Search NASA⌕ Search

SEARCH · Search NASA

Results for “Manufactured solutions”

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 325 records · Page 18

Nature's crucible: Manufacturing optical nonlinearities for high resolution, high sensitivity encoding in the compound eye of the fly, Musca domestica

The number of pixels per unit area sampling an image determines Nyquist resolution. Therefore, the highest pixel density is the goal. Unfortunately, as reduction in pixel size approaches the wavelength of light, sensitivity is lost and noise increases. Animals face the same problems and have achieved novel solutions. Emulating these solutions offers potentially unlimited sensitivity with detector size approaching the diffraction limit. Once an image is 'captured', cellular preprocessing of information allows extraction of high resolution information from the scene. Computer simulation of this system promises hyperacuity for machine vision.

Wilcox, Mike↗

Elemental Metals or Oxides Distributed on a Carbon Substrate or Self-Supported and the Manufacturing Process Using Graphite Oxide as Template

A process for providing elemental metals or metal oxides distributed on a carbon substrate or self-supported utilizing graphite oxide as a percursor. The graphite oxide is exposed to one or more metal chlorides to form an intermediary product comprising carbon, metal, chloride, and oxygen. This intermediary product can be further processed by direct exposure to carbonate solutions to form a second intermediary product comprising carbon, metal carbonate, and oxygen. Either intermediary product may be further processed: a) in air to produce metal oxide; b) in an inert environment to produce metal oxide on carbon substrate; c) in a reducing environment to produce elemental metal distributed on carbon substrate. The product generally takes the shape of the carbon precursor.

Hung, Ching-Chen↗

Product Lifecycle Management and the Quest for Sustainable Space Explorations

Product Lifecycle Management (PLM) is an outcome of lean thinking to eliminate waste and increase productivity. PLM is inextricably tied to the systems engineering business philosophy, coupled with a methodology by which personnel, processes and practices, and information technology combine to form an architecture platform for product design, development, manufacturing, operations, and decommissioning. In this model, which is being implemented by the Engineering Directorate at the National Aeronautics and Space Administration's (NASA's) Marshall Space Flight Center, total lifecycle costs are important variables for critical decision-making. With the ultimate goal to deliver quality products that meet or exceed requirements on time and within budget, PLM is a powerful concept to shape everything from engineering trade studies and testing goals, to integrated vehicle operations and retirement scenarios. This paper will demonstrate how the Engineering Directorate is implementing PLM as part of an overall strategy to deliver safe, reliable, and affordable space exploration solutions. It has been 30 years since the United States fielded the Space Shuttle. The next generation space transportation system requires a paradigm shift such that digital tools and knowledge management, which are central elements of PLM, are used consistently to maximum effect. The outcome is a better use of scarce resources, along with more focus on stakeholder and customer requirements, as a new portfolio of enabling tools becomes second nature to the workforce. This paper will use the design and manufacturing processes, which have transitioned to digital-based activities, to show how PLM supports the comprehensive systems engineering and integration function. It also will go through a launch countdown scenario where an anomaly is detected to show how the virtual vehicle created from paperless processes will help solve technical challenges and improve the likelihood of launching on schedule, with less hands-on labor needed for processing and troubleshooting.

Caruso, Pamela W.↗

Small Launch Vehicle Design Approaches: Clustered Cores Compared with Multi-Stage Inline Concepts

In an effort to better define small launch vehicle design options two approaches were investigated from the small launch vehicle trade space. The primary focus was to evaluate a clustered common core design against a purpose built inline vehicle. Both designs focused on liquid oxygen (LOX) and rocket propellant grade kerosene (RP-1) stages with the terminal stage later evaluated as a LOX/methane (CH4) stage. A series of performance optimization runs were done in order to minimize gross liftoff weight (GLOW) including alternative thrust levels, delivery altitude for payload, vehicle length to diameter ratio, alternative engine feed systems, re-evaluation of mass growth allowances, passive versus active guidance systems, and rail and tower launch methods. Additionally manufacturability, cost, and operations also play a large role in the benefits and detriments for each design. Presented here is the Advanced Concepts Office's Earth to Orbit Launch Team methodology and high level discussion of the performance trades and trends of both small launch vehicle solutions along with design philosophies that shaped both concepts. Without putting forth a decree stating one approach is better than the other; this discussion is meant to educate the community at large and let the reader determine which architecture is truly the most economical; since each path has such a unique set of limitations and potential payoffs.

