Search NASA⌕ Search

SEARCH · Search NASA

Results for “manufacturing technology”

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.

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

At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

DSMC simulation of ionized rarefied flows

Recently a renewed interest has been exhibited in understanding contamination and space environmental effect in the LEO range of 200 to 600 km as well as in low density microelectronics manufacturing technologies. Realistic simulations must model the physics of the highly coupled effects of neutral and charged particle flows, thermodynamic nonequilibrium, surface charging, and electromagnetic field effects. The computational requirements are enormous for this level of modeling and are almost impossible on current single processor supercomputers. An effort was initiated to develop this capability on a massively parallel MIMD supercomputers. The Wake Shield Facility experiment will be used for test case calculations. Preliminary results indicate that parallel supercomputers may be the only computers capable of simulating the required level of physics and spatial resolution. Calculations which contain from 1 to 8 million simulation particles are presented.

Bartel, Timothy J.↗
NASA NTRS1990

A stiffness tailored wing cover concept for structural efficiency and postbuckling application

The weight savings due to usage of composite materials in aircraft structural applications is well known. Significant weight and cost benefits are achievable by developing structurally tailored concepts and efficiently integrating them with suitable material and manufacturing technologies. The proposed paper will describe such an efficient concept for application to primary aircraft structures.

Ambur, D. R.↗
NASA NTRS1993

The Iridium (tm) system: Personal communications anytime, anyplace

The Iridium system is designed to provide handheld personal communications between diverse locations around the world at any time and without prior knowledge of the location of the personal units. This paper provides an overview of the system, the services it provides, its operation, and an overview of the commercial practices and relatively high volume satellite production techniques which will make the system cost effective. A constellation of 66 satellites will provide an orbiting, spherical-shell, infrastructure for this global calling capability. The satellites act as tall cellular towers and allow convenient operation for portable handheld telephones. The system will provide a full range of services including voice, paging, data, geolocation, and fax capabilities. Motorola is a world leader in the production of high volume, high quality, reliable telecommunications hardware. One of Iridium's goals is to apply these production techniques to high reliability space hardware. Concurrent engineering, high performance work teams, advanced manufacturing technologies, and improved assembly and test methods are some of the techniques that will keep the Iridium system cost effective. Mobile, global, flexible personal communications are coming that will allow anyone to call or receive a call from/to anyplace at anytime. The Iridium system will provide communications where none exist today. This connectivity will allow increased information transfer, open new markets for various business endeavors, and in general increase productivity and development.

Hatlelid, John E.↗
NASA NTRS1993

Flow visualization study in high aspect ratio cooling channels for rocket engines

The structural integrity of high pressure liquid propellant rocket engine thrust chambers is typically maintained through regenerative cooling. The coolant flows through passages formed either by constructing the chamber liner from tubes or by milling channels in a solid liner. Recently, Carlile and Quentmeyer showed life extending advantages (by lowering hot gas wall temperatures) of milling channels with larger height to width aspect ratios (AR is greater than 4) than the traditional, approximately square cross section, passages. Further, the total coolant pressure drop in the thrust chamber could also be reduced, resulting in lower turbomachinery power requirements. High aspect ratio cooling channels could offer many benefits to designers developing new high performance engines, such as the European Vulcain engine (which uses an aspect ratio up to 9). With platelet manufacturing technology, channel aspect ratios up to 15 could be formed offering potentially greater benefits. Some issues still exist with the high aspect ratio coolant channels. In a coolant passage of circular or square cross section, strong secondary vortices develop as the fluid passes through the curved throat region. These vortices mix the fluid and bring lower temperature coolant to the hot wall. Typically, the circulation enhances the heat transfer at the hot gas wall by about 40 percent over a straight channel. The effect that increasing channel aspect ratio has on the curvature heat transfer enhancement has not been sufficiently studied. If the increase in aspect ratio degrades the secondary flow, the fluid mixing will be reduced. Analysis has shown that reduced coolant mixing will result in significantly higher wall temperatures, due to thermal stratification in the coolant, thus decreasing the benefits of the high aspect ratio geometry. A better understanding of the fundamental flow phenomena in high aspect ratio channels with curvature is needed to fully evaluate the benefits of this geometry. The fluid dynamic and conjugate heat transfer problem of high aspect ratio rocket engine coolant channels are being investigated numerically, but these efforts have been hampered by a lack of validating data. Wall temperature data is available for the conjugate problem for channels without curvature and aspect ratio = 5.0, and unheated fluid dynamic data are available for square and circular cross section channels with curvature at Reynold's numbers up to 40,000. But the effects of aspect ratio on secondary flow development have not been experimentally studied. To provide some insight into the effects of channel aspect ratio on secondary flow and to qualitatively provide anchoring for the numerical codes, a flow visualization experiment was initiated at the NASA Lewis Research Center.

