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At least 271 records · Page 15

Optical Density Analysis of X-Rays Utilizing Calibration Tooling to Estimate Thickness of Parts

This process is designed to estimate the thickness change of a material through data analysis of a digitized version of an x-ray (or a digital x-ray) containing the material (with the thickness in question) and various tooling. Using this process, it is possible to estimate a material's thickness change in a region of the material or part that is thinner than the rest of the reference thickness. However, that same principle process can be used to determine the thickness change of material using a thinner region to determine thickening, or it can be used to develop contour plots of an entire part. Proper tooling must be used. An x-ray film with an S-shaped characteristic curve or a digital x-ray device with a product resulting in like characteristics is necessary. If a film exists with linear characteristics, this type of film would be ideal; however, at the time of this reporting, no such film has been known. Machined components (with known fractional thicknesses) of a like material (similar density) to that of the material to be measured are necessary. The machined components should have machined through-holes. For ease of use and better accuracy, the throughholes should be a size larger than 0.125 in. (.3 mm). Standard components for this use are known as penetrameters or image quality indicators. Also needed is standard x-ray equipment, if film is used in place of digital equipment, or x-ray digitization equipment with proven conversion properties. Typical x-ray digitization equipment is commonly used in the medical industry, and creates digital images of x-rays in DICOM format. It is recommended to scan the image in a 16-bit format. However, 12-bit and 8-bit resolutions are acceptable. Finally, x-ray analysis software that allows accurate digital image density calculations, such as Image-J freeware, is needed. The actual procedure requires the test article to be placed on the raw x-ray, ensuring the region of interest is aligned for perpendicular x-ray exposure capture. One or multiple machined components of like material/ density with known thicknesses are placed atop the part (preferably in a region of nominal and non-varying thickness) such that exposure of the combined part and machined component lay-up is captured on the x-ray. Depending on the accuracy required, the machined component fs thickness must be carefully chosen. Similarly, depending on the accuracy required, the lay-up must be exposed such that the regions of the x-ray to be analyzed have a density range between 1 and 4.5. After the exposure, the image is digitized, and the digital image can then be analyzed using the image analysis software.

Grau, David↗

Aeroservoelastic Testing of Free Flying Wind Tunnel Models Part 1: A Sidewall Supported Semispan Model Tested for Gust Load Alleviation and Flutter Suppression

of a two part document. Part 2 is titled: "Aeroservoelastic Testing of Free Flying Wind Tunnel Models, Part 2: A Centerline Supported Fullspan Model Tested for Gust Load Alleviation." A team comprised of the Air Force Research Laboratory (AFRL), Northrop Grumman, Lockheed Martin, and the NASA Langley Research Center conducted three aeroservoelastic wind tunnel tests in the Transonic Dynamics Tunnel to demonstrate active control technologies relevant to large, flexible vehicles. In the first of these three tests, a semispan, aeroelastically scaled, wind tunnel model of a flying wing SensorCraft vehicle was mounted to a force balance to demonstrate gust load alleviation. In the second and third tests, the same wing was mated to a new, multi-degree of freedom, sidewall mount. This mount allowed the half-span model to translate vertically and pitch at the wing root, allowing better simulation of the full span vehicle's rigid body modes. Gust load alleviation (GLA) and Body freedom flutter (BFF) suppression were successfully demonstrated. The rigid body degrees-of-freedom required that the model be flown in the wind tunnel using an active control system. This risky mode of testing necessitated that a model arrestment system be integrated into the new mount. The safe and successful completion of these free flying tests required the development and integration of custom hardware and software. This paper describes the many systems, software, and procedures that were developed as part of this effort.

Scott, Robert C.↗

Cleaning and Cleanliness Measurement of Additive Manufactured Parts

The successful acquisition and utilization of piece parts and assemblies for contamination sensitive applications requires application of cleanliness acceptance criteria. Contamination can be classified using many different schemes. One common scheme is classification as organic, ionic and particulate contaminants. These may be present in and on the surface of solid components and assemblies or may be dispersed in various gaseous or liquid media. This discussion will focus on insoluble particle contamination on the surface of piece parts and assemblies. Cleanliness of parts can be controlled using two strategies, referred to as gross cleanliness and precision cleanliness. Under a gross cleanliness strategy acceptance is based on visual cleanliness. This approach introduces a number of concerns that render it unsuitable for controlling cleanliness of high technology products. Under the precision cleanliness strategy, subjective, visual assessment of cleanliness is replaced by objective measurement of cleanliness. When a precision cleanliness strategy is adopted there naturally arises the question: How clean is clean enough? The six commonly used methods for establishing objective cleanliness acceptance limits will be discussed. Special emphasis shall focus on the use of multiple extraction, a technique that has been demonstrated for additively manufactured parts.