Waters, Eric D.↗

NASA Wearable Technology CLUSTER 2013-2014 Report

Wearable technology has the potential to revolutionize the way humans interact with one another, with information, and with the electronic systems that surround them. This change can already be seen in the dramatic increase in the availability and use of wearable health and activity monitors. These devices continuously monitor the wearer using on-­‐body sensors and wireless communication. They provide feedback that can be used to improve physical health and performance. Smart watches and head mounted displays are also receiving a great deal of commercial attention, providing immediate access to information via graphical displays, as well as additional sensing features. For the purposes of the Wearable Technology CLUSTER, wearable technology is broadly defined as any electronic sensing, human interfaces, computing, or communication that is mounted on the body. Current commercially available wearable devices primarily house electronics in rigid packaging to provide protection from flexing, moisture, and other contaminants. NASA mentors are interested in this approach, but are also interested in direct integration of electronics into clothing to enable more comfortable systems. For human spaceflight, wearable technology holds a great deal of promise for significantly improving safety, efficiency, autonomy, and research capacity for the crew in space and support personnel on the ground. Specific capabilities of interest include: Continuous biomedical monitoring for research and detection of health problems. Environmental monitoring for individual exposure assessments and alarms. Activity monitoring for responsive robotics and environments. Multi-modal caution and warning using tactile, auditory, and visual alarms. Wireless, hands-free, on-demand voice communication. Mobile, on-demand access to space vehicle and robotic displays and controls. Many technical challenges must be overcome to realize these wearable technology applications. For example, to make a wearable device that is both functional and comfortable for long duration wear, developers must strive to reduce electronic mass and volume while also addressing constraints imposed by the body attachment method. Depending on the application, the device must be placed in a location that the user can see and reach, and that provides the appropriate access to air and the wearer's skin. Limited power is available from body-­‐worn batteries and heat must be managed to prevent discomfort. If the clothing is to be washed, there are additional durability and washability hurdles that traditional electronics are not designed to address. Finally, each specific capability has unique technical challenges that will likely require unique solutions. In addition to the technical challenges, development of wearable devices is made more difficult by the diversity of skills required and the historic lack of collaboration across domains. Wearable technology development requires expertise in textiles engineering, apparel design, software and computer engineering, electronic design and manufacturing, human factors engineering, and application-­‐specific fields such as acoustics, medical devices, and sensing. Knowledge from each of these domains must be integrated to create functional and comfortable devices. For this reason, the diversity of knowledge and experience represented in the Wearable Technology is critical to overcoming the fundamental challenges in the field.

Simon, Cory↗

Process Development and Testing for Lunar Habitats

Non-metallic solutions for Lunar bases are appealing due to their light weight and ability to block many forms of radiation. Composite materials made from different combinations of these non-metallic materials enable effective mating of dissimilar materials for strong structures such as pressurized habitats. Inserting and manufacturing composite structural materials on the Moon presents several challenges, however: the oxygen levels inside pressurized habitats will be relatively high, radiation that is blocked causes damage and the lack of atmosphere results in a high-magnitude negative pressure environment. In the past two years, the Materials and Processes Lab (EM01) invested in two internal research and development (IRAD) proposals for testing and procurement of composite materials. One proposal endeavors to determine flammability and radiation damage of various composite materials with a focus on carbon fiber and ultra-high molecular weight polyethylene (UHWMPE). The other proposal enables procurement of chopped fiber spray equipment materials which will be used to develop a novel technique for chopped UHMWPE fiber layup, similar to the chopped fiberglass layups used for making large structures such a boat hulls and hot tubs.

Composite↗

Investigation of Physical Mechanisms for Jet Noise Reduction by Plug Nozzle Porosity

This paper presents the results of a computational study on porous-plug nozzles for their eventual application in reducing takeoff noise levels for supersonic civil transport. The study explores a wide range of porous-plug geometries, encompassing variations in hole size, plug length and porosity. Computational fluid dynamics (CFD) analyses are employed in concert with an advanced automated mesh refinement (AMR) scheme, Sketch-to-Solution (S2S), to investigate porous plug nozzle design strategies that may diminish shock strength, broad-band shock noise (BBSN), flow separation, and other undesirable characteristics associated with high takeoff noise levels. A selected subset of the porous-plug nozzles that were analyzed computationally were manufactured at subscale using stereolithography 3D printing. These nozzles were tested experimentally, obtaining far-field noise spectral data and schlieren flow visualization pictures. Detailed comparisons between CFD predictions and experimental results were conducted. These comparisons focus on gaining a better understanding of the underlying physical mechanisms responsible for noise reduction with the porous plugs relative to corresponding solid plugs.

