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At least 235 records · Page 13

A review of the solar array manufacturing industry costing standards

The solar array manufacturing industry costing standards model is designed to compare the cost of producing solar arrays using alternative manufacturing processes. Constructive criticism of the methodology used is intended to enhance its implementation as a practical design tool. Three main elements of the procedure include workbook format and presentation, theoretical model validity and standard financial parameters.

Source record↗

Contamination Control and Hardware Processing Solutions at Marshall Space Flight Center

The Contamination Control Team of Marshall Space Flight Center's Materials and Processes Laboratory supports many Programs/ Projects that design, manufacture, and test a wide range of hardware types that are sensitive to contamination and foreign object damage (FOD). Examples where contamination/FOD concerns arise include sensitive structural bondline failure, critical orifice blockage, seal leakage, and reactive fluid compatibility (liquid oxygen, hydrazine) as well as performance degradation of sensitive instruments or spacecraft surfaces such as optical elements and thermal control systems. During the design phase, determination of the sensitivity of a hardware system to different types or levels of contamination/FOD is essential. A contamination control and FOD control plan must then be developed and implemented through all phases of ground processing, and, sometimes, on-orbit use, recovery, and refurbishment. Implementation of proper controls prevents cost and schedule impacts due to hardware damage or rework and helps assure mission success. Current capabilities are being used to support recent and on-going activities for multiple Mission Directorates / Programs such as International Space Station (ISS), James Webb Space Telescope (JWST), Space Launch System (SLS) elements (tanks, engines, booster), etc. The team also advances Green Technology initiatives and addresses materials obsolescence issues for NASA and external customers, most notably in the area of solvent replacement (e.g. aqueous cleaners containing hexavalent chrome, ozone depleting chemicals (CFC s and HCFC's), suspect carcinogens). The team evaluates new surface cleanliness inspection and cleaning technologies (e.g. plasma cleaning), and maintains databases for processing support materials as well as outgassing and optical compatibility test results for spaceflight environments.

Burns, DeWitt H.↗

Composite intermediate case manufacturing scale-up for advanced engines

This Manufacturing Technology for Propulsion Program developed a process to produce a composite intermediate case for advanced gas turbine engines. The method selected to manufacture this large, complex part uses hard tooling for surfaces in the airflow path and trapped rubber to force the composite against the mold. Subelements were manufactured and tested to verify the selected design, tools, and processes. The most significant subelement produced was a half-scale version of a composite intermediate case. The half-scale subelement maintained the geometry and key dimensions of the full-scale case, allowing relevant process development and structural verification testing to be performed on the subelement before manufacturing the first full-scale case.

Ecklund, Rowena H.↗

Demonstration of the feasibility of automated silicon solar cell fabrication

A study effort was undertaken to determine the process, steps and design requirements of an automated silicon solar cell production facility. Identification of the key process steps was made and a laboratory model was conceptually designed to demonstrate the feasibility of automating the silicon solar cell fabrication process. A detailed laboratory model was designed to demonstrate those functions most critical to the question of solar cell fabrication process automating feasibility. The study and conceptual design have established the technical feasibility of automating the solar cell manufacturing process to produce low cost solar cells with improved performance. Estimates predict an automated process throughput of 21,973 kilograms of silicon a year on a three shift 49-week basis, producing 4,747,000 hexagonal cells (38mm/side), a total of 3,373 kilowatts at an estimated manufacturing cost of $0.866 per cell or $1.22 per watt.

Taylor, W. E.↗

Electronic Design Automation: Integrating the Design and Manufacturing Functions

As the complexity of electronic systems grows, the traditional design practice, a sequential process, is replaced by concurrent design methodologies. A major advantage of concurrent design is that the feedback from software and manufacturing engineers can be easily incorporated into the design. The implementation of concurrent engineering methodologies is greatly facilitated by employing the latest Electronic Design Automation (EDA) tools. These tools offer integrated simulation of the electrical, mechanical, and manufacturing functions and support virtual prototyping, rapid prototyping, and hardware-software co-design. This report presents recommendations for enhancing the electronic design and manufacturing capabilities and procedures at JSC based on a concurrent design methodology that employs EDA tools.