Welker, Roger W.↗

Assessment of NASA GISS CMIP5 and Post-CMIP5 Simulated Clouds and TOA Radiation Budgets Using Satellite Observations: TOA Radiation Budget and CREs - Part 2

In Part I of this study, the NASA GISS Coupled Model Intercomparison Project (CMIP5) and post-CMIP5 (herein called C5 and P5, respectively) simulated cloud properties were assessed utilizing multiple satellite observations, with a particular focus on the southern midlatitudes (SMLs). This study applies the knowledge gained from Part I of this series to evaluate the modeled TOA radiation budgets and cloud radiative effects (CREs) globally using CERES EBAF (CE) satellite observations and the impact of regional cloud properties and water vapor on the TOA radiation budgets. Comparisons revealed that the P5- and C5-simulated global means of clear-sky and all-sky outgoing longwave radiation (OLR) match well with CE observations, while biases are observed regionally. Negative biases are found in both P5- and C5-simulated clear-sky OLR. P5-simulated all-sky albedo slightly increased over the SMLs due to the increase in low-level cloud fraction from the new planetary boundary layer (PBL) scheme. Shortwave, longwave, and net CRE are quantitatively analyzed as well. Regions of strong large-scale atmospheric upwelling/downwelling motion are also defined to compare regional differences across multiple cloud and radiative variables. In general, the P5 and C5 simulations agree with the observations better over the downwelling regime than over the upwelling regime. Comparing the results herein with the cloud property comparisons presented in Part I, the modeled TOA radiation budgets and CREs agree well with the CE observations. These results, combined with results in Part I, have quantitatively estimated how much improvement is found in the P5-simulated cloud and radiative properties, particularly over the SMLs and tropics, due to the implementation of the new PBL and convection schemes.

Model comparison↗

Elastic and Piezoelectric Properties of Boron Nitride Nanotube Composites: Finite Element Model - Part II

This paper is the second part of a two-part series where the first part presents a molecular dynamics model of a single Boron Nitride Nanotube (BNNT) and this paper scales up to multiple BNNTs in a polymer matrix. This paper presents finite element (FE) models to investigate the effective elastic and piezoelectric properties of (BNNT) nanocomposites. The nanocomposites studied in this paper are thin films of polymer matrix with aligned co-planar BNNTs. The FE modelling approach provides a computationally efficient way to gain an understanding of the material properties. We examine several FE models to identify the most suitable models and investigate the effective properties with respect to the BNNT volume fraction and the number of nanotube walls. The FE models are constructed to represent aligned and randomly distributed BNNTs in a matrix of resin using 2D and 3D hollow and 3D filled cylinders. The homogenisation approach is employed to determine the overall elastic and piezoelectric constants for a range of volume fractions. These models are compared with an analytical model based on Mori-Tanaka formulation suitable for finite length cylindrical inclusions. The model applies to primarily single-wall BNNTs but is also extended to multi-wall BNNTs, for which preliminary results will be presented. Results from the Part 1 of this series can help to establish a constitutive relationship for input into the finite element model to enable the modeling of multiple BNNTs in a polymer matrix.

Kim, H. Alicia↗

The PMIP4 Contribution to CMIP6 - Part 1: Overview and Over-Arching Analysis Plan