computational fluid dynamics↗

Investigation of Physical Mechanisms for Jet Noise Reduction by Plug Nozzle Porosity

This paper presents the results of a computational study on porous-plug nozzles for their eventual application in reducing takeoff noise levels for supersonic civil transport. The study explores a wide range of porous-plug geometries, encompassing variations in hole size, plug length and porosity. Computational fluid dynamics (CFD) analyses are employed in concert with an advanced automated mesh refinement (AMR) scheme, Sketch-to-Solution (S2S), to investigate porous plug nozzle design strategies that may diminish shock strength, broad-band shock noise (BBSN), flow separation, and other undesirable characteristics associated with high takeoff noise levels. A selected subset of the porous-plug nozzles that were analyzed computationally were manufactured at subscale using stereolithography 3D printing. These nozzles were tested experimentally, obtaining far-field noise spectral data and schlieren flow visualization pictures. Detailed comparisons between CFD predictions and experimental results were conducted. These comparisons focus on gaining a better understanding of the underlying physical mechanisms responsible for noise reduction with the porous plugs relative to corresponding solid plugs.

Nozzles↗

Work Term Assignment Spring 2017

My tour in the Engineering Robotics directorate exceeded my expectations. I learned lessons about Creo, manufacturing and assembly, collaboration, and troubleshooting. During my first tour, last spring, I used Creo on a smaller project, but had limited experience with it before starting in the Dynamic Systems Test branch this spring. I gained valuable experience learning assembly design, sheet metal design and designing with intent for manufacturing and assembly. These skills came from working both on the hatch and the floor. I also learned to understand the intent of other designers on models I worked with. While redesigning the floor, I was modifying an existing part and worked to understand what the previous designer had done to make it fit with the new model. Through working with the machine shop and in the mock-up, I learned much more about manufacturing and assembly. I used a Dremel, rivet gun, belt sander, and countersink for the first time. Through taking multiple safety training for different machine shops, I learned new machine shop safety skills specific to each one. This semester also gave me new collaborative opportunities. I collaborated with engineers within my branch as well as with Human Factors and the building 10 machine shop. This experience helped me learn how to design for functionality and assembly, not only for what would be easiest in my designs. In addition to these experiences, I learned many lessons in troubleshooting. I was the first person in my office to use a Windows 10 computer. This caused unexpected issues with NASA services and programs, such as the Digital Data Management Server (DDMS). Because of this, I gained experience finding solutions to lockout and freeze issues as well as Creo specific settings. These will be useful skills to have in the future and will be implemented in future rotations. This co-op tour has motivated me more to finish my degree and pursue my academic goals. I intend to take a machining Career Gateway Elective in the Fall to improve my skills in building as well as designing with manufacturing intent. I am also inspired to take more mechatronics CGE courses before I graduate to learn more about the crossover between mechanical and electrical engineering. This semester, I worked on multiple projects and had the opportunity to learn from engineers of different disciplines. I became proficient in Creo 2.0, a program I had not used significantly before. I finished modifying the hatch for 3D print and made sizeable modifications to the nose floor support design. I also gained hands-on experience that will be useful in my engineering career in the future. I would consider all of these major achievements from this spring semester. Lastly, I learned to ask more questions and to search for the right people to find answers which I know will be a valuable skill in the future. This summer, I will be completing my last rotation in the Flight Operations Directorate at Ellington Air Field. After this last tour, I will be returning to school for the Fall, Spring and Summer. I will graduate in August of 2018. I am looking forward to learning more about the different jobs available to engineers. This division works directly with many different types of aircrafts and I am excited to learn more about this focus of engineering. The Aircraft Operations Division values team work greatly and I intend to improve my interpersonal skills by working with them this summer.

Sico, Mallory↗

Elemental Metals or Oxides Distributed on a Carbon Substrate or Self-Supported and the Manufacturing Process Using Graphite Oxide as Template

A process for providing elemental metals or metal oxides distributed on a carbon substrate or self-supported utilizing graphite oxide as a precursor. The graphite oxide is exposed to one or more metal chlorides to form an intermediary product comprising carbon, metal, chloride, and oxygen. This intermediary product can be further processed by direct exposure to carbonate-solutions to form a second intermediary product comprising carbon, metal carbonate, and oxygen. Either intermediary product may be further processed: a) in air to produce metal oxide; b) in an inert environment to produce metal oxide on carbon substrate; c) in a reducing environment to produce elemental metal distributed on carbon substrate. The product generally takes the shape of the carbon precursor.