Bachnak, Rafic↗

Additive Manufacturing of Liquid Rocket Engine Combustion Devices: A Summary of Process Developments and Hot-Fire Testing Results

Additive Manufacturing (AM) of metals is a processing technology that has significantly matured over the last decade. For liquid propellant rocket engines, the advantages of AM for replacing conventional manufacturing of complicated and expensive metallic components and assemblies are very attractive. AM can significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing for use in liquid rocket engine component design, development, and testing since 2010. The AM technique most often used at the NASA MSFC has been powder-bed fusion or selective laser melting (SLM), although other techniques including laser directed energy deposition (DED), arc-based deposition, and laser-wire cladding techniques have also been used to develop several components. The purpose of this paper is to discuss the various internal programs at the NASA MSFC using AM to develop combustion devices hardware. To date at the NASA MSFC, combustion devices component hardware ranging in size from 100 lbf to 35,000 lbf have been designed and manufactured using SLM and deposition-based AM processes, and many of these pieces have been hot-fire tested. Combustion devices component hardware have included thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. Ongoing and future developments for combustion devices have also included design of components sized for boost-class engines. Several design and hot-fire test iterations have been completed on these subscale and larger scale components, and a summary of these results will be presented as well.

Gradl, Paul↗

Solar Sails

The Solar Sail Propulsion investment area has been one of the three highest priorities within the In-Space Propulsion Technology (ISPT) Project. In the fall of 2003, the NASA Headquarters' Science Mission Directorate provided funding and direction to mature the technology as far as possible through ground research and development from TRL 3 to 6 in three years. A group of experts from government, industry, and academia convened in Huntsville, Alabama to define technology gaps between what was needed for science missions to the inner solar system and the current state of the art in ultra1ightweight materials and gossamer structure design. This activity set the roadmap for development. The centerpiece of the development would be the ground demonstration of scalable solar sail systems including masts, sails, deployment mechanisms, and attitude control hardware and software. In addition, new materials would be subjected to anticipated space environments to quantify effects and assure mission life. Also, because solar sails are huge structures, and it is not feasible to validate the technology by ground test at full scale, a multi-discipline effort was established to develop highly reliable analytical models to serve as mission assurance evidence in future flight program decision-making. Two separate contractor teams were chosen to develop the SSP System Ground Demonstrator (SGD). After a three month conceptual mission/system design phase, the teams developed a ten meter diameter pathfinder set of hardware and subjected it to thermal vacuum tests to compare analytically predicted structural behavior with measured characteristics. This process developed manufacturing and handling techniques and refined the basic design. In 2005, both contractor teams delivered 20 meter, four quadrant sail systems to the largest thermal vacuum chamber in the world in Plum Brook, Ohio, and repeated the tests. Also demonstrated was the deployment and articulation of attitude control mechanisms. In conjunction with these tests, the stowed sails were subjected to launch vibration and ascent vent tests. Other investments studied radiation effects on the solar sail materials, investigated spacecraft charging issues, developed shape measuring techniques and instruments, produced advanced trajectory modeling capabilities, and identified and resolved gossamer structure dynamics issues. Technology validation flight and application to a He1iophysics science mission is on the horizon.

Young, Roy↗

Additive Manufacturing Design Considerations for Liquid Engine Components

The Marshall Space Flight Center's Propulsion Systems Department has gained significant experience in the last year designing, building, and testing liquid engine components using additive manufacturing. The department has developed valve, duct, turbo-machinery, and combustion device components using this technology. Many valuable lessons were learned during this process. These lessons will be the focus of this presentation. We will present criteria for selecting part candidates for additive manufacturing. Some part characteristics are 'tailor made' for this process. Selecting the right parts for the process is the first step to maximizing productivity gains. We will also present specific lessons we learned about feature geometry that can and cannot be produced using additive manufacturing machines. Most liquid engine components were made using a two-step process. The base part was made using additive manufacturing and then traditional machining processes were used to produce the final part. The presentation will describe design accommodations needed to make the base part and lessons we learned about which features could be built directly and which require the final machine process. Tolerance capabilities, surface finish, and material thickness allowances will also be covered. Additive Manufacturing can produce internal passages that cannot be made using traditional approaches. It can also eliminate a significant amount of manpower by reducing part count and leveraging model-based design and analysis techniques. Information will be shared about performance enhancements and design efficiencies we experienced for certain categories of engine parts.

