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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 307 records · Page 17
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NASA NTRS1995

Automated data acquisition technology development:Automated modeling and control development

This report documents the completion of, and improvements made to, the software developed for automated data acquisition and automated modeling and control development on the Texas Micro rackmounted PC's. This research was initiated because a need was identified by the Metal Processing Branch of NASA Marshall Space Flight Center for a mobile data acquisition and data analysis system, customized for welding measurement and calibration. Several hardware configurations were evaluated and a PC based system was chosen. The Welding Measurement System (WMS), is a dedicated instrument strickly for use of data acquisition and data analysis. In addition to the data acquisition functions described in this thesis, WMS also supports many functions associated with process control. The hardware and software requirements for an automated acquisition system for welding process parameters, welding equipment checkout, and welding process modeling were determined in 1992. From these recommendations, NASA purchased the necessary hardware and software. The new welding acquisition system is designed to collect welding parameter data and perform analysis to determine the voltage versus current arc-length relationship for VPPA welding. Once the results of this analysis are obtained, they can then be used to develop a RAIL function to control welding startup and shutdown without torch crashing.

Romine, Peter L.↗
NASA NTRS2004

Manufacturing High-Quality Carbon Nanotubes at Lower Cost

A modified electric-arc welding process has been developed for manufacturing high-quality batches of carbon nanotubes at relatively low cost. Unlike in some other processes for making carbon nanotubes, metal catalysts are not used and, consequently, it is not necessary to perform extensive cleaning and purification. Also, unlike some other processes, this process is carried out at atmospheric pressure under a hood instead of in a closed, pressurized chamber; as a result, the present process can be implemented more easily. Although the present welding-based process includes an electric arc, it differs from a prior electric-arc nanotube-production process. The welding equipment used in this process includes an AC/DC welding power source with an integral helium-gas delivery system and circulating water for cooling an assembly that holds one of the welding electrodes (in this case, the anode). The cathode is a hollow carbon (optionally, graphite) rod having an outside diameter of 2 in. (approximately equal to 5.1 cm) and an inside diameter of 5/8 in. (approximately equal to 1.6 cm). The cathode is partly immersed in a water bath, such that it protrudes about 2 in. (about 5.1 cm) above the surface of the water. The bottom end of the cathode is held underwater by a clamp, to which is connected the grounding cable of the welding power source. The anode is a carbon rod 1/8 in. (approximately equal to 0.3 cm) in diameter. The assembly that holds the anode includes a thumbknob- driven mechanism for controlling the height of the anode. A small hood is placed over the anode to direct a flow of helium downward from the anode to the cathode during the welding process. A bell-shaped exhaust hood collects the helium and other gases from the process. During the process, as the anode is consumed, the height of the anode is adjusted to maintain an anode-to-cathode gap of 1 mm. The arc-welding process is continued until the upper end of the anode has been lowered to a specified height above the surface of the water bath. The process causes carbon nanotubes to form in the lowest 2.5 cm of the anode. It also causes a deposit reminiscent of a sandcastle to form on the cathode. The nanotube-containing material is harvested. The cathode and anode can then be cleaned (or the anode is replaced, if necessary) and the process repeated to produce more nanotubes. Tests have shown that the process results in approximately equal to 50-percent yield of carbon nanotubes (mostly of the single-wall type) of various sizes. Whereas the unit cost of purified single-wall carbon nanotubes produced by other process is about $1,000/g in the year 2000, it has been estimated that for the present process, the corresponding cost would be about $10/g.

