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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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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

TPSAS-NF1676L-18913-DND

Composite materials and structures are enabling technology for modern aerospace vehicles. Numerical-control manufacturing, including automated fiber placement (AFP), is widely used to fabricate these components. However, weight and performance requirements for the next generation of aerospace vehicles will push the state-of-art even further, and require development of more advanced materials, manufacturing, and structures technologies that are both affordable and efficient. The Integrated Structural Assembly of Advanced Composites (ISAAC) system is intended to address much of NASA?s critical research needs in advanced composites. The baseline ISAAC system, combining a commercial robot with multiple redundant degrees of freedom, a tool changer interface, and a special-purpose AFP end effector, enables precise and accurate additive manufacturing of composite structures, as well as development of advanced tow-steered structures with tailored load paths. The highly capable baseline system can quickly change end effectors, thus enabling further research for composites manufacturing. This extended system is similar to a high-speed machining center, where interchangeable cutters are used for different operations during metal structures fabrication. This capability enables future development, integration and assessment of new advanced manufacturing technologies, such as in-situ curing and NDE, and through-thickness reinforcements to reduce delaminations. End effectors with these advanced capabilities may be purchased, developed internally or with industry or academia, and then integrated onto the existing robotic platform to perform advanced manufacturing operations and develop new techniques and processes. Technologies, techniques and processes developed using this research-oriented system could then be transitioned to the broader composites industry.

Rob Martin↗
NASA NTRS2014

TPSAS-NF1676L-19134-DND

Composite materials and structures are state-of-art enabling technology for modern aerospace vehicles, reducing weight and maintenance requirements, and increasing performance and reliability. Numerical-control manufacturing systems, including automated fiber placement (AFP), are widely used to fabricate these components. However, the challenging weight and performance requirements necessary for the next generation of aerospace vehicles will push the composites state-of-art even further, and require development of even more advanced materials, manufacturing, and structures technologies that are more affordable and more efficient. The Integrated Structural Assembly of Advanced Composites (ISAAC) system is intended to address many of NASA's critical research needs in the field of advanced composites. The baseline ISAAC system, combining a commercial robot with multiple degrees of freedom, a tool changer interface, and a special-purpose AFP end effector, will enable very precise and accurate additive manufacturing of composite structures. One promising area of research enabled by the ISAAC system is advanced composite tow-steered structures that have tailored structural load paths. Several examples are presented that describe these tow-steered composite structures in more detail.

Brian K Stewart↗
NASA NTRS2020

Integrated Silicon Platform for Co-planar Design of Vertically Stacked 2.06 THz Mixer Module

The process for fabricating and utilizing the threedimensional Si stack receiver front-end is described in this paper. The capability to have exact dimensionality becomes essential as frequency scales due to the complexity arising in assembly and finer tolerances. Total process yields can be improved through Si fabrication by verifying achievement of specified tolerances lithographically and compatibility to rapid process changes and design fine-tuning. The integrated Si platform with the mounted device is shown in Figure 1. Signal I/O and alignment modalities enable lownoise measurements. Silicon micromachining provides the necessary accuracy for integration at the several THz regime. Particularly, processing and etch recipes have demonstrated smooth surfaces of < 1 μm surface roughness. In consideration is pre-compensating for minute offsets, matching mechanical strain on all interfaces, and including passive alignment verification in the design. As compared to metal blocks, computer numerical controlled (CNC) milling can produce slight burrs in the interfaces resulting in misalignment and resultant strain between two pieces of components. Furthermore, Si integration can make possible arrays of pixel transceivers through compact subsystems for the purpose of measuring multiple lines of spectral content simultaneously in space.

Mehdi, Imran↗
NASA NTRS2023

Influences of Varied Electrical Discharge Machining Operations on Surface Conditions of Several Nickel-Based Superalloys

Nickel-based superalloys designed for use in gas turbine engines blades are difficult and expensive to properly machine without undue surface damage, due in part to their superior mechanical properties at high temperatures. Numerically controlled electrical discharge machining (EDM) has progressed to commonly be used as a machining process for initial sectioning, detailed roughing, and even some finishing operations. The objective of this study was to examine the effect of EDM on resulting surface conditions of superalloy 718 after slicing using typical rough, semi-finish, and finish condition sets with a typical wire EDM machine. Surface roughness, residual stress, and microstructures were compared for these conditions. The varied EDM conditions influenced surface roughness as intended. The residual stresses and surface roughness directly corresponding to the EDM steps were determined. While roughness decreased when progressing from rough to finish EDM conditions, tensile residual stresses unexpectedly increased. Brief assessments after EDM of two higher performance powder metallurgy disk superalloys ME209 and LSHR indicated this inverse relationship of roughness versus tensile residual stress was also present for these superalloys, where tensile residual stresses were significantly enhanced.