Meyer, Michael L.↗
NASA NTRS1994

Test Plan. GCPS Task 4, subtask 4.2 thrust structure development

The Single Stage To Orbit (SSTO) vehicle is designed to lift off from a vertical position, go into orbit, return to earth for a horizontal landing, and be reusable for the next mission. (NASA baseline only) In order to meet its performance goals, the SSTO relies on light weight structure and the use of 8 tri-propellant engines. These engines are mounted to the thrust structure. This test plan addresses selection of the material for this structure, and the integrity of the design through testing of elements and a full-scale subcomponent. This test plan supports the development of the design for an advanced composite thrust structure for a Single Stage to Orbit manned, heavy launch vehicle. The thrust structure is designed to transmit very high thrust loads from the engines to the rest of the vehicle (see Figure 1 ). The thrust structure will also be used for primary attachment of the twin vertical tails and possibly act as the aft attach point for the wing. The combination of high loading, high vibration, long service life and high acoustic environments will need to be evaluated by tests. To minimize design risk, a building block approach will be used. We will first screen materials to determine which materials show the most promise for this application. Factors in this screening will be the suitability of these materials for chosen design concepts, particularly concerning specific strength, environmental compatibility and applicability to fabrication processes. Next we will characterize two material systems that will be used in the design; the characterization will allow us to generate preliminary design data that will be used for the analysis. Element testing will be performed to evaluate critical structural locations under load. Final testing on the full scale test article will be performed to verify the design and to demonstrate predictability of the analysis. Additionally, risks associated with fabricating full scale thrust structures will be reduced through testing activities. One of the major concerns that stems from full scale fabrication is the realities of size and the associated complexities of handling, manufacturing, and assembly. The need exists to fabricate, assemble and test_representative joint specimens to achieve_confidence in the design and manufacturing technologies being proposed.

Greenberg, H. S.↗
NASA NTRS1994

Use of prismatic films to control light distribution

Piping light for illumination purposes is a concept which has been around for a long time. In fact, it was the subject of an 1881 United States patent which proposed the use of mirrors inside a tube to reflect light from wall to wall down the tube. The use of conventional mirrors for this purpose, however, has not worked because mirrors do not reflect well enough. On the other hand, optical fibers composed of certain glasses or plastics are known to transport light much more efficiently. The light that enters is reflected back and forth within the walls of the fiber until it reaches the other end. This is possible by means of a principle known as 'total internal reflection'. No light escapes through the walls and very little is absorbed in the bulk of the fiber. However, while optical fibers are very efficient in transporting light, they are impractical for transporting large quantities of light. Lorne Whitehead, as a student at the University of British Columbia, recognized that prismatic materials could be used to create a 'prism light guide', a hollow structure that can efficiently transport large quantities of light. This invention is a pipe whose transparent walls are formed on the outside into precise prismatic facets. The facets are efficient total internal reflection mirrors which prevent light travelling down the guide from escaping. Very little light is absorbed by the pipe because light travels primarily in the air space within the hollow guide. And, because the guide is hollow, weight and cost factors are much more favorable than would be the case with very large solid fibers. Recent advances in precision micromachining, polymer processing, and certain other manufacturing technologies have made the development of OLF (Optical Lighting Film) possible. The process is referred to as 'microreplication' and has been found to have broad applicability in a number of diverse product areas.

Kneipp, K. G.↗
NASA NTRS1998

Composite Bus Structure for the SMEX/WIRE Satellite

In an effort to reduce the weight and optimize the structural design of the Small Explorer (SMEX) Wide-Field Infrared Explorer (WIRE) spacecraft, it has become desirable to change the material and construction from mechanically fastened aluminum structure to a fully bonded fiber-reinforced composite (FRC) structure. GSFC has developed the WIRE spacecraft structural bus design concept, including the instrument and launch vehicle requirements. The WIRE Satellite is the fifth of a series of SMEX satellites to be launched once per year. GSFC has chosen Composite Optics Inc. (COI) as the prime contractor for the development and procurement of the WIRE composite structure. The detailed design of the fully bonded FRC structure is based on COI's Short Notice Accelerated Production SATellite ("SNAPSAT") approach. SNAPSAT is a state of the art design and manufacturing technology for advanced composite materials which utilizes flat-stock detail parts bonded together to produce a final structural assembly. The structural design approach adopted for the WIRE structure provides a very viable alternative to both traditional aluminum construction as well as high tech. molded type composite structures. This approach to composite structure design is much less costly than molded or honeycomb sandwich type composite construction, but may cost slightly more than conventional aluminum construction on the subsystem level. However on the overall program level the weight saving achieved is very cost effective, since the primary objective is to allocate more mass for science payloads.