Benavides, Jeanette M.↗
NASA NTRS2005

Fabrication end Deployment Testing of Meter Solar Sail Quadrants for a Scaleable Square Solar Sail Ground Test System

In order for solar sail propulsion technologies to be considered as a viable option for a wide range of near term practical missions a predictable, stable, reliable, manufactureable, scaleable, and cost effective system must be developed and tested first on earth and then on orbit. The design and development of a Scaleable Square Solar Sail System (S^4) is well underway a t AEC-Able Engineering Co. Inc., and the design and production of the Solar Sails for this system is being carried out by SRS Technologies. In April and May of 2004 a single quadrant 10-meter system was tested at NASA LARC's vacuum chamber and a four quadrant 20-meter system has been designed and built for deployment and testing in the Spring of 2005 at NASA/Glenn Research Center's Plumb Brook Facility. SRS has developed an effective and efficient design for triangular sail quadrants that are supported are three points and provide a flat reflective surface with a high fill factor. This sail design is robust enough for deployments in a one atmosphere, one gravity environment and incorporates several advanced features including adhesiveless seaming of membrane strips, compliant edge borders to allow for film membrane cord strain mismatch without causing wrinkling and low mass (3% of total sail mass) ripstop. This paper will outline the sail design and fabrication process, the lessons learned and the resulting mature production, packaging and deployment processes that have been developed. It will also highlight the scalability of the equipment and processes that were developed to fabricate and package the sails. Based on recent experience, SRS is confidant that flight worthy solar sails in the 40-120-meter size range with areal density in the 4-5g/sq m (sail minus structure) range can be produced with existing technology. Additional film production research will lead to further reductions in film thickness to less than 1 micron enabling production of sails with areal densities as low as 20 g/sq m using the current design resulting in a system areal density of as low as 5.3g/sq m. These areal densities are low enough to allow nearly all of the Solar Sail missions that have been proposed by the scientific community and the fundamental technology required to produce these sails has been demonstrated on the ground test sails that have recently been built. These demonstrations have shown that the technology is mature enough to build sails needed to support critical science missions. Solar Sails will be an enabling technology for NASA's Vision for Space Exploration by allowing communication satellite orbits that can maintain continuous communication with the polar regions of the Moon and Mars and to support solar weather monitoring to provide early warning of solar flares and storms that could threaten the safety of astronauts and other spacecraft.

Laue, Greg↗
NASA NTRS1992

Planning for the semiconductor manufacturer of the future

Texas Instruments (TI) is currently contracted by the Air Force Wright Laboratory and the Defense Advanced Research Projects Agency (DARPA) to develop the next generation flexible semiconductor wafer fabrication system called Microelectronics Manufacturing Science & Technology (MMST). Several revolutionary concepts are being pioneered on MMST, including the following: new single-wafer rapid thermal processes, in-situ sensors, cluster equipment, and advanced Computer Integrated Manufacturing (CIM) software. The objective of the project is to develop a manufacturing system capable of achieving an order of magnitude improvement in almost all aspects of wafer fabrication. TI was awarded the contract in Oct., 1988, and will complete development with a fabrication facility demonstration in April, 1993. An important part of MMST is development of the CIM environment responsible for coordinating all parts of the system. The CIM architecture being developed is based on a distributed object oriented framework made of several cooperating subsystems. The software subsystems include the following: process control for dynamic control of factory processes; modular processing system for controlling the processing equipment; generic equipment model which provides an interface between processing equipment and the rest of the factory; specification system which maintains factory documents and product specifications; simulator for modelling the factory for analysis purposes; scheduler for scheduling work on the factory floor; and the planner for planning and monitoring of orders within the factory. This paper first outlines the division of responsibility between the planner, scheduler, and simulator subsystems. It then describes the approach to incremental planning and the way in which uncertainty is modelled within the plan representation. Finally, current status and initial results are described.

Fargher, Hugh E.↗
NASA NTRS1994

Confessions of a robot lobotomist

Since its inception, numerically controlled (NC) machining methods have been used throughout the aerospace industry to mill, drill, and turn complex shapes by sequentially stepping through motion programs. However, the recent demand for more precision, faster feeds, exotic sensors, and branching execution have existing computer numerical control (CNC) and distributed numerical control (DNC) systems running at maximum controller capacity. Typical disadvantages of current CNC's include fixed memory capacities, limited communication ports, and the use of multiple control languages. The need to tailor CNC's to meet specific applications, whether it be expanded memory, additional communications, or integrated vision, often requires replacing the original controller supplied with the commercial machine tool with a more powerful and capable system. This paper briefly describes the process and equipment requirements for new controllers and their evolutionary implementation in an aerospace environment. The process of controller retrofit with currently available machines is examined, along with several case studies and their computational and architectural implications.