This paper is the first of a series of four GMD (Geoscientific Model Development) papers on the PMIP4-CMIP6 (Paleoclimate Modelling Intercomparison Project - Phase 4 -- Coupled Model Intercomparison Project - Phase 6) experiments. Part 2 (Otto-Bliesner et al., 2017) gives details about the two PMIP4-CMIP6 interglacial experiments, Part 3 (Jungclaus et al., 2017) about the last millennium experiment, and Part 4 (Kageyama et al., 2017) about the Last Glacial Maximum experiment. The mid-Pliocene Warm Period experiment is part of the Pliocene Model Intercomparison Project (PlioMIP) - Phase 2, detailed in Haywood et al. (2016). The goal of the Paleoclimate Modelling Intercomparison Project (PMIP) is to understand the response of the climate system to different climate forcings for documented climatic states very different from the present and historical climates. Through comparison with observations of the environmental impact of these climate changes, or with climate reconstructions based on physical, chemical, or biological records, PMIP also addresses the issue of how well state-of-the-art numerical models simulate climate change. Climate models are usually developed using the present and historical climates as references, but climate projections show that future climates will lie well outside these conditions. Palaeoclimates very different from these reference states therefore provide stringent tests for state-of-the-art models and a way to assess whether their sensitivity to forcings is compatible with palaeoclimatic evidence. Simulations of five different periods have been designed to address the objectives of the sixth phase of the Coupled Model Intercomparison Project (CMIP6): the millennium prior to the industrial epoch (CMIP6 name: past1000); the mid-Holocene, 6000 years ago (midHolocene); the Last Glacial Maximum, 21,000 years ago (lgm); the Last Interglacial, 127,000 years ago (lig127k); and the mid-Pliocene Warm Period, 3.2 million years ago (midPliocene-eoi400). These climatic periods are well documented by palaeoclimatic and palaeoenvironmental records, with climate and environmental changes relevant for the study and projection of future climate changes. This paper describes the motivation for the choice of these periods and the design of the numerical experiments and database requests, with a focus on their novel features compared to the experiments performed in previous phases of PMIP and CMIP. It also outlines the analysis plan that takes advantage of the comparisons of the results across periods and across CMIP6 in collaboration with other MIPs.

climate↗

Overview of Developments in Voluntary Consensus Standards for Counterfeit Parts Avoidance

The presentation provides an introduction to the electronic parts supply chain and various standards used for preventing counterfeit parts. The presentation provides detailed instruction on various non-destructive techniques, destructive and analytical steps for inspecting suspect counterfeit parts. The techniques are based on the AS6171 Aerospace Standard which standardizes the test and inspection procedures, workmanship criteria, and minimum training and certification requirements to detect counterfeit electrical, electronic, and electromechanical parts. Also included are discussions of other inspection, sampling and distribution standards.

Sood, Bhanu↗

Electrical and Thermal Characterization of 3D Printed Thermoplastic Parts with Embedded Wires for High Current-Carrying Applications

Fabrication of parts exhibiting multi-functionality has recently been complemented by hybrid polymer extrusion additive manufacturing in combination with wire embedding technology. While much mechanical characterization has been performed on parts produced with fused deposition modeling, limited characterization has been performed when combined electrical and thermal loads are applied to 3D printed multi-material parts. As such, this work describes the design, fabrication, and testing of 3D printed thermoplastic coupons containing embedded copper wires that carried current. An automated fabrication process was used employing a hybrid additive manufacturing machine that dispensed polycarbonate thermoplastic and embedded bare copper wires. Testing included AC and DC hipot testing as well as thermal testing on as-fabricated and heat treated coupons to determine the effect of porosity in the substrate. The heat-treated parts contained reduced amounts of porosity, as corroborated through scanning electron microscopy, which led to 50 % increased breakdown strength and 30 to 40 % increased heat dissipation capabilities. The results of this research are describing a set of design protocol that can be used as a guideline for 3D printed embedded electronics to predict the electrical and thermal behavior.

Hipot testing↗

In-Space Inspection Needs: Opportunities for advanced NDE tools such as x-ray CT for additively manufactured parts, in-situ resource utilization, geological applications, and more