Whitten, Dave↗

Manufacture of astroloy turbine disk shapes by hot isostatic pressing, volume 1

The Materials in Advanced Turbine Engines project was conducted to demonstrate container technology and establish manufacturing procedures for fabricating direct Hot Isostatic Pressing (HIP) of low carbon Astroloy to ultrasonic disk shapes. The HIP processing procedures including powder manufacture and handling, container design and fabrication, and HIP consolidation techniques were established by manufacturing five HIP disks. Based upon dimensional analysis of the first three disks, container technology was refined by modifying container tooling which resulted in closer conformity of the HIP surfaces to the sonic shape. The microstructure, chemistry and mechanical properties of two HIP low carbon Astroloy disks were characterized. One disk was subjected to a ground base experimental engine test, and the results of HIP low carbon Astroloy were analyzed and compared to conventionally forged Waspaloy. The mechanical properties of direct HIP low carbon Astroloy exceeded all property goals and the objectives of reduction in material input weight and reduction in cost were achieved.

Eng, R. D.↗

NASA flight cell and battery issues

The author presents the important battery and cell problems, encompassing both test failures and accidents, which were encountered during the past year. Practical issues facing programs, which have to be considered in the development of a battery program strategy, are addressed. The problems of one program, the GRO (Gamma Ray Observatory), during the past year are focused on to illustrate the fundamental types of battery problems that occur. Problems encountered by other programs are briefly mentioned to complete the accounting. Two major categories of issues are defined, namely, whose which are quality and design related, i.e., problems having inherent manufacturing-process-related aspects with an impact on cell reliability, and these which are accident triggered or man induced, i.e., those operational issues having an impact on battery and cell reliability.

Schulze, N. R.↗

OMC Compressor Case

This report summarizes efforts expended in the development of an all-composite compressor case. Two pre-production units have been built, one utilizing V-CAP and one utilizing AFR-700B resin systems. Both units have been rig tested at elevated temperatures well above design limit loads. This report discusses the manufacturing processes, test results, and Finite Element Analysis performed. The V-CAP unit was funded by NASA-Lewis Research Center in 1994 under contract number NAS3- 27442 for Development of an All-Composite OMC Compressor Case. This contract was followed by an Air Force study in 1996 to build and identical unit using the AFR-700B resin system in place of the V-CAP system. The second compressor case was funded under U.S. Air Force contract F33615-93-D-5326, Advanced Materials for Aerospace Structures Special Studies (AMAS3), Delivery Order 0021 entitled "Advanced Polymeric Composite Materials and Structures Technology for Advanced High Temperature Gas Turbine Engines.' Initial studies using the V-CAP resin system were undertaken in 1993 under a NASA Lewis contract (NAS3-26829). A first prototype unit was developed in a joint program between Textron-Lycoming (now Allied Signal) and Brunswick (now Lincoln Composites). This unit included composite end closures using low density, high temperature molded end closures. The units was similar in size and shape to a titanium case currently used on the PT-21 0 engine and was funded as part of the integrated High Performance Turbine Engine Technology (EHPTET) initiative of DOD and NASA.

