Search NASA⌕ Search

SEARCH · Search NASA

Results for “assembly processes”

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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Spin Formability of High-Strength Aluminum Alloys for Aerospace Applications

Near-net-shape fabrication of launch vehicle tanks and aircraft fuselages is critical for meeting the growing demand for unitized structures in the aerospace industry. Cryogenic tank manufacturing relies on multi-piece construction requiring hundreds of meters of welds that increase both structural weight and inspection time. Currently, fuselages have an immense part count requiring tens of thousands of rivets and long assembly time. NASA is pursuing spin and flow forming technology for manufacturing such structures with minimal assembly. These processes enable domes and stiffened barrels to be fabricated using single-piece construction, offering significant manufacturing rate benefits over conventional methods. However, Al alloys with sufficient formability, such as Al 6061, tend to have insufficient strength for aerospace structural applications. In contrast, alloys with higher strength, such as Al 2139 and Al 2050, exhibit insufficient formability during ambient temperature forming. This study investigates the spin formability of competitive 5xxx and 2xxx series Al alloys, identifies defects impeding formability, and sheds light on future processing routes for successful forming.

Aluminum↗
NASA NTRSDate not supplied

Spin Formability of High-Strength Aluminum Alloys for Aerospace Applications

Near-net-shape fabrication of launch vehicle tanks and aircraft fuselages is proposed to increase manufacturing rates of aerospace structures. Currently, cryogenic tank manufacturing relies on multi-piece construction requiring hundreds of meters of welds that increase both structural weight and inspection time. Metallic aircraft fuselages involve installation of tens of thousands of rivets resulting in long assembly times. NASA is pursuing spin and flow forming technologies for manufacturing such structures with minimal assembly. These processes enable domes and stiffened barrels to be fabricated using single-piece construction, offering significant manufacturing rate benefits over conventional methods. However, aluminum alloys with sufficient formability, such as Al 6061, tend to have insufficient strength for aerospace structural applications. In contrast, alloys with higher strength, such as Al 2139 and Al 2050, exhibit insufficient formability during ambient temperature forming. This study investigates the spin formability of competitive 5xxx- and 2xxx-series Al alloys, identifies defects impeding formability, and sheds light on future processing routes for successful forming.

Aluminum↗
NASA NTRS2023

Sea Ice Drift Tracks From Autonomous Buoys in the MOSAiC Distributed Network

A network of autonomous, ice-tethered buoys was deployed around the Multidisciplinary drifting Observatory for the Study of Arctic Climate (MOSAiC) experiment in late September 2019 for a year-long drift in the Arctic Transpolar Drift Stream. The buoys were deployed as part of the MOSAiC distributed network (DN) which included 12 multi-instrumented ice stations and an additional 116 GPS buoys distributed primarily within a 40 km radius of the MOSAiC Central Observatory. Buoy coverage within the DN was maintained with additional deployments throughout the year-long drift allowing for collection of data over a full sea ice growth and melt cycle. All GPS position data from buoys deployed within the DN have been assembled and processed into the collection of 216 quality-controlled buoy drift tracks presented in this dataset covering the period 26 September 2019 – 23 May 2021. The drift tracks in this collection are ideal for studies of dynamic sea ice motion around the MOSAiC experiment at cascading spatial scales ranging from 100s of meters to 100s of km.

Angela C. Bliss↗
NASA NTRS1981

Flat-plate solar array project: Experimental process system development unit for producing semiconductor-grade silicon using the silane-to-silicon process

The engineering design, fabrication, assembly, operation, economic analysis, and process support research and development for an Experimental Process System Development Unit for producing semiconductor-grade silicon using the slane-to-silicon process are reported. The design activity was completed. About 95% of purchased equipment was received. The draft of the operations manual was about 50% complete and the design of the free-space system continued. The system using silicon power transfer, melting, and shotting on a psuedocontinuous basis was demonstrated.

Source record↗
NASA NTRS1981

Flat-plate solar-array project. Experimental process system development unit for producing semiconductor-grade silicon using the silane-to-silicon process

The engineering design, fabrication, assembly, operation, economic analysis, and process support R and D for an Experimental Process System Development Unit (EPSDU) are reported. About 95% of purchased equipment is received and will be reshipped to the West Coast location. The Data Collection System is completed. In the area of melting/consolidation, to the system using silicon powder transfer, melting and shotting on a pseudocontinuous basis is demonstrated. It is proposed to continue the very promising fluid bed work.