Rosanova, Giulio G.↗
NASA NTRS1999

Development of Advanced In-Cylinder Components and Tribological Systems for Low Heat Rejection Diesel Engines

In-cylinder components and tribological system concepts were designed, fabricated and tested at conditions anticipated for a 55% thermal efficiency heavy duty diesel engine for the year 2000 and beyond. A Cummins L10 single cylinder research engine was used to evaluate a spherical joint piston and connecting rod with 19.3 MPa (2800 psi) peak cylinder pressure capability, a thermal fatigue resistant insulated cylinder head, radial combustion seal cylinder liners, a highly compliant steel top compression ring, a variable geometry turbocharger, and a microwave heated particulate trap. Components successfully demonstrated in the final test included spherical joint connecting rod with a fiber reinforced piston, high conformability steel top rings with wear resistant coatings, ceramic exhaust ports with strategic oil cooling and radial combustion seal cylinder liner with cooling jacket transfer fins. A Cummins 6B diesel was used to develop the analytical methods, materials, manufacturing technology and engine components for lighter weight diesel engines without sacrificing performance or durability. A 6B diesel engine was built and tested to calibrate analytical models for the aluminum cylinder head and aluminum block.

Yonushonis, T. M.↗
NASA NTRS2000

Cryogenic Optical Systems and Instrumentation IX (AM 116) Newly Modified Cryogenic Optical Test Facility at the Marshall Space Flight Center

Marshall Space Flight Center (MSFC) has maintained and operated a world-class x-ray optics and detector testing facility known as the X-ray Calibration Facility (XRCF) since the mid 1970's. The ground test and calibration of the Chandra X-ray Observatory optics and detectors were successfully completed at the XRCF in 1997. The beginning of the Next Generation Space Telescope (NGST) development programs (NMSD, SBMD, AMSD, etc.) and the establishment of the Space Optics Manufacturing Technology Center at MSFC have led to an XRCF modification. In 1999 the facility was upgraded to perform cryogenic testing of lightweight visible optics (without compromising the existing x-ray testing capability). A thermal enclosure capable of 20 degrees Kelvin and vibration isolated instrumentation mount were added. A vacuum-compatible five-axis motion table was modified to operate under cryogenic conditions. Optics up to two meters in diameter with radii of curvature of up to twenty meters can be accommodated. Facility characterization tests and one NGST program mirror test have been completed to date. By July 2000, two other mirrors will be tested. Optical wavefront measurements were made at < 35 degrees Kelvin with several instruments located at the test mirror's radius of curvature. The current wavefront measuring instruments include a Shack-Hartman wavefront sensor, a point diffraction interferometer, a point spread function-measuring device, and a radius of curvature measuring instrument. A vibration insensitive phase shifting interferometer is planned for future optical testing. This paper will present a brief history of the facility, a discussion of its current x-ray optic testing capabilities, and a complete description of the new capabilities in the visible optical testing regime.

Eng, Ronnie↗
NASA NTRS2000

Electro-Formed Mirrors for Both X-Ray and Visible Astronomy

The Space Optics Manufacturing Technology Center of NASA's Marshall Space Flight Center is involved in the development of nickel and nickel alloy electroformed mirrors for rapid production of space-based optical systems. The current state of the process is discussed- for both cylindrical x-ray mirrors and normal incidence mirrors for visible and infrared applications.

Ritter, J.↗
NASA NTRS2001

XRCF Testing Capabilities

The Space Optics Manufacturing Technology Center's X-ray Calibration Facility has been recently modified to test Next Generation Space Telescope (NGST) developmental mirrors at cryogenic temperatures (35 degrees Kelvin) while maintaining capability for performance testing of x-ray optics and detectors. The facility's current cryo-optical testing capability and potential modifications for future support of NGST will be presented.

Reily, Cary↗
NASA NTRS2002

Labview Implementation of Image Processing and Phasing Control for the SIBOA Segmented Mirror Testbed

NASA is preparing to launch the Next Generation Space Telescope (NGST). This telescope will be larger than the Hubble Space Telescope, be launched on an Atlas missile rather than the Space Shuttle, have a segmented primary mirror, and be placed in a higher orbit. All these differences pose significant challenges.' This effort addresses the challenge of implementing an algorithm for aligning the segments of the primary mirror during the initial deployment that was designed by Philip Olivier and members of SOMTC (Space Optics Manufacturing Technology Center). The implementation was to be performed on the SIBOA (Systematic Image Based Optical Alignment) test bed. Unfortunately, hardware/software aspect concerning SIBOA and an extended time period for algorithm development prevented testing before the end of the study period. Properties of the digital camera were studied and understood, resulting in the current ability of selecting optimal settings regarding saturation. The study was successful in manually capturing several images of two stacked segments with various relative phases. These images can be used to calibrate the algorithm for future implementation. Currently the system is ready for testing.

