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At least 325 records · Page 18

Design and specification of a centralized manufacturing data management and scheduling system

As was revealed in a previous study, the Materials and Processes Laboratory's Productivity Enhancement Complex (PEC) has a number of automated production areas/cells that are not effectively integrated, limiting the ability of users to readily share data. The recent decision to utilize the PEC for the fabrication of flight hardware has focused new attention on the problem and brought to light the need for an integrated data management and scheduling system. This report addresses this need by developing preliminary designs specifications for a centralized manufacturing data management and scheduling system for managing flight hardware fabrication in the PEC. This prototype system will be developed under the auspices of the Integrated Engineering Environment (IEE) Oversight team and the IEE Committee. At their recommendation the system specifications were based on the fabrication requirements of the AXAF-S Optical Bench.

Farrington, Phillip A.↗

Spacesuit glove manufacturing enhancements through the use of advanced technologies

The sucess of astronauts performing extravehicular activity (EVA) on orbit is highly dependent upon the performance of their spacesuit gloves.A study has recently been conducted to advance the development and manufacture of spacesuit gloves. The process replaces the manual techniques of spacesuit glove manufacture by utilizing emerging technologies such as laser scanning, Computer Aided Design (CAD), computer generated two-dimensional patterns from three-dimensionl surfaces, rapid prototyping technology, and laser cutting of materials, to manufacture the new gloves. Results of the program indicate that the baseline process will not increase the cost of the gloves as compared to the existing styles, and in production, may reduce the cost of the gloves. perhaps the most important outcome of the Laserscan process is that greater accuracy and design control can be realized. Greater accuracy was achieved in the baseline anthropometric measurement and CAD data measurement which subsequently improved the design feature. This effectively enhances glove performance through better fit and comfort.

Cadogan, David↗

Modeling and Design Analysis Methodology for Tailoring of Aircraft Structures with Composites

Composite materials provide design flexibility in that fiber placement and orientation can be specified and a variety of material forms and manufacturing processes are available. It is possible, therefore, to 'tailor' the structure to a high degree in order to meet specific design requirements in an optimum manner. Common industrial practices, however, have limited the choices designers make. One of the reasons for this is that there is a dearth of conceptual/preliminary design analysis tools specifically devoted to identifying structural concepts for composite airframe structures. Large scale finite element simulations are not suitable for such purposes. The present project has been devoted to creating modeling and design analysis methodology for use in the tailoring process of aircraft structures. Emphasis has been given to creating bend-twist elastic coupling in high aspect ratio wings or other lifting surfaces. The direction of our work was in concert with the overall NASA effort Twenty- First Century Aircraft Technology (TCAT). A multi-disciplinary team was assembled by Dr. Damodar Ambur to work on wing technology, which included our project.

Rehfield, Lawrence W.↗

Design and evaluation of a foam-filled hat-stiffened panel concept for aircraft primary structural applications

A structurally efficient hat-stiffened panel concept that utilizes a structural foam as stiffener core has been designed for aircraft primary structural applications. This stiffener concept utilizes a manufacturing process that can be adapted readily to grid-stiffened structural configurations which possess inherent damage tolerance characteristics due to their multiplicity of load paths. The foam-filled hat-stiffener concept in a prismatically stiffened panel configuration is more efficient than most other stiffened panel configurations in a load range that is typical for both fuselage and wing structures. The prismatically stiffened panel concept investigated here has been designed using AS4/3502 preimpregnated tape and Rohacell foam core and evaluated for its buckling and postbuckling behavior with and without low-speed impact damage. The results from single-stiffener and multi-stiffener specimens suggest that this structural concept responds to loading as anticipated and has good damage tolerance characteristics.