Gottshall, R. Marc↗
NASA NTRS2010

Development of an Uncertainty Model for the National Transonic Facility

This paper introduces an uncertainty model being developed for the National Transonic Facility (NTF). The model uses a Monte Carlo technique to propagate standard uncertainties of measured values through the NTF data reduction equations to calculate the combined uncertainties of the key aerodynamic force and moment coefficients and freestream properties. The uncertainty propagation approach to assessing data variability is compared with ongoing data quality assessment activities at the NTF, notably check standard testing using statistical process control (SPC) techniques. It is shown that the two approaches are complementary and both are necessary tools for data quality assessment and improvement activities. The SPC approach is the final arbiter of variability in a facility. Its result encompasses variation due to people, processes, test equipment, and test article. The uncertainty propagation approach is limited mainly to the data reduction process. However, it is useful because it helps to assess the causes of variability seen in the data and consequently provides a basis for improvement. For example, it is shown that Mach number random uncertainty is dominated by static pressure variation over most of the dynamic pressure range tested. However, the random uncertainty in the drag coefficient is generally dominated by axial and normal force uncertainty with much less contribution from freestream conditions.

Walter, Joel A.↗
NASA NTRS1980

Grinding and polishing articles in bulk: Burnishing

Various processes and equipment used for burnishing different materials are discussed. Drum and vibration installations are considered, as are processing chemicals and additive materials used in the burnishing process.

Schmotz, K.↗
NASA NTRS1987

Knowledge based jet engine diagnostics

A fielded expert system automates equipment fault isolation and recommends corrective maintenance action for Air Force jet engines. The knowledge based diagnostics tool was developed as an expert system interface to the Comprehensive Engine Management System, Increment IV (CEMS IV), the standard Air Force base level maintenance decision support system. XMAM (trademark), the Expert Maintenance Tool, automates procedures for troubleshooting equipment faults, provides a facility for interactive user training, and fits within a diagnostics information feedback loop to improve the troubleshooting and equipment maintenance processes. The application of expert diagnostics to the Air Force A-10A aircraft TF-34 engine equipped with the Turbine Engine Monitoring System (TEMS) is presented.

Jellison, Timothy G.↗
NASA NTRS1999

Feature Profile Evolution of SiO2 Trenches In Fluorocarbon Plasmas

Etching of silicon microstructures for semiconductor manufacturing in chlorine plasmas has been well characterized. The etching proceeds in a two-part process, where the chlorine neutrals passivate the Si surface and then the ions etch away SiClx. However, etching in more complicated gas mixtures and materials, such as etching of SiO2 in Ar/C4F8, requires knowledge of the ion and neutral distribution functions as a function of angle and velocity, in addition to modeling the gas surface reactions. In order to address these needs, we have developed and integrated a suite of models to simulate the etching process from the plasma reactor level to the feature profile evolution level. This arrangement allows for a better understanding, control, and prediction of the influence of equipment level process parameters on feature profile evolution. We are currently using the HPEM (Hybrid Plasma Equipment Model) and PCMCM (Plasma Chemistry Monte Carlo Model) to generate plasma properties and ion and neutral distribution functions for argon/fluorocarbon discharges in a GEC Reference Cell. These quantities are then input to the feature scale model, Simulation of Profile Evolution by Level Sets (SPELS). A surface chemistry model is used to determine the interaction of the incoming species with the substrate material and simulate the evolution of the trench profile. The impact of change of gas pressure and inductive power on the relative flux of CFx and F to the wafer, the etch and polymerization rates, and feature profiles will be examined. Comparisons to experimental profiles will also be presented.