superalloys↗
NASA NTRS2022

Hybrid data-driven and model-informed online tool wear detection in milling machines

Precision machining tool wear is responsible for low product throughput and quality. Monitoring the tool wear online is vital to prevent degradation in machining quality. However, direct real-time tool wear measurement is not practical. This paper presents residual-based anomaly detection models, combining a hybrid model comprised of a physics-based model and a data-driven model (a decision tree or a neural network) to predict signals of interest (e.g., power or forces) under nominal conditions, followed by Page’s cumulative sum test for detecting tool wear on-line using the computer numerical control machine measurements. The most informative features are ranked using dynamic programming and its approximation variants from real-time measurements and machine settings, such as the width of cut, depth of cut, feed rate and spindle speed, that serve as inputs to the predictive models. The baseline nominal model is incrementally updated with experimental data via a gradient boosted adaptation model to generate the residuals that account for discrepancies between the actual machine data under normal conditions and the baseline nominal model predictions. The hybrid model is validated against 20 Mazak milling machine experimental tests and one Haas run-to-failure experiment. The proposed anomaly detector is applied to synthetic data from simulations of the physics-based model at different operating conditions, measurement noise levels, and tool wear levels, and the methods were able to achieve an overall 92% accuracy in data with 1% noise. The anomaly detection methods based on hybrid model reduced the false alarms of either the data-driven or physical-based models alone, and are found to be capable of good online detection of tool wear.

Online anomaly detection↗
NASA NTRSDate not supplied

Electrical Discharge Machining of Additively Manufactured Superalloys Containing Oxide Dispersions

Superalloys can be strengthened by oxide dispersions to potentially improve their mechanical properties at high temperatures. Additive manufacturing has opened new paths for introducing oxide particles into superalloys with increased processing flexibility, to potentially provide oxide dispersion strengthening. Numerically controlled electrical discharge machining (EDM) has often been used as a machining process for initial sectioning, detailed roughing, and even finishing operations of conventional superalloys. The objective of this study was to examine how additively manufactured superalloys containing oxide dispersions respond when sectioned using EDM. Consistent sections of several superalloys, two containing an oxide dispersion, were sliced using a typical EDM machine with standard brass wire and a typical roughing condition set. Roughness, microstructure, and residual stress at the EDM surfaces were compared for the varied superalloys.

superalloys↗
DOE OSTI2020

Ultrasonic Additive Manufacturing

Ultrasonic additive manufacturing (UAM) is a solid-state hybrid manufacturing technique that leverages the principles of ultrasonic welding, mechanized tape layering, and computer numerical control (CNC) machining operations to create three-dimensional metal parts. This article begins with a discussion on the process fundamentals and process parameters of UAM. It then describes metallurgical aspects in UAM. The article provides a detailed description of a wide range of mechanical characterization techniques of UAM, namely tensile testing, peel testing, and pushpin testing. The article ends with information on sensor embedding.

Niyanth S, Niyanth↗
DOE OSTI2021

The Role of the Digital Thread for Security, Resilience, and Adaptability in Manufacturing

The manufacturing sector is dramatically evolving with recent technical and digital advances. Among these, the digital thread is revolutionizing manufacturing operations well beyond the historic downloading of programs to computer numerically controlled (CNC) machine tools and the uploading of edited programs from CNC controllers. The digital thread is “the communication framework that enables a connected data flow and integrated view of the asset’s data throughout its lifecycle across traditionally siloed functional perspectives” (Leiva 2016). It is pervasive around the world and has changed the way society operates; for example, map apps are used to provide time-optimal directions to destinations using real-time traffic feedback. The digital thread makes it possible to digitally verify products, ensure that the latest technologies are deployed across the entire manufacturing ecosystem, and strengthen the workforce by making each individual more efficient and effective. These three foundational advanced manufacturing concepts will ensure a next-generation secure, resilient, and adaptable manufacturing ecosystem and sustainably support current and future needs of society (Lynn et al. 2020).