Source record↗
NASA NTRS2000

Demonstration of a Large-Scale Tank Assembly via Circumferential Friction Stir Welds

A collaborative effort between NASA/Marshall Space Flight Center and the Michoud Unit of Lockheed Martin Space Systems Company was undertaken to demonstrate assembly of a large-scale aluminum tank using circumferential friction stir welds. The hardware used to complete this demonstration was fabricated as a study of near-net- shape technologies. The tooling used to complete this demonstration was originally designed for assembly of a tank using fusion weld processes. This presentation describes the modifications and additions that were made to the existing fusion welding tools required to accommodate circumferential friction stir welding, as well as the process used to assemble the tank. The tooling modifications include design, fabrication and installation of several components. The most significant components include a friction stir weld unit with adjustable pin length capabilities, a continuous internal anvil for 'open' circumferential welds, a continuous closeout anvil, clamping systems, an external reaction system and the control system required to conduct the friction stir welds and integrate the operation of the tool. The demonstration was intended as a development task. The experience gained during each circumferential weld was applied to improve subsequent welds. Both constant and tapered thickness 14-foot diameter circumferential welds were successfully demonstrated.

Jones, Clyde S.↗
NASA NTRS2005

Orbiter Processing Overview

Footage of orbiter processing is shown. The Space Shuttle Discovery Landing Operations, Rollback to Orbiter Processing Facility After Landing, Orbiter Processing Facility, Vehicle Assembly Building (VAB), Orbiter Rollover from the Orbiter Processing Facility to the VAB, Atlantis Orbiter Lift and Mate, Atlantis Rollout to Launch Pad 39, Payload Canister Door Opened and Payload Move into Payload Ground Handling Mechanism, Payload into Orbiter, Orbiter Payload Bay Door Closure, Launch Pad Processing at Launch Complex 39, Rotating Service Structure Rollback at Launch Pad, Discovery Lift-off and SRB separation is presented.

Source record↗
NASA NTRS1995

Parallel Processing with Digital Signal Processing Hardware and Software

The assembling and testing of a parallel processing system is described which will allow a user to move a Digital Signal Processing (DSP) application from the design stage to the execution/analysis stage through the use of several software tools and hardware devices. The system will be used to demonstrate the feasibility of the Algorithm To Architecture Mapping Model (ATAMM) dataflow paradigm for static multiprocessor solutions of DSP applications. The individual components comprising the system are described followed by the installation procedure, research topics, and initial program development.

Swenson, Cory V.↗
NASA NTRS1989

Space Shuttle Main Engine component assembly, assignment, and scheduling expert system

The SSME's Component Assembly and Life Management Expert System (CALMES) assists the engine assembly and scheduling process, ensuring that these activities utilize available resources with the greatest possible efficiency. On the basis of parts inventories and a proposed flight schedule, CALMES (1) determined how components may be optimally assembled from the parts inventory, (2) assigns components to flights, (3) schedules component testing, and (4) schedules component assembly. A graph-theoretical optimal matching algorithm, based on a modified simplex method, is applied to the major functions required by the SSME component assembly and scheduling processes.

Dietz, W. E.↗
NASA NTRS2005

VPS Process for Copper Components in Thrust Chamber Assemblies

For several years, NASA's Marshall Space Flight Center (MSFC) has been working with Plasma Processes, Inc., (PPI) to fabricate thrust chamber liners with GRCop-84. Using the vacuum plasma spray (VPS) process, chamber liners of a variety of shapes and sizes have been created. Each has been formed as a functional gradient material (FGM) that creates a unique protective layer of NiCrAlY on the GRCop-84 liner s hot wall surface. Hot-fire testing was successfully conducted on a subscale unit to demonstrate the liner's durability and performance. Similar VPS technology has also been applied to create functional gradient coatings (FGC) on copper injector faceplates. Protective layers of NiCrAlY and zirconia were applied to both coaxial and impinging faceplate designs. Hot-fire testing is planned for these coated injectors in April 2005. The resulting material systems for both copper alloy components allows them to operate at higher temperatures with improved durability and operating margins.

Elam, Sandra↗
NASA NTRS2011

NASA Space Technology Draft Roadmap Area 13: Ground and Launch Systems Processing