James D. Partridge↗
NASA NTRS2002

Robots and Humans in Planetary Exploration: Working Together?

Today's approach to human-robotic cooperation in planetary exploration focuses on using robotic probes as precursors to human exploration. A large portion of current NASA planetary surface exploration is focussed on Mars, and robotic probes are seen as precursors to human exploration in: Learning about operation and mobility on Mars; Learning about the environment of Mars; Mapping the planet and selecting landing sites for human mission; Demonstration of critical technology; Manufacture fuel before human presence, and emplace elements of human-support infrastructure

Landis, Geoffrey A.↗
NASA NTRS2002

Analysis of Small Aircraft as a Transportation System

An analysis was conducted to examine the market viability of small aircraft as a transportation mode in competition with automobile and scheduled commercial air travel by estimating the pool of users that would potentially switch to on-demand air travel due to cost/time savings. The basis for the analysis model was the Integrated Air Transportation System Evaluation Tool (IATSET) which was developed under contract to NASA by the Logistics Management Institute. IATSET is a macroeconomic model that predicts at a National level the mode choice between automobile, scheduled air, and on-demand air travel based on the value of a travelers time and monetary cost of the trip. A number of modifications are detailed to the original IATSET to better model the changing small aircraft environment. The potential trip market was modeled for the Eclipse 500 operated as a corporate jet and as an air taxi for the business travel market. The Cirrus 20R and a $80K single engine piston aircraft (based on automobile manufacturing technology) are evaluated in the pleasure and personal business travel market.

Dollyhigh, Samuel M.↗
NASA NTRS2003

High Accuracy Thermal Expansion Measurement At Cryogenic Temperatures

A new, interferometer based system for measuring thermal expansion to an absolute accuracy of 20 ppb or better at cryogenic temperatures has been developed. Data from NIST Copper SRM 736 measured from room temperature to 15 K will be presented along with data from many other materials including beryllium, ULE, Zerodur, and composite materials. Particular attention will be given to a study by the Space Optics Manufacturing Technology Center (SOMTC) investigating the variability of ULE and beryllium materials used in the AMSD program. Approximately 20 samples of each material, tested from room temperature to below 30 K are compared as a function of billet location.

Stallcup, Michael↗
NASA NTRS2003

Electronic Power System Application of Diamond-Like Carbon Films

A prototype manufacturing technology for producing high volume efficiency and high energy density diamond-like carbon (DLC) capacitors has been developed. Unique dual ion-beam deposition and web-handling systems have been designed and constructed to deposit high quality DLC films simultaneously on both sides of capacitor grade aluminum foil and aluminum-coated polymer films. An optimized process, using inductively coupled RF ion sources, has been used to synthesize electrically robust DLC films. DLC films are amorphous and highly flexible, making them suitable for the production of wound capacitors. DLC capacitors are reliable and stable over a wide range of AC frequencies from 20 Hz to 1 MHz, and over a temperature range from .500 C to 3000 C. The compact DLC capacitors offer at least a 50% decrease in weight and volume and a greater than 50% increase in temperature handling capability over equal value capacitors built with existing technologies. The DLC capacitors will be suitable for high temperature, high voltage, pulsed power and filter applications.

Wu, Richard L. C.↗
NASA NTRS2003

High Accuracy Thermal Expansion Measurement at Cryogenic Temperatures

A new, interferometer-based system for measuring thermal expansion to an absolute accuracy of 20 ppb or better at cryogenic temperatures has been developed. Data from NIST Copper SRM 736 measured from room temperature to 15 K will be presented along with data from many other materials including beryllium, ULE, Zerodur, and composite materials. Particular attention will be given to a study by the Space Optics Manufacturing Technology Center (SOMTC) investigating the variability of ULE and beryllium materials used in the AMSD program Approximately 20 samples of each material, tested from room temperature to below 30 K are compared as a function of billet location.

Tucker, Jim↗
NASA NTRS2004

Progress on Space Borne Laser Risk Reduction at Goddard Space Flight Center

At the direction of NASA Headquarters NASA Goddard Space Flight Center (GSFC) and NASA Langley Research Center (LaRC) undertook in 2002 a program in fundamental research on laser manufacturing technologies aimed at improving the performance and lifetime of lasers sent into space for remote sensing applications. The work at GSFC has concentrated on three areas: 1) development of high power 1 micron lasers, 2) lifetime and reliability testing for 808 nm pump diodes, and 3) efficient conversion of 1 micron radiation to wavelengths needed for various remote sensing tasks. After almost 2 years of development interesting results in all three areas are beginning to emerge. Some of these results will be described along with discussion of future directions.

Heaps, William S.↗