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2026

A Mobile Hot Cell for Conditioning Disused Sealed Radioactive Sources for Storage or Transportation

An innovative Mobile Hot Cell (MHC) has been developed for conditioning Disused Sealed Radioactive Sources (DSRS) category 1 and 2 for storage or transportation. The MHC is designed to provide both Radiological and Biological containment with a maximum capacity of 1000 Ci Co60 or 5000Ci Cs137 source and can be transported via standard cargo containers. This project has been supported through the National Nuclear Safety Administration (NNSA) Offsite Source Recovery Program (OSRP). The project is intended for the international community rather than domestic although domestic use is a possibility. Many countries have significant stockpiles of these devices that are often stored in less-than-optimal circumstances. This necessitates that these devices be addressed expeditiously, and the sources secured. The MHC utilizes robotics, automation, and other non-traditional methods for disassembling, characterizing, and packaging these sources that have reached end of life or are otherwise not needed. These innovative approaches are necessary to facilitate an expedited timeline to efficiently and safely secure these sources in a non-proliferation effort. Conditioning efforts include disassembling the device such as a teletherapy head used for cancer treatment, or blood/research irradiators such that the radioactive sources may be removed safely. The sources are then characterized. Leak checks are performed, dimensions are verified, and serial numbers are confirmed. Upon completion, the sources are typically placed into a Standard Forms Capsule which is seal welded closed. It is leak tested and placed into a Long-Term Storage Shield (LTSS) which can either be secured for storage directly or loaded into an appropriate cask for transportation. Further innovations include multiple deployment scenarios that include a full deployment of MHC components, deployment of the MHC automation internal components to an existing hot cell, deployment of minimally required MHC components and incorporation of sand for shielding, and integration of the MHC for Silo Storage, or Bore Hole Storage efforts. The MHC has evolved from a very specific use case to a “Swiss Army Knife” type of a tool in that it can be readily adapted to a large variety of situations. Innovative approaches such as the use of robotics, Computer Numeric Control (CNC) machining centers, automated welding equipment, HDMI Cameras, and LED lighting are some of the developed technologies incorporated into the MHC design. Shielding is accomplished with a steel walled Base Box which is surrounded by four nesting doll shield shells which when combined limits the external dose rate to 5mr/hr when a 1000 Ci Co60 source is exposed inside.

99 - GENERAL AND MISCELLANEOUS↗
NASA NTRS1992

A numerical approach to controller design with an application to a space structure test facility

An iterative numerical algorithm that improves feasible closed loop design criteria by updating the parameters of a linear controller is developed. The algorithm allows the use of experimentally derived data collected from the open loop plant. It eliminates the need for an accurate parametric model of the open loop system. Experimental results from the application of a controller designed for a large space structure ground test facility using the algorithm are presented.

Frazier, W. G.↗
NASA NTRS1992

Recent advances in numerical simulation and control of asymmetric flows around slender bodies

The problems of asymmetric flow around slender bodies and its control are formulated using the unsteady, compressible, thin-layer or full Navier-Stokes equations which are solved using an implicit, flux-difference splitting, finite-volume scheme. The problem is numerically simulated for both locally-conical and three-dimensional flows. The numerical applications include studies of the effects of relative incidence, Mach number and Reynolds number on the flow asymmetry. For the control of flow asymmetry, the numerical simulation cover passive and active control methods. For the passive control, the effectiveness of vertical fins placed in the leeward plane of geometric symmetry and side strakes with different orientations is studied. For the active control, the effectiveness of normal and tangential flow injection and surface heating and a combination of these methods is studied.

Kandil, Osama A.↗
NASA NTRS1984

Numerical simulation of controlled flow tunnel for V/STOL testing

A 'smart' wind tunnel concept for V/STOL transition regime studies is presented and performance is projected with numerical simulations. The wind tunnel would provide a flow that faithfully represents free air flow and thereby permits accurate lift calculations for V/STOL aircraft. The design concept is based on free-air tunnels used for planar wings. Modifications are necessary to account for the highly deflected, vortical wake produced in low-speed take-off and landing situations. A three-step numerical procedure covering the potential flow of a high lift system in free-air, controlled flow data with a model in a wind tunnel and addition of the wall conditions to the simulation as a feedback loop to correct the closed-tunnel is described. The initial simulation is for three-dimensional full span jet flapped wings, and is derived from extended two-dimensional calculations. The results indicate that only partial control of the tunnel flow is sufficient to serve as a valid environment for V/STOl studies.