It is now 50 years since the first human presence on the surface of the Moon and as we strive to return with women and men in the next few years, we embrace new technical challenges, goals, and innovative solutions to address 21st century objectives. These new ambitions carry fresh challenges and risks, with the field of NDE playing an increasingly more relevant role towards meeting these essential goals. In recent years, more advanced NDE tools have triggered a rapid expansion of applications for the space industry. In particular, x-ray Computed Tomography (CT) has proven to be a trusted and powerful asset for spaceflight hardware inspection, as well as applied geotechnical analysis for natural materials (e.g., rocks, soils) for NASA and across industry. However, such methods have yet to be extended to “deep space” applications such as those that are now part of the US National Space Policy Directive (SPD-1) and the accelerated push to return humans to the Moon (i.e., Artemis). For this reason, advancing these powerful Earth-based laboratory methods via new technologies, integrated computational solutions, and creative engineering approaches is directly aligned with national space policies, as well as with multiple NASA Strategic Plan priorities. The use of x-ray CT at scales as fine as a few microns or smaller can identify spacecraft part failure modes relevant to quality assurance for flight hardware and AM parts such as those recently developed for ISS. This technology could also identify valuable metallic phases within geological materials (i.e., rocks or drill cores), enabling resource-relevant triage of samples for In-Situ Resource Utilization (ISRU) and high science value sample return to Earth laboratories. There is also significant application for 3D imaging tools for medical use such as inspecting protective gear as well as bone density degradation studies which are critical in establishing a sustained presence in space. Timing for development of these tools for space use is advantageous as we prepare for new opportunities in the next few years and recognize recent commercial technology advancements which make it feasible. Moreover, as NASA strives to take full advantage of developments in AM technologies, including In-Space Manufacturing (ISM), it is widely recognized that NDE tools such as CT will play an essential role in acceptance of these parts for widespread use. New in-space 3D inspection tools with complimentary technology such as AI-based automated feature recognition (accelerated by machine learning), rapid compositional analysis, and advanced sample manipulation, would be a game-changing step toward a new class of crew-based laboratory sensors once human outposts on the Moon are established.

In-Space Non-Destructive Evaluation↗

Select Electronic Parts Operation at Extreme Low Temperature

The purpose of the study presented in this paper is to extend the test period of a selected set of electronics parts at cryogenic condition to dwell period of about 24 hours to demonstrate extreme cold operational capability of these components. The parts tested are tantalum polymer, BX and P90 type ceramic capacitors, thick film resistors, analog multiplexers, a digital inverter, and a D-flip-flop. These parts were tested to assist identifying candidate components that can be used for development of a cold capable telemetry board. There are several past investigations that have shown that COTS (commercial-off-the-shelf) capacitors and resistors tested at cryogenic temperatures and frequencies up to 10MHz did not exhibit significant changes in capacitance and resistance values. Also, there are several test results for active parts. These past tests collected measurements during a temperature sweep from room temperature down to cryogenic temperature with very short dwell time at cryogenic temperature, and back to room temperature. This study extends the operational dwell time to at least 24 hours and returning to room temperature operation without significant degradation in performance, thus, demonstrating the potential for longer dwell time in actual operation in these extreme cold temperatures and a method for identifying the cold operability.

Ashtijou, Mohammad↗

Effects of Porous Gap Fillers on Leading-Edge Slat Noise of 30P30N. Part II: PIV Measurements

The leading edge slat of a high-lift system is one of the main contributors to the airframe noise during approach conditions. This paper, the second of two parts, continues our previous studies on the slat gap filler as a passive noise control device on the two-dimensional, 30P30N multielement airfoil. Whereas the earlier study was focused on the effects of an impermeable gap filler that completely blocks the flow through the gap, this follow-on assessment is devoted to permeable slat gap fillers that allow limited amounts of flow to pass through the gap. Part I of this two-part abstract described the aerodynamic and acoustic effects of the permeable gap fillers, as inferred from both the measurements of static and unsteady surface pressures and the microphone array data for the radiated noise. To understand the physical mechanism responsible for the noise reduction documented in Part I, as well as for the accompanying aerodynamic penalty due to the porous gap fillers, Particle Image Velocimetry (PIV) is used in this paper to measure the flow details in the slat-cove region of the 30P30N model. A single angle of attack (𝛼 = 5.5◦) and a chord based Reynolds number of 1.71𝑒6 are selected as the test conditions. The PIV results show that the slat flow features are significantly altered with the presence of the porous gap filler, resulting in a more stable slat-cove shear layer and, thus, reduced velocity fluctuations with a successive decrease in the permeability. The porous gap filler with the lowest permeability acts similar to the solid gap filler. However, flow separation is observed on the upper side of the porous interface, which leads to an aerodynamic performance penalty via a reduction in lift on the main wing.

slat noise↗

Characterization and Testing of Copper-Nickel Electroplated 3D Printed Parts for Space Flight Applications