This slide presentation reviews the technology development roadmap for the area of ground and launch systems processing. The scope of this technology area includes: (1) Assembly, integration, and processing of the launch vehicle, spacecraft, and payload hardware (2) Supply chain management (3) Transportation of hardware to the launch site (4) Transportation to and operations at the launch pad (5) Launch processing infrastructure and its ability to support future operations (6) Range, personnel, and facility safety capabilities (7) Launch and landing weather (8) Environmental impact mitigations for ground and launch operations (9) Launch control center operations and infrastructure (10) Mission integration and planning (11) Mission training for both ground and flight crew personnel (12) Mission control center operations and infrastructure (13) Telemetry and command processing and archiving (14) Recovery operations for flight crews, flight hardware, and returned samples. This technology roadmap also identifies ground, launch and mission technologies that will: (1) Dramatically transform future space operations, with significant improvement in life-cycle costs (2) Improve the quality of life on earth, while exploring in co-existence with the environment (3) Increase reliability and mission availability using low/zero maintenance materials and systems, comprehensive capabilities to ascertain and forecast system health/configuration, data integration, and the use of advanced/expert software systems (4) Enhance methods to assess safety and mission risk posture, which would allow for timely and better decision making. Several key technologies are identified, with a couple of slides devoted to one of these technologies (i.e., corrosion detection and prevention). Development of these technologies can enhance life on earth and have a major impact on how we can access space, eventually making routine commercial space access and improve building and manufacturing, and weather forecasting for example for the effect of these process improvements on our daily lives.

Clements, Greg↗
NASA NTRS1978

CTS-type variable conductance heat pipes for SEP FM/PPU

The development effort for, and the fabrication and testing of, six CTS-type variable conductance heat pipes is described. The heat pipes are constructed of stainless steel, use methanol as a working fluid, and a nitrogen/helium mixture as the control gas. The wicking structure consists of interior wall grooves, a metal-felt diametral slab wick, and two wire-mesh arteries. The heat pipes are used to cool two Functional Model/Power Processing Units in a Solar Electric Propulsion prototype BIMOD thruster subsystem assembly. The Power Processing Units convert the electric power from a spacecraft solar array system to the voltages required to operate the electric thrusters which are part of the BIMOD assembly.

Antoniuk, D.↗
NASA NTRS1988

Assembly Test Article (ATA)

The assembly test article (ATA) consisted of two live loaded redesigned solid rocket motor (RSRM) segments which were assembled and disassembled to simulate the actual flight segment stacking process. The test assembly joint was flight RSRM design, which included the J-joint insulation design and metal capture feature. The ATA test was performed mid-November through 24 December 1987, at Kennedy Space Center (KSC), Florida. The purpose of the test was: certification that vertical RSRM segment mating and separation could be accomplished without any damage; verification and modification of the procedures in the segment stacking/destacking documents; and certification of various GSE to be used for flight assembly and inspection. The RSRM vertical segment assembly/disassembly is possible without any damage to the insulation, metal parts, or seals. The insulation J-joint contact area was very close to the predicted values. Numerous deviations and changes to the planning documents were made to ensure the flight segments are effectively and correctly stacked. Various GSE were also certified for use on flight segments, and are discussed in detail.

Ricks, Glen A.↗
NASA NTRS2001

Correlation of Hollow Cathode Assembly and Plasma Contactor Data from Ground Testing and In-Space Operation on the International Space Station

Charge control on the International Space Station (ISS) is currently being provided by two plasma contactor units (PCUs). The plasma contactor includes a hollow cathode assembly (HCA), power processing unit and Xe gas feed system. The hollow cathode assemblies in use in the ISS plasma contactors were designed and fabricated at the NASA Glenn Research Center. Prequalification testing of development HCAs as well as acceptance testing of the flight HCAs is presented. Integration of the HCAs into the Boeing North America built PCU and acceptance testing of the PCU are summarized in this paper. Finally, data from the two on-orbit PCUs is presented.

Kovalkeski, Scott D.↗
NASA NTRS1981

Interplanetary dust in the transmission electron microscope - Diverse materials from the early solar system

An analytical electron microscope study of dispersed interplanetary dust aggregates collected in the earth's stratosphere shows that, in spite of their similarities, the aggregates exhibit significant differences in composition, internal morphology, and mineralogy. Of 11 chondritic particles examined, two consist mostly of a noncrystalline chondritic material with an atomic S/Fe ratio equal to or greater than 2 in places, one consists of submicron metal and reduced silicate 'microchondrules' and sulfide grains embedded in a carbonaceous matrix, and another consists of submicron magnetic-decorated unequilibrated silicate and sulfide grains with thick low-Z coatings. Although the particles are unmetamorphosed by criteria commonly applied for chondritic meteorites, the presence of reduced chemistries and the ubiquity of mafic, instead of hydrated, silicates confirm that they are not simply C1 or C2 chondrite matrix material. The observations indicate that portions of some particles have not been significantly altered by thermal or radiation processes since their assembly, and that the particles probably contain fine debris from diverse processes in the early solar system.

Fraundorf, P.↗
NASA NTRS2019

Additive Manufacturing and Hot-Fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers Using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul R.↗
NASA NTRS2019

Additive Manufacturing and Hot-fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul↗