Ambur, Damodar R.↗

Low Cost, Upper Stage-Class Propulsion

The low cost, upper stage-class propulsion (LCUSP) element will develop a high strength copper alloy additive manufacturing (AM) process as well as critical components for an upper stage-class propulsion system that will be demonstrated with testing. As manufacturing technologies have matured, it now appears possible to build all the major components and subsystems of an upper stage-class rocket engine for substantially less money and much faster than traditionally done. However, several enabling technologies must be developed before that can happen. This activity will address these technologies and demonstrate the concept by designing, manufacturing, and testing the critical components of a rocket engine. The processes developed and materials' property data will be transitioned to industry upon completion of the activity. Technologies to enable the concept are AM copper alloy process development, AM post-processing finishing to minimize surface roughness, AM material deposition on existing copper alloy substrate, and materials characterization.

Vickers, John↗

Space Manufacturing: The Next Great Challenge

Space manufacturing encompasses the research, development and manufacture necessary for the production of any product to be used in near zero gravity, and the production of spacecraft required for transporting research or production devices to space. Manufacturing for space, and manufacturing in space will require significant breakthroughs in materials and manufacturing technology, as well as in equipment designs. This report reviews some of the current initiatives in achieving space manufacturing. The first initiative deals with materials processing in space, e.g., processing non-terrestrial and terrestrial materials, especially metals. Some of the ramifications of the United States Microgravity Payloads fourth (USMP-4) mission are discussed. Some problems in non-terrestrial materials processing are mentioned. The second initiative is structures processing in space. In order to accomplish this, the International Space Welding Experiment was designed to demonstrate welding technology in near-zero gravity. The third initiative is advancements in earth-based manufacturing technologies necessary to achieve low cost access to space. The advancements discussed include development of lightweight material having high specific strength, and automated fabrication and manufacturing methods for these materials.

Whitaker, Ann F.↗

Textile technology development

The objectives of this report were to evaluate and select resin systems for Resin Transfer Molding (RTM) and Powder Towpreg Material, to develop and evaluate advanced textile processes by comparing 2-D and 3-D braiding for fuselage frame applications and develop window belt and side panel structural design concepts, to evaluate textile material properties, and to develop low cost manufacturing and tooling processes for the automated manufacturing of fuselage primary structures. This research was in support of the NASA and Langley Research Center (LaRc) Advanced Composite Structural Concepts and Materials Technologies for Primary Aircraft Structures program.

Shah, Bharat M.↗

Small Scale Turbopump Manufacturing Technology and Material Processes

As part of an internal research and development project, NASA Marshall Space Flight Center (MSFC) has been developing a high specific impulse 9,000-lbf LOX/LH2 pump-fed engine testbed with the capability to throttle 10:1. A Fuel Turbopump (FTP) with the ability to operate across a speed range of 30,000-rpm to 100,000-rpm was developed and analyzed. This small size and flight-like Fuel Turbopump has completed the design and analysis phase and is currently in the manufacturing phase. This paper highlights the manufacturing and processes efforts to fabricate an approximately 20-lb turbopump with small flow passages, intricately bladed components and approximately 3-in diameter impellers. As a result of the small scale and tight tolerances of the hardware on this turbopump, several unique manufacturing and material challenges were encountered. Some of the technologies highlighted in this paper include the use of powder metallurgy technology to manufacture small impellers, electron beam welding of a turbine blisk shroud, and casting challenges. The use of risk reduction efforts such as non-destructive testing (NDT) and evaluation (NDE), fractography, material testing, and component spin testing are also discussed in this paper.

Alvarez, Erika↗

Reconfigurable, Bi-Directional Flexfet Level Shifter for Low-Power, Rad-Hard Integration