3D printing enables novel designs which are impossible to replicate with conventional machining. The process involves 3D printing components from a polymer using a standard resin-based printing process, then electroplating the parts with a thin layer of copper-nickel. Initial results have shown these electroplated components have increased structural strength, while being less expensive; less massive; and can be made faster compared to conventional CNC machining. The focus and metric of success was to qualify this process and to answer the question if the 3D printed electroplated parts can be fabricated in a more cost, mass and schedule efficient manor compared to traditional CNC machining. Also, to determine if using this method will cause parts to have contamination issues or if parts can survive space environment testing. This was accomplished by conducting several critical tests such as outgassing, material testing and thermal cycling. In addition, this method is being used to develop a practical structural application for KArLE (Potassium Argon Laser Experiment).

3-D Printing↗

Towards Integrated Computational Materials Engineering for Quantifying Performance Impacts of Microstructure and Defect Interactions in Powder Bed Fusion Parts

Powder bed fusion (PBF) additive manufacturing (AM) enables the creation of parts with complexity and functionality levels that were previously impossible with traditional manufacturing methods. By modifying the laser power, hatch spacing, or the numerous other processing parameters, the PBF process supports the production of a wide set of materials and geometries. However, that same process parameter design flexibility causes the process-design space of PBF to be massive and expensive to explore experimentally. Another challenge is quality variation across a build. As a part is being built, geometric variance between locations, such as at a thin-wall section vs. the bulk material, may cause the specified processing parameters to no longer be acceptable for producing defect-free printing. Furthermore, if the processing parameters deviate during the print process, it is difficult to assess if the part will still perform satisfactorily. Integrated Computational Materials Engineering (ICME) provides a way to understand and address these various challenges. This talk will present advancements in process-structure simulations of PBF at NASA Langley Research Center. The ability to simulate grain-scale PBF microstructures using the Physically Based Monte Carlo method will be demonstrated and compared to experimental measurements. Techniques for simulating three-dimensional lack-of-fusion and keyhole porosity defects based on the specific processing conditions and approaches for integrating the two porosity prediction techniques alongside the computational microstructure evolution models will be shown. Finally, the integration of simulated PBF microstructures, embedded process defects, and crystal plasticity finite element models to elucidate the interaction of porosity and microstructure on micromechanical fields will be demonstrated. These integrated techniques demonstrate an example of using ICME to relate processing to performance for PBF AM materials. With continued maturity, it is hoped that such ICME approaches will lead to next-generation computational-materials supported qualification and certification of AM parts.

Additive manufacturing↗

Three-Dimensional Reconstruction of Defects and Structures in Additively Manufactured Parts with Automated Serial Sectioning

Metal additive manufacturing (AM) processes have been demonstrated to be effective at reducing costs and lead times associated with complex components for space flight applications. Laser powderbed fusion (L-PBF) is a commonly used AM technology due to the ability to produce complex parts with fine feature resolution in a wide variety of alloys and applications. L-PBF, like many other manufacturing processes, can produce minor flaws in parts when in nominal operation as well as process-escape defects when process abnormalities occur. The effects of the flaws and methods of detecting the flaws are a subject of interest to understand the difficulties in detecting these flaws with current technology and how much risk the flaws or defects pose to potential flight parts. Using a RoboMet.3D automated serial sectioning system, seeded defects as well as minor process flaws can be imaged and reconstructed in three dimensions to compare to non-destructive evaluation (NDE) techniques, such as x-ray computed tomography (CT), neutron CT, and in-situ monitoring. The RoboMet automates the metallography process by automatically grinding, polishing, and imaging samples in a single system and providing the control data for NDE comparisons to know the real size of defects built into coupons. These comparisons provide an understanding behind the technological limitations of the NDE techniques for different alloys. The same serial sectioning methods have also been utilized to characterize the surfaces of parts to reconstruct the surfaces and take measurements of internal features not easily examined with non-destructive methods. Using the RoboMet, fine lattice structures built with L-PBF have been characterized to determine the actual thicknesses of struts and density of the lattice structures. These structures have been used as finer build supports for the L-PBF process, designs for fine catalysts, and other design considerations for small components. The RoboMet data helps to inform the modeling and design efforts around these fine components.

