing and prototyping skills during my tour including learning about a CAD (Computer-Aided Design) program called Creo (Creo Parametric; design software), gaining valuable conventional machining experience with lathes, CNC (Computer Numerical Control) milling machines and various other tools, and improving my engineering project communication and collaboration skills. The internship also allowed me to better understand operations at NASA. I plan to work in the aerospace industry or do academic research benefitting space science and exploration, and this internship experience will enable me to have insight into manufacturing processes for research and development.

Grenfell, Peter↗
NASA NTRS2018

On the Development of the Marshall Grazing Incidence X-ray Spectrograph (MaGIXS) Mirrors

The Marshall Grazing Incidence X-ray Spectrograph (MaGIXS) is a sounding rocket experiment that will obtain spatially resolved soft X-ray spectra of the solar corona from 0.5 - 2 keV. The optical system comprises a Wolter-I telescope mirror, a slit spectrograph, and a CCD camera. The spectrograph has a finite conjugate paraboloid pair, which re-images the slit, and a varied line-space planar reflection grating. Both the Wolter-I mirror and paraboloid pair are being fabricated at the NASA Marshall Space Flight Center (MSFC), using nickel replication. The MaGIXS mirror mandrels have been diamond turned, polished, and have yielded a set of engineering mirrors. Unlike other grazing incidence instruments, such as FOXSI, ART-XC, and IXPE, the MaGIXS prescriptions have large departure from a cone. This property exacerbates challenges with conventional lap polishing techniques and interferometric metrology. Here we discuss the progression of the optical surfaces of the mandrels through lap polishing, X-ray data from the replicated shells obtained in the MSFC Stray Light Facility (SLF), and our transition to using the ZEEKO computer numerical controlled (CNC) polisher for figure correction.

Champey, Patrick↗
NASA NTRS2019

Deterministic Polishing of Replicating Grazing-Incidence Mandrels

In an effort to manufacture high-angular-resolution, grazing-incidence, x-ray optics, Marshall Space Flight Center (MSFC) is taking measures to improve its electroformed replicated optics. A key development is the use of computer-numerical control (CNC) polishing to deterministically improve the surface of electroless nickel mandrels used to replicate grazing- incidence optics. Metrology, control software and polishing parameters must function together seamlessly to reach the specifications required to replicate sub-arcsecond optics. Each change in polishing parameters effects the wear pattern of the polishing head. Using Richardson-Lucy deconvolution, the controller software fits the wear pattern to metrology data to calculate the changing feedrates across the mandrel. Here we present an overview of our process, and early results showing the effectiveness of deterministic polishing for replicated optics.

Davis, Jacqueline↗
NASA NTRS2019

X-ray Evaluation of the Marshall Grazing Incidence X-Ray Spectrometer (MaGIXS) Nickel-Replicated Mirrors

X-ray observations of astronomical objects provides diagnostics not available in any other wavelength regime, however the capability of making these observation at a high spatial resolution has proven challenging. Recently, NASA Marshall Space Flight Center (MSFC) has made good progress in employing computer numerical control (CNC) polishing techniques on electroless nickel mandrels as part of our replicated grazing incidence optics program. CNC polishing has afforded the ability to deterministically refine mandrel figure, thereby improving mirror performance. The Marshall Grazing Incidence X-ray Spectrometer (MaGIXS) is a MSFC-led sounding rocket instrument that is designed to make the first ever soft x-ray spectral observations of the Sun spatially resolved along a narrow slit. MaGIXS incorporates some of the first mirrors produced at MSFC using this polishing technique. Here we present the predicted mirror performance obtained from metrology, after completion of CNC polishing, as well as the results of X-ray tests performed on the MaGIXS telescope mirror before and after mounting.

MaGIXS X-ray Tests↗