Hwang, Helen↗
NASA NTRS2005

Liquid Nitrogen Removal of Critical Aerospace Materials

Identification of innovative solutions to unique materials problems is an every-day quest for members of the aerospace community. Finding a technique that will minimize costs, maximize throughput, and generate quality results is always the target. United Space Alliance Materials Engineers recently conducted such a search in their drive to return the Space Shuttle fleet to operational status. The removal of high performance thermal coatings from solid rocket motors represents a formidable task during post flight disassembly on reusable expended hardware. The removal of these coatings from unfired motors increases the complexity and safety requirements while reducing the available facilities and approved processes. A temporary solution to this problem was identified, tested and approved during the Solid Rocket Booster (SRB) return to flight activities. Utilization of ultra high-pressure liquid nitrogen (LN2) to strip the protective coating from assembled space shuttle hardware marked the first such use of the technology in the aerospace industry. This process provides a configurable stream of liquid nitrogen (LN2) at pressures of up to 55,000 psig. The performance of a one-time certification for the removal of thermal ablatives from SRB hardware involved extensive testing to ensure adequate material removal without causing undesirable damage to the residual materials or aluminum substrates. Testing to establish appropriate process parameters such as flow, temperature and pressures of the liquid nitrogen stream provided an initial benchmark for process testing. Equipped with these initial parameters engineers were then able to establish more detailed test criteria that set the process limits. Quantifying the potential for aluminum hardware damage represented the greatest hurdle for satisfying engineers as to the safety of this process. Extensive testing for aluminum erosion, surface profiling, and substrate weight loss was performed. This successful project clearly demonstrated that the liquid nitrogen jet possesses unique strengths that align remarkably well with the unusual challenges that space hardware and missile manufacturers face on a regular basis. Performance of this task within the confines of a critical manufacturing facility marks a milestone in advanced processing.

Noah, Donald E.↗
NASA NTRS1974

Procedure for preparation for shipment of natural gas storage vessel

A method for preparing a natural gas storage vessel for shipment is presented. The gas is stored at 3,000 pounds per square inch. The safety precautions to be observed are emphasized. The equipment and process for purging the tank and sampling the exit gas flow are described. A diagram of the pressure vessel and the equipment is provided.

Amawd, A. M.↗
NASA NTRS1988

Localized coating removal using plastic media blasting

Steps taken to qualify the use of plastic media blasting for safely and effectively removing paint and other coatings from solid rocket booster aluminum structures are described. As a result of the effort, an improvement was made in the design of surface finishing equipment for processing flight hardware, in addition to a potentially patentable idea on improved plastic media composition. The general arrangement of the blast equipment and the nozzle configuration are presented.

Novak, Howard L.↗
NASA NTRS1991

Indigenous lunar construction materials

The objectives are the following: to investigate the feasibility of the use of local lunar resources for construction of a lunar base structure; to develop a material processing method and integrate the method with design and construction of a pressurized habitation structure; to estimate specifications of the support equipment necessary for material processing and construction; and to provide parameters for systems models of lunar base constructions, supply, and operations. The topics are presented in viewgraph form and include the following: comparison of various lunar structures; guidelines for material processing methods; cast lunar regolith; examples of cast basalt components; cast regolith process; processing equipment; mechanical properties of cast basalt; material properties and structural design; and future work.

Rogers, Wayne↗
NASA NTRS1987

Space processing viewed by a scientist-astronaut

An account is given of NASA astronaut T. G. Wang's 1985 experiences with Spacelab-borne containerless processing experiment equipment handling and experimental management. The mission in question was marred by the initial malfunction of the zero-gravity materials-processing experiment package; Wang's first task was accordingly to attempt repairs, and led to his living inside the experiment package for 2.5 days in order to operate the system as well as possible, on a 16-hr workday basis, with the assistance of two other astronauts.