Humphrey, W. Donald↗

Engineering Design Unit Primary Mirror Segment

The James Webb Space Telescope Primary Mirror Engineering Design Unit (EDU) recently demonstrated the final manufacturing process at L-3-SSG/Tinsley in Richmond, California. Shown in the picture below, the EDU is a prototype 1.4 meter diameter Beryllium mirror that is identical to the 18 flight mirror segments and is used to check out all mirror manufacturing processes prior to the actual flight mirror processing. This recent result gives confidence that all manufacturing processes are in place to figure the 18 flight mirrors. Lessons learned from the EDU have been applied to the flight mirrors improving the performance and processing time and all 18 flight mirrors are well along in their processing at L3-SSG/Tinsley. As a result of completing the final manufacturing demonstration, the EDU mirror was sent to Ball Aerospace in Boulder, Colorado where it is now undergoing integration with the hexapod mount assembly and optical testing checkout. After integration to mount assemblies, flight mirrors will be sent for cryogenic (50 degrees Kelvin) optical testing where the cryogenic distortions will be measured. After cryogenic testing, mirrors will eventually be returned to Tinsley for final cryogenic polishing. During final cryogenic polishing, the inverse of the measured cryogenic distortions will be polished into the mirror to assure the mirror works at it's cryogenic operating temperature. Once cryogenic polishing is completed to final specifications, the mirror will be coated and sent for final cryogenic testing.

Alongi, Chris↗

Innovations in Continuous Ultrasonic Welding of Thermoplastic Composites and Evaluation for Space Applications

The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include and assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities, including failure prediction of thermoplastic composites including joints. This presentation will provide an overview of the materials and manufacturing effort within the TDEA project. Three semi-crystalline and one amorphous thermoplastic composite system were selected for initial screening and provided an opportunity to gain manufacturing experience across a range of processing temperatures, rheological behavior, and composite properties. Equivalency to the National Center for Advanced Materials Performance (NCAMP) test report for Toray’s TC1225 material was established to provide confidence in in-house manufacturing and material properties were generated through baseline mechanical tests for each material. Material characterization data was generated for a subset of materials to (1) provide data for analysis and model development and (2) generate thermal, rheological and conductivity data across relevant temperatures. A key objective of the TDEA project is evaluation of thermoplastic composite joining processes suitable for in-space operations. This presentation will outline the project’s progress in fusion bonding candidate materials by common welding techniques to assess the quality, reproducibility and strength of the bond, as well as identify limitations to in-space manufacturing. The feasibility of joint disassembly and reassembly will be discussed.

thermoplastic composite↗

Manufacture, Characterization, and Fusion Welding of Thermoplastic Composites for Space Applications

The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include an assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities. This presentation will provide an overview of the materials and manufacturing effort within the TDEA project. Three semi-crystalline and one amorphous thermoplastic composite materials were selected for initial screening and provided an opportunity to gain manufacturing experience across a range of processing temperatures, rheological behavior, and composite properties. Equivalency to the National Center for Advanced Materials Performance (NCAMP) test report for Toray’s TC1225 material was established to provide confidence in in-house manufacturing and material properties were generated through baseline mechanical tests for each material. Material characterization data was generated for a subset of materials to (1) provide data for analysis and model development and (2) generate thermal, rheological and conductivity data across relevant temperatures. A key objective of the TDEA project is evaluation of thermoplastic composite joining processes suitable for in-space operations. This presentation will outline the project’s progress in fusion bonding of candidate materials to assess the quality, reproducibility and strength of the bond, as well as identify limitations to in-space manufacturing. The feasibility of joint disassembly and reassembly will be discussed.

thermoplastic composite↗

Manufacture, Characterization, and Fusion Welding of Thermoplastic Composites for Space Applications

The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include an assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities.1

thermoplastic composite↗

Manufacture, Characterization, and Fusion Welding of Thermoplastic Composites for Space Applications

The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include and assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities, including failure prediction of thermoplastic composites including joints. This presentation will provide an overview of the materials and manufacturing effort within the TDEA project. Three semi-crystalline and one amorphous thermoplastic composite system were selected for initial screening and provided an opportunity to gain manufacturing experience across a range of processing temperatures, rheological behavior, and composite properties. Equivalency to the National Center for Advanced Materials Performance (NCAMP) test report for Toray’s TC1225 material was established to provide confidence in in-house manufacturing and material properties were generated through baseline mechanical tests for each material. Material characterization data was generated for a subset of materials to (1) provide data for analysis and model development and (2) generate thermal, rheological and conductivity data across relevant temperatures. A key objective of the TDEA project is evaluation of thermoplastic composite joining processes suitable for in-space operations. This presentation will outline the project’s progress in fusion bonding candidate materials by common welding techniques to assess the quality, reproducibility and strength of the bond, as well as identify limitations to in-space manufacturing. The feasibility of joint disassembly and reassembly will be discussed.