Two prototype Reconfigurable, Bi-directional Flexfet Level Shifters (ReBiLS) have been developed, where one version is a stand-alone component designed to interface between external low voltage and high voltage, and the other version is an embedded integrated circuit (IC) for interface between internal low-voltage logic and external high-voltage components. Targeting stand-alone and embedded circuits separately allows optimization for these distinct applications. Both ReBiLS designs use the commercially available 180-nm Flex fet Independently Double-Gated (IDG) SOI CMOS (silicon on insulator, complementary metal oxide semiconductor) technology. Embedded ReBiLS circuits were integrated with a Reed-Solomon (RS) encoder using CMOS Ultra-Low-Power Radiation Tolerant (CULPRiT) double-gated digital logic circuits. The scope of the project includes: creation of a new high-voltage process, development of ReBiLS circuit designs, and adjustment of the designs to maximize performance through simulation, layout, and manufacture of prototypes. The primary technical objectives were to develop a high-voltage, thick oxide option for the 180-nm Flexfet process, and to develop a stand-alone ReBiLS IC with two 8-channel I/O busses, 1.8 2.5 I/O on the low-voltage pins, 5.0-V-tolerant input and 3.3-V output I/O on the high-voltage pins, and 100-MHz minimum operation with 10-pF external loads. Another objective was to develop an embedded, rad-hard ReBiLS I/O cell with 0.5-V low-voltage operation for interface with core logic, 5.0-V-tolerant input and 3.3-V output I/O pins, and 100-MHz minimum operation with 10- pF external loads. A third objective was to develop a 0.5- V Reed-Solomon Encoder with embedded ReBilS I/O: Transfer the existing CULPRiT RS encoder from a 0.35-micron bulk-CMOS process to the ASI 180-nm Flexfet, rad-hard SOI Process. 0.5-V low-voltage core logic. 5.0-V-tolerant input and 3.3-V output I/O pins. 100-MHz minimum operation with 10- pF external loads. The stand-alone ReBiLS chip will allow system designers to provide efficient bi-directional communication between components operating at different voltages. Embedding the ReBiLS cells into the proven Reed-Solomon encoder will demonstrate the ability to support new product development in a commercially viable, rad-hard, scalable 180-nm SOI CMOS process.

DeGregorio, Kelly↗

Handbook for Additively Manufactured Materials: Microstructure, Properties, and Fractography

As the additive manufacturing (AM) industry has grown and the processes have matured more alloys have been adapted to the various AM processes. Understanding the microstructure and properties of these AM alloys is important in designing parts that perform appropriately in application. For decades materials handbooks have been informative references for designers and engineers alike to know what properties and microstructures to expect in alloys produced by other forms of manufacturing. AM alloy references for properties and microstructures have been largely limited to literature that may not be subject to the same industry standard heat treatments or in standard process parameters. NASA has worked with partners to characterize various commercially available AM alloys with a high degree of traceability. This work aims utilize industry-relevant, traceable datasets to develop a new handbook for AM alloys to better inform designers and engineers of the microstructures, fractures, and first order properties from over 30 AM alloys produced across the industry.

Additive Manufacturing↗

Expert systems for superalloy studies

There are many areas in science and engineering which require knowledge of an extremely complex foundation of experimental results in order to design methodologies for developing new materials or products. Superalloys are an area which fit well into this discussion in the sense that they are complex combinations of elements which exhibit certain characteristics. Obviously the use of superalloys in high performance, high temperature systems such as the Space Shuttle Main Engine is of interest to NASA. The superalloy manufacturing process is complex and the implementation of an expert system within the design process requires some thought as to how and where it should be implemented. A major motivation is to develop a methodology to assist metallurgists in the design of superalloy materials using current expert systems technology. Hydrogen embrittlement is disasterous to rocket engines and the heuristics can be very complex. Attacking this problem as one module in the overall design process represents a significant step forward. In order to describe the objectives of the first phase implementation, the expert system was designated Hydrogen Environment Embrittlement Expert System (HEEES).

Workman, Gary L.↗

Source-circuit design with multiple photovoltaic manufacturers

The problems associated with source circuit design for use in photovoltaic (PV) hardware of different manufacturers or processes are discussed. The varying performance of dissimilar materials is examined and the need for standardization of equipment and performance output is investigated.