Wang, Taylor G.↗
NASA NTRS1998

Computational Modeling Program

An Integrated Product Team (IPT) has been formed at NASA Ames Research Center which has set objectives to investigate devices and processes suitable for meeting NASA requirements on ultrahigh performance computers, fast and low power devices, and high temperature wide bandgap materials. These devices may ultimately be sub-100nm feature-size. Processes and equipment must meet the stringent demands posed by the fabrication of such small devices. Until now, the reactors for Chemical Vapor Deposition (CVD) and plasma processes have been designed by trial and error procedures. Further, once the reactor is in place, optimum processing parameters are found through expensive and time-consuming experimentation. If reliable models are available that describe processes and the operation of the reactors, that chore would be reduced to a routine task while being a cost-effective option. The goal is to develop such a design tool, validate that tool using available data from current generation processes and reactors, and then use that tool to explore avenues for meeting NASA needs for ultrasmall device fabrication. Under the present grant, ARL/Penn State along with other IPT members has been developing models and computer code to meet IPT goals. Some of the accomplishments achieved during the first year of the grant are described in this report

Govindan, T. R.↗
NASA NTRS1997

2195 Aluminum-Copper-Lithium Friction Plug Welding Development

Technology developments and applications of friction plug welding is presented. This friction repair welding technology is being studied for implementation on the Space Transportation System's Super Light Weight External Tank. Single plug repairs will be used on a vast majority of weld defects, however, linear defects of up to several inches can be repaired by overlapping plug welds. Methods and results of tensile, bend, simulated service, surface crack tension and other tests at room and cryogenic temperatures is discussed. Attempts to implement Friction Plug Welding has led to both tool and process changes in an attempt to minimize expansive tooling and lengthy implementation times. Process control equipment and data storage methods intended for large scale production will also be addressed. Benefits include increased strength and toughness, decreased weld repair time, automated and highly reliable process, and a lower probability of having to re-repair defect locations.

Takeshita, Rike P.↗
NASA NTRS2008

Precision Cleaning - Path to Premier

ITT Space Systems Division s new Precision Cleaning facility provides critical cleaning and packaging of aerospace flight hardware and optical payloads to meet customer performance requirements. The Precision Cleaning Path to Premier Project was a 2007 capital project and is a key element in the approved Premier Resource Management - Integrated Supply Chain Footprint Optimization Project. Formerly precision cleaning was located offsite in a leased building. A new facility equipped with modern precision cleaning equipment including advanced process analytical technology and improved capabilities was designed and built after outsourcing solutions were investigated and found lacking in ability to meet quality specifications and schedule needs. SSD cleans parts that can range in size from a single threaded fastener all the way up to large composite structures. Materials that can be processed include optics, composites, metals and various high performance coatings. We are required to provide verification to our customers that we have met their particulate and molecular cleanliness requirements and we have that analytical capability in this new facility. The new facility footprint is approximately half the size of the former leased operation and provides double the amount of throughput. Process improvements and new cleaning equipment are projected to increase 1st pass yield from 78% to 98% avoiding $300K+/yr in rework costs. Cost avoidance of $350K/yr will result from elimination of rent, IT services, transportation, and decreased utility costs. Savings due to reduced staff expected to net $4-500K/yr.

Mackler, Scott E.↗
NASA NTRS1987

The influence of the launch site operational environment on Space Shuttle scientific payloads

The effects of prelaunch assembly, testing, and integration activities on the scientific payload at the KSC are examined. The functions of the Shuttle and payload organizations of the KSC are discussed. The processing of the various types of pyaloads, and the amount of access to the payload during processing and after landing are described. The KSC facility contains: an Operations and Checkout Building, a Vertical Processing Facility, Cargo Integration and Test Equipment, an Orbiter Processing Facility, a Payload Changeout Room, payload transportation equipment, and Shuttle launch pads.

Schuiling, Roelof L.↗