additive manufacturing↗

NASA Risk Management Handbook: Version 2.0, Part 1

The purpose of this handbook is to provide an in-depth reference for the practice of risk management in NASA, updating the guidance offered in its original version, NASA/SP-2011-3422 (November 2011), and closely aligning the updated guidance with the current NASA Procedural Requirements for Agency Risk Management, NPR 8000.4, and the parent NASA Policy Directive for NASA Governance and Strategic Management, NPD 1000.0. NPD 1000.0 introduces with emphasis the concept of “Risk Leadership,” making it a fundamental tenet and pillar of the risk management culture that it advocates for the Agency. NPR 8000.4 applies this concept and establishes Risk Management (RM) requirements for the Agency as an integrated enterprise, as well as the RM requirements for portfolio elements within the enterprise. Such elements include the various programs and projects that contribute to the Agency’s objectives and the various institutional activities carried out by entities that contribute to mission support. The present version of the handbook also emphasizes the integration of risk management processes across activity and project life cycles and their coordination and interaction with day-to-day programmatic and organizational functions. Areas of application of risk assessment and management that were not covered with specific guidance in the preceding version are addressed in this version with in-depth examples. The handbook is structured into two parts, whose chapters are in turn organized in a sequential order intended to facilitate a gradual and progressive introduction of the reader to risk management principles and practices. Part 1 of the handbook is dedicated to the introduction of the basic foundations of the NASA integrated risk management framework, the related fundamental risk concepts, the description of the risk management and decision processes that are to be implemented within the framework, the discussion of the risk assessment techniques that should be utilized in support of such processes, and the management and organizational interactions and interfaces that should be enabled to implement an effective integration of risk management activities within the Agency. Part 2 provides self-contained, end-to-end examples of application of the processes and techniques introduced in Part 1, in the context of both programmatic (i.e., project and/or mission related) and institutional activities.

Uncertainty↗

NASA Risk Management Handbook: Version 2.0, Part 2

The purpose of this handbook is to provide an in-depth reference for the practice of risk management in NASA, updating the guidance offered in its original version, NASA/SP-2011-3422 (November 2011), and closely aligning the updated guidance with the current NASA Procedural Requirements for Agency Risk Management, NPR 8000.4, and the parent NASA Policy Directive for NASA Governance and Strategic Management, NPD 1000.0 (January 2020). NPD 1000.0 introduces with emphasis the concept of “Risk Leadership,” making it a fundamental tenet and pillar of the risk management culture that it advocates for the Agency. NPR 8000.4 applies this concept and establishes Risk Management (RM) requirements for the Agency as an integrated enterprise, as well as the RM requirements for portfolio elements within the enterprise. Such elements include the various programs and projects that contribute to the Agency’s objectives and the various institutional activities carried out by entities that contribute to mission support. The present version of the handbook also emphasizes the integration of risk management processes across activity and project life cycles and their coordination and interaction with day-to-day programmatic and organizational functions. Areas of application of risk assessment and management that were not covered with specific guidance in the preceding version are addressed in this version with in-depth examples. The handbook is structured into two parts, whose chapters are in turn organized in a sequential order intended to facilitate a gradual and progressive introduction of the reader to risk management principles and practices. Part 1 of the handbook is dedicated to the introduction of the basic foundations of the NASA integrated risk management framework, the related fundamental risk concepts, the description of the risk management and decision processes that are to be implemented within the framework, the discussion of the risk assessment techniques that should be utilized in support of such processes, and the management and organizational interactions and interfaces that should be enabled to implement an effective integration of risk management activities within the Agency. Part 2 provides self-contained, end-to-end examples of application of the processes and techniques introduced in Part 1, in the context of both programmatic (i.e., project and/or mission related) and institutional activities.

Risk Leadership↗

NASA Electronic Parts and Packaging (NEPP) Program Focus, Strategic Collaborations, and Our Path to the Future

NASA Electronic Parts and Packaging (NEPP) Program Overview Mission Statement: Provide NASA's leadership for developing and maintaining guidance for the screening, qualification, test, and reliable use of EEE parts by NASA, in collaboration with other government agencies and industry. The NASA Electronic Parts Assurance Group (NEPAG) is a core portion of NEPP.

NASA Electronic Parts and Packaging (NEPP) Program↗