thermoplastic composite↗

Genesis Solar Wind Sample Curation Documentation

Introduction: A scientist with experience as a sample science analyst, provider of flight hardware for multiple missions, and senior engineer in an ISO 2000-rated manufacturing plant has described the timeline of key participants in any PI-led sample return mission, the breadth of the organizations involved [1,2], and, of interest to this meeting, choosing the types of data to preserve and issues of future data accessibility. This work broadens that perspective by giving similar lessons from Genesis sample curation point-of-view. Curation participation regarding data gathering was part of the mission review process from the beginning. Genesis’ story illustrates outcome of several choices about types of data to record and preserve. Precision analysis of solar wind atoms captured in pure, ultraclean substrates is the driving science goal; therefore, detailed documentation was captured from all mission and curation phases and from investigator laboratories because these processes affect the final analytical results [3]. Pre-flight: Design and fabrication of the spacecraft. Like many modern small sample return missions, Genesis was a tightly managed team integrated across science, engineering and curation. Communication across the team was excellent, and, for the most part, the hands-on engineering technicians understood the impacts of “small choices” they routinely make, and the eyes-on oversight of manufacturing processes by scientists was mindful of details. The payload was designed by the Jet Propulsion Laboratory and the spacecraft by Lockheed Martin. Solar wind collectors and instruments were fabricated by multiple vendors and laboratories. The main portion of the payload was assembled at JSC. Fabrication procedures and contamination-control data (with witness coupons) were stored primarily at JSC. The original composition, dimensions and configuration of components, results of thermal testing, etc. are still needed for interpretation of analytical data. At times, these must be estimated from secondary information acquired pre-flight. Moreover, some files (e.g., original 3-D models and early Powerpoint) cannot be opened using software. Archived curation data includes 2-D drawings, material usage lists, QA documentation and analyses of consumables used during fabrication. Important chemical information still resides in archived hardware, paints and lubricants, material coupons, cleaning coupons, environmental witness plates and reference materials from manufacturing facilities. Purity and cleanliness of collector substrates. Semi-conductor vendors provided surface cleanliness data and some purity data. Purity for specific elements of interest was verified by science team members in their laboratories [4]. Curation archived procurement and shipping records, analysis reports, and non-proprietary fabrication data. A physical archive of flight collector reference materials is maintained for future use so additional data can be collected as analytical techniques improve. These are of increased value due to the hard landing upon re-entry. Cleaning and cleanliness assessments of flight hardware. Cleaning of the science canister payload was performed at JSC in a dedicated ISO 4 cleanroom using ultrapure water (UPW). The cleanliness of this UPW was monitored throughout processing. The archive for the clean lab also includes airborne particle counts, airborne molecular and inorganic contamination measurements as well as cleanroom construction material coupons and witness coupons. Hardware cleanliness was assessed by particle counts in rinse water batches. This information is recorded in batch cleaning forms and logbooks, and are, perhaps, of decreased value due to the hard landing. Post-flight: Curation-generated data. The curation handling history of each Genesis sample is documented in a typical astromaterials sample database which captures sample location, physical description and characterization data. Samples have a “shelf life”. Crucial to the preservation of samples is ongoing documentation of the sample environment, initially under curatorial control but is now a separate facility function with requires coordination. PI-generated data. Data on sample characterization and cleaning techniques continues to be generated by sample users [5]. These are often captured in LPSC abstracts, but these “engineering” results often are not publishable as stand-alone papers. We are actively looking for ways to make this information more accessible to users. Ion implants into samples have aided science return and can be shared among investigators. These (and similar) materials should be added to the curatorial collection with appropriate process and characterization data generated externally. Summary: Complete data archives for returned astromaterial samples must be broad in types and formats, and inclusive of environmental monitoring.

Genesis↗