Joppa, R. G.↗
NASA NTRS1998

A Numerical Optimization Approach for Tuning Fuzzy Logic Controllers

This paper develops a method to tune fuzzy controllers using numerical optimization. The main attribute of this approach is that it allows fuzzy logic controllers to be tuned to achieve global performance requirements. Furthermore, this approach allows design constraints to be implemented during the tuning process. The method tunes the controller by parameterizing the membership functions for error, change-in-error and control output. The resulting parameters form a design vector which is iteratively changed to minimize an objective function. The minimal objective function results in an optimal performance of the system. A spacecraft mounted science instrument line-of-sight pointing control is used to demonstrate results.

Woodard, Stanley E.↗
NASA NTRS1989

Numerical investigation of the control of the secondary instability process in boundary layers

A numerical model has been developed for investigating boundary layer transition control for a flat plate boundary layer. Active control of a periodically forced boundary layer in an incompressible fluid is studied using surface heating techniques. The spatially evolving boundary layer is simulated. The Navier-Stokes and energy equations are integrated using a fully implicit finite difference/spectral method. Temperature perturbations are introduced locally along finite heater strips to directly attenuate the instability waves in the flow. A feedback control loop is employed in which a downstream sensor is used to monitor wall shear stress fluctuations. Active control of small amplitude two-dimensional and three-dimensional disturbances is numerically simulated. With proper phase control, in-phase reinforcement and out-of-phase attenuation are demonstrated. A receptivity study of the localized temperature perturbations is made. It is shown that narrow heater strips are more receptive in that they maximize the amplitude level of the disturbances in the flow. Active control of the early stages of the fundamental breakdown process is also numerically simulated. Control is achieved with either two-dimensional or three-dimensional control inputs.

Kral, L. D.↗
DOE OSTI2020

An Efficient Numerical Algorithm for Solving Data Driven Feedback Control Problems

The goal of this paper is to solve a class of stochastic optimal control problems numerically, in which the state process is governed by an Itô type stochastic differential equation with control process entering both in the drift and the diffusion, and is observed partially. The optimal control of feedback form is determined based on the available observational data. In this work, we call this type of control problems the data driven feedback control. The computational framework that we introduce to solve such type of problems aims to find the best estimate for the optimal control as a conditional expectation given the observational information. To make our method feasible in providing timely feedback to the controlled system from data, we develop an efficient stochastic optimization algorithm to implement our computational framework.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1984

Numerical optimization of circulation control airfoil at high subsonic speed

A numerical procedure for optimizing the design of the circulation control airfoil for use at high subsonic speeds is presented. The procedure consists of an optimization scheme coupled with a viscous potential flow analysis for the blowing jet. The desired airfoil is defined by a combination of three baseline shapes (cambered ellipse and cambered ellipse with drooped and spiraled trailing edges). The coefficients of these shapes are used as design variables in the optimization process. Under the constraints of lift augmentation and lift-to-drag ratios, the airfoil, optimized at free-stream Mach 0.54 and alpha = -2 degrees can be characterized as a cambered ellipse with a drooped trailing edge. Experimental tests support the performance improvement predicted by numerical optimization.

Tai, T. C.↗
NASA NTRS1972

The computation of optimal control programmes using a modified successive sweep method.

A second-order method for numerically solving control optimization problems has been developed. The method, referred to as the modified sweep method (MSM), differs from the successive sweep method (SSM) proposed by McReynolds and Bryson (1965) in that the conditions for local control optimality are used to determine the control as an explicit function of the state variables and time. The control is eliminated from the problem and the solution to the resulting two-point boundary value problem can be obtained by linear perturbation methods. The modified sweep method proposed here uncouples the perturbation equations for the state variables and the Lagrange multipliers by using a generalized matrix-Riccati transformation of variables. The resulting algorithm for the numerical iteration process is concerned with determining the initial values of a set of Lagrange multipliers rather than correcting a numerical control programme over the entire time interval of interest.

Colunga, D.↗
NASA NTRS1978

Numerical solutions of a control problem governed by functional differential equations

A numerical procedure is proposed for solving optimal control problems governed by linear retarded functional differential equations. The procedure is based on the idea of 'averaging approximations', due to Banks and Burns (1975). For illustration, numerical results generated on an IBM 370/158 computer, which demonstrate the rapid convergence of the method are presented.

Banks, H. T.↗