Spencer, R.↗

Common problems and pitfalls in gear design

There are several pitfalls and problems associated with the successful design of a new gear transmission. A new design will require the knowledge and experience of several technical areas of engineering. Most of the pitfalls and problems associated with a new design are related to an inadequate evaluation of several areas, such as, the lubrication and cooling requirements, complete static and dynamic load analysis, evaluation of materials and heat treatment and the latest manufacturing technology. Some of the common problems of the gear design process are discussed with recommendations made for avoiding these conditions.

Townsend, Dennis P.↗

Performance analysis of Integrated Communication and Control System networks

This paper presents statistical analysis of delays in Integrated Communication and Control System (ICCS) networks that are based on asynchronous time-division multiplexing. The models are obtained in closed form for analyzing control systems with randomly varying delays. The results of this research are applicable to ICCS design for complex dynamical processes like advanced aircraft and spacecraft, autonomous manufacturing plants, and chemical and processing plants.

Halevi, Y.↗

Impact-damaged graphite-thermoplastic trapezoidal-corrugation sandwich and semi-sandwich panels

The results of a study of the effects of impact damage on compression-loaded trapezoidal-corrugation sandwich and semi-sandwich graphite-thermoplastic panels are presented. Sandwich panels with two identical face sheets and a trapezoidal corrugated core between them, and semi-sandwich panels with a corrugation attached to a single skin are considered in this study. Panels were designed, fabricated and tested. The panels were made using the manufacturing process of thermoforming, a less-commonly used technique for fabricating composite parts. Experimental results for unimpacted control panels and panels subjected to impact damage prior to loading are presented. Little work can be found in the literature about these configurations of thermoformed panels.

Jegley, D.↗

Applying Taguchi Methods To Brazing Of Rocket-Nozzle Tubes

Report describes experimental study in which Taguchi Methods applied with view toward improving brazing of coolant tubes in nozzle of main engine of space shuttle. Dr. Taguchi's parameter design technique used to define proposed modifications of brazing process reducing manufacturing time and cost by reducing number of furnace brazing cycles and number of tube-gap inspections needed to achieve desired small gaps between tubes.

Gilbert, Jeffrey L.↗

Design for Safety - The Ares Launch Vehicles Paradigm Change

The lessons learned from the S&MA early involvement in the Ares I launch vehicle design phases proved that performing an in-line function jointly with engineering is critical for S&MA to have an effective role in supporting the system, element, and component design. These lessons learned were used to effectively support the Ares V conceptual design phase and planning for post conceptual design phases. The Top level Conceptual LOM assessment for Ares V performed by the S&MA community jointly with the engineering Advanced Concept Office (ACO) was influential in the final selection of the Ares V system configuration. Post conceptual phase, extensive reliability effort should be planned to support future Heavy Lift Launch Vehicles (HLLV) design. In-depth reliability analysis involving the design, manufacturing, and system engineering communities is critical to understand design and process uncertainties and system integrated failures.

Safie, Fayssal M.↗

Orbital management and design considerations for NiCd satellite power systems

Several recently manufactured 50 and 60 ampere hour aerospace NiCd battery cell lots, produced by Gates Aerospace Batteries, are prone to premature on orbit performance degradation. The failure mechanism is cadmium migration, and the consequent development of soft shorts. A Martin Marietta Astronautics satellite program instituted an orbital management strategy for a set of these batteries that reduced the rate of degradation and brought the system to stable operation. This strategy involves: (1) minimizing the accumulated battery overcharge; (2) regular discharge exercises; and (3) periodic battery reconditioning. Because of changes in the NiCd cell manufacturing process, the actual performance of subsequent lots of NiCd cells is open to question. Future NiCd based power system designs should therefore allow for fine control of charge parameters, and an on orbit battery reconditioning capability. To minimize risk, it is much better to perform a full life test to qualify the cells before launch, rather than in parallel with orbital operations. If there are any changes in the manufacturing process of cells, it is extremely important to maintain very strong cognizance of secondary subcontractors, recognizing that the cell and battery manufacturing discipline is easily atrophied.

Tausch, Benjamin J., II↗