Hung, Ching-Cheh↗

Refractory inserts used to form cooling passages in cast superalloy turbine vanes

Economical technique has been developed for manufacturing air-cooled turbine blades and vanes for gas turbine engines. Process uses tungsten inserts to form coolant passages. After casting, inserts are reduced to tungsten oxide during sublimation with oxygen at elevated temperature. Tungsten oxide is leached out of coolant passages with a molten salt solution.

Terpay, A.↗

Marshall Space Flight Center Research and Technology Report 2017

This report features over 60 technology development and scientific research efforts that collectively aim to enable new capabilities in spaceflight, expand the reach of human exploration, and reveal new knowledge about the universe in which we live. These efforts include a wide array of strategic developments: launch propulsion technologies that facilitate more reliable, routine, and cost effective access to space; in-space propulsion developments that provide new solutions to space transportation requirements; autonomous systems designed to increase our utilization of robotics to accomplish critical missions; life support technologies that target our ability to implement closed-loop environmental resource utilization; science instruments that enable terrestrial, solar, planetary and deep space observations and discovery; and manufacturing technologies that will change the way we fabricate everything from rocket engines to in situ generated fuel and consumables.

Research and Technology Report↗

Electrodynamic Dust Shield Testing on the Materials on International Space Station Experiment 11

Dust is a major concern for lunar exploration. To combat the effects of dust, NASA, academia, and industry are developing solutions to the dust problem. One potential technology solution for this problem is the Electrodynamic Dust Shield (EDS). Many years of research and development have gone into this technology. The Materials on International Space Station Experiment – 11 (MISSE-11) provides a long term space exposure platform for this technology to verify compatibility of materials and manufacturing processes to the space environment. The MISSE-11 EDS experiment consists of 12 EDS panels. These panels are made of glass, polyimide, or prototype spacesuit fabric. Some panels are covered with a lotus leaf coating while others are covered with thermal paint. They are flown in the wake position of the ISS to simulate the lunar environment. Two panels are in an active configuration and are energized with a high voltage power supply, which generates high-voltage pulses to activate the dust shields. Current and voltage data are recovered from each of these trials to compare to baseline data. Also, each of the EDS panels are imaged on a monthly basis to track any changes with time that may occur with the EDS variants. In this paper, we report preliminary data and analysis from this spaceflight experiment.

Electrostatics↗

Engineering workstation: Sensor modeling

The purpose of the engineering workstation is to provide an environment for rapid prototyping and evaluation of fusion and image processing algorithms. Ideally, the algorithms are designed to optimize the extraction of information that is useful to a pilot for all phases of flight operations. Successful design of effective fusion algorithms depends on the ability to characterize both the information available from the sensors and the information useful to a pilot. The workstation is comprised of subsystems for simulation of sensor-generated images, image processing, image enhancement, and fusion algorithms. As such, the workstation can be used to implement and evaluate both short-term solutions and long-term solutions. The short-term solutions are being developed to enhance a pilot's situational awareness by providing information in addition to his direct vision. The long term solutions are aimed at the development of complete synthetic vision systems. One of the important functions of the engineering workstation is to simulate the images that would be generated by the sensors. The simulation system is designed to use the graphics modeling and rendering capabilities of various workstations manufactured by Silicon Graphics Inc. The workstation simulates various aspects of the sensor-generated images arising from phenomenology of the sensors. In addition, the workstation can be used to simulate a variety of impairments due to mechanical limitations of the sensor placement and due to the motion of the airplane. Although the simulation is currently not performed in real-time, sequences of individual frames can be processed, stored, and recorded in a video format. In that way, it is possible to examine the appearance of different dynamic sensor-generated and fused images.

Pavel, M↗

Method for Selective Cleaning of Mold Release from Composite Honeycomb Surfaces

Honeycomb structures are commonly employed as load- and force-bearing structures as they are structurally strong and lightweight. Manufacturing processes for heat-molded composite honeycomb structures commence with the placement of pre-impregnated composite layups over metal mandrels. To prevent permanent bonding between the composite layup and the metal mandrels, an agent, known as a mold release agent, is used. Mold release agents allow the molded composite material to be removed from mandrels after a heat-forming process. Without a specific removal process, mold release agents may continue to adhere to the surface of the composite material, thereby affecting the bonding of other materials that may come into contact with the composite surface in later stages of processing A constituent common to commercially available household cleaning agents is employed for the removal of mold release agents common to the manufacturing of heat-formed composite materials. The reliability of the solvent has been proven by the longevity and reliability of commercial household cleaners. At the time of this reporting, no one has attempted using constituent for this purpose. The material to be cleaned is immersed in the solution, vertically removed so that the solution is allowed to drain along cell walls and into a solvent bath, and then placed on a compressed airflow table for drying.

Pugel, Diane↗

Development of an Additively Manufactured Turbine Blade Tuned Mass Absorber

An innovative concept using a tuned mass absorber for resonant response reduction of turbine blades that is integrally fabricated into the blades using additive manufactured has been developed. Avoiding high resonant response and resulting high cycle fatigue failure is a major concern of the $100B worldwide turbine industry, which encompasses power generation, jet engines and rocket engine turbomachinery. Blade failure is potentially catastrophic, and although preventative measures using dampers do exist, these solutions are extremely expensive to develop and are not always effective. In addition, many of the existing techniques do not work for newer integrally bladed disks (or blisks), where there is no inherent damping in the assembly. The proposed concept, in which a tuned mass absorber re-arranges the structural dynamics and moves energy from the blade to the absorber, is designed specifically for blisks, and is intentionally linear, enabling accurate response prediction during design. Single blade prototypes have been analyzed, fabricated, and tested, and different absorber concepts have shown a reduction in response of up to 60%. After an extensive commercialization and prior art search, MSFC determined the innovation merited the generation and submission of a patent application in August ’21. Funding is now being sought to fabricate a 20-bladed blisk which would be spun at operational speeds with substantially higher and more realistic pressure loads in a special spin facility. Successful completion of this program would raise the TRL from 3/4 to 6/7, significantly improving the viability for adoption of the concept not only in rocket engines but other industrial applications as well.

Turbine Blades↗

Precise positioning and compliance synthesis for automatic assembly using Lorentz levitation

Many manufacturing assembly tasks require fine compliant motion and fast, accurate positioning. Conventional robots perform poorly in these tasks because of their large mass, friction and backlash in gears, cogging in drive motors and other deleterious effects. Even robots equipped with special control systems enabling compliant operation offer only partial solutions. It is difficult or impossible to automate many product assemblies requiring fine, compliant motion. This problem can be greatly alleviated by dividing the manipulation system into coarse and fine domains. In this scenario, a standard industrial robot can serve as a coarse positioner which in turn carries a six degrees of freedom fine motion wrist. Thus the robot can access a workspace measured in meters at low bandwidth and low resolution while the wrist can move over millimeters at high bandwidth and high resolution during the final phase of the assembly operation. Work indicates that fine motion wrists using Lorentz levitation can greatly augment the accuracy and dexterity of robots because they are frictionless, have high bandwidths and have a single back drivable moving part. Also, since there is no contact between the moving and stationary parts, wear and contamination can be eliminated. The use of six Lorentz force actuators in combination with real time position and orientation sensing offers several important advantages over magnetic bearing approaches.

Hollis, R. L.↗

Polymers Advance Heat Management Materials for Vehicles

For 6 years prior to the retirement of the Space Shuttle Program, the shuttles carried an onboard repair kit with a tool for emergency use: two tubes of NOAX, or "good goo," as some people called it. NOAX flew on all 22 flights following the Columbia accident, and was designed to repair damage that occurred on the exterior of the shuttle. Bill McMahon, a structural materials engineer at Marshall Space Flight Center says NASA needed a solution for the widest range of possible damage to the shuttle s exterior thermal protection system. "NASA looked at several options in early 2004 and decided on a sealant. Ultimately, NOAX performed the best and was selected," he says. To prove NOAX would work effectively required hundreds of samples manufactured at Marshall and Johnson, and a concerted effort from various NASA field centers. Johnson Space Center provided programmatic leadership, testing, tools, and crew training; Glenn Research Center provided materials analysis; Langley Research Center provided test support and led an effort to perform large patch repairs; Ames Research Center provided additional testing; and Marshall provided further testing and the site of NOAX manufacturing. Although the sealant never had to be used in an emergency situation, it was tested by astronauts on samples of reinforced carbon-carbon (RCC) during two shuttle missions. (RCC is the thermal material on areas of the shuttle that experience the most heat, such as the nose cone and wing leading edges.) The material handled well on orbit, and tests showed the NOAX patch held up well on RCC.

Source record↗