A NASA Perspective on the Growing Role of In-Situ Process Monitoring in Managing Risk of AM Hardware
No abstract available
Lanigan, Erin↗
SEARCH · Search NASA
Results for “in situ processing”
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.
Role of NDE and In-Situ Process Monitoring in Managing Risk of AM Hardware in Space
Explore the source record for details and available documents.
Erin Lanigan↗
Role of NDE and In-Situ Process Monitoring in Managing Risk of AM Space Hardware
Explore the source record for details and available documents.
Erin Lanigan↗
Role of NDE and In Situ Process Monitoring in Managing Risk of AM Space Hardware
Explore the source record for details and available documents.
Erin Lanigan↗
Support Routines for In Situ Image Processing
This software consists of a set of application programs that support ground-based image processing for in situ missions. These programs represent a collection of utility routines that perform miscellaneous functions in the context of the ground data system. Each one fulfills some specific need as determined via operational experience. The most unique aspect to these programs is that they are integrated into the large, in situ image processing system via the PIG (Planetary Image Geometry) library. They work directly with space in situ data, understanding the appropriate image meta-data fields and updating them properly. The programs themselves are completely multimission; all mission dependencies are handled by PIG. This suite of programs consists of: (1)marscahv: Generates a linearized, epi-polar aligned image given a stereo pair of images. These images are optimized for 1-D stereo correlations, (2) marscheckcm: Compares the camera model in an image label with one derived via kinematics modeling on the ground, (3) marschkovl: Checks the overlaps between a list of images in order to determine which might be stereo pairs. This is useful for non-traditional stereo images like long-baseline or those from an articulating arm camera, (4) marscoordtrans: Translates mosaic coordinates from one form into another, (5) marsdispcompare: Checks a Left Right stereo disparity image against a Right Left disparity image to ensure they are consistent with each other, (6) marsdispwarp: Takes one image of a stereo pair and warps it through a disparity map to create a synthetic opposite- eye image. For example, a right eye image could be transformed to look like it was taken from the left eye via this program, (7) marsfidfinder: Finds fiducial markers in an image by projecting their approximate location and then using correlation to locate the markers to subpixel accuracy. These fiducial markets are small targets attached to the spacecraft surface. This helps verify, or improve, the pointing of in situ cameras, (8) marsinvrange: Inverse of marsrange . given a range file, re-computes an XYZ file that closely matches the original. . marsproj: Projects an XYZ coordinate through the camera model, and reports the line/sample coordinates of the point in the image, (9) marsprojfid: Given the output of marsfidfinder, projects the XYZ locations and compares them to the found locations, creating a report showing the fiducial errors in each image. marsrad: Radiometrically corrects an image, (10) marsrelabel: Updates coordinate system or camera model labels in an image, (11) marstiexyz: Given a stereo pair, allows the user to interactively pick a point in each image and reports the XYZ value corresponding to that pair of locations. marsunmosaic: Extracts a single frame from a mosaic, which will be created such that it could have been an input to the original mosaic. Useful for creating simulated input frames using different camera models than the original mosaic used, and (12) merinverter: Uses an inverse lookup table to convert 8-bit telemetered data to its 12-bit original form. Can be used in other missions despite the name.
Deen, Robert G.↗
In-situ materials processing systems and bioregenerative life support systems interrelationships
The synergy and linkages between bioregenerative life support systems and the materials produced by in-situ materials processing systems was investigated. Such systems produce a broad spectrum of byproducts such as oxygen, hydrogen, processed soil material, ceramics, refractory, and other materials. Some of these materials may be utilized by bioregenerative systems either directly or with minor modifications. The main focus of this project was to investigate how these materials can be utilized to assist a bioregenerative life support system. Clearly the need to provide a sustainable bioregenerative life support system for long term human habitation of space is significant.
Mignon, George V.↗
The Additive Manufacturing Moment Measure (AM3) Approach to Predictions of Solid Cooling Rate and Time Above Melt
Qualification of a laser powder bed fusion additive manufacturing (LPBF-AM) process requires knowledge of the multi-scale material physics during the process, per part. As the LPBF-AM build occurs, each moment is influenced by the process history. Knowledge of the build sequence can be used to generate a discretized time-space-condition point field that when coupled with a nearest neighbors’ calculation results in a generalized and fully parallel process model computation. This GPU accelerated approach was developed for part-scale analysis of build files along with in-situ process monitoring sensor data and is termed the “Additive Manufacturing Moment Measure” (AM3). The AM3 approach will be presented and then used to evaluate an AM Bench relevant geometry with synchronized in-situ process data, ex-situ nondestructive evaluation, and optical microscopy observations. These comparisons permit a better understanding of how the process actions can affect the LPBF-AM build quality and the signals generated during in-situ process monitoring.
Additive Manufacturing↗
Effect of Processing Pressure on Isolated Pore Formation during Controlled Directional Solidification in Small Channels
Directional solidification experiments were performed, using succinonitrile saturated with nitrogen gas, to examine the effects of in-situ processing pressure changes on the formation growth, and evolution of an isolated, cylindrical gaseous pore. A novel solidification facility, capable of processing thin cylindrical samples (I.D. < 1.0 mm), under controlled pressure conditions, was used for the experiments. A new experimental method for growing the isolated pore from a seed bubble is introduced. The experimental results indicate that an in-situ processing pressure change will result in either a transient change in pore diameter or a complete termination of pore growth, indicating that pressure changes can be used as a control parameter to terminate bubble growth. A simple analytical model has been introduced to explain the experimental observations.
Cox, Matthew C.↗
Advanced Metal Foam Structures for Outer Space
A document discusses a proposal to use advanced materials especially bulk metallic glass (BMG) foams in structural components of spacecraft, lunar habitats, and the like. BMG foams, which are already used on Earth in some consumer products, are superior to conventional metal foams: BMG foams have exceptionally low mass densities and high strength-to-weight ratios and are more readily processable into strong, lightweight objects of various sizes and shapes. These and other attractive properties of BMG foams would be exploited, according to the proposal, to enable in situ processing of BMG foams for erecting and repairing panels, shells, containers, and other objects. The in situ processing could include (1) generation of BMG foams inside prefabricated deployable skins that would define the sizes and shapes of the objects thus formed and (2) thermoplastic deformation of BMG foams. Typically, the generation of BMG foams would involve mixtures of precursor chemicals that would be subjected to suitable pressure and temperature schedules. In addition to serving as structural components, objects containing or consisting of BMG foams could perform such functions as thermal management, shielding against radiation, and shielding against hypervelocity impacts of micrometeors and small debris particles.
Hanan, Jay↗
Planetary sample transfer acquisition and handling: in-situ sampling/sample processing strategies and technologies for Venus, comets/asteroids and Titan
Explore the source record for details and available documents.
in situ sample acquisition sample handling planeta↗
Mining and beneficiation: A review of possible lunar applications
Successful exploration of Mars and outer space may require base stations strategically located on the Moon. Such bases must develop a certain self-sufficiency, particularly in the critical life support materials, fuel components, and construction materials. Technology is reviewed for the first steps in lunar resource recovery-mining and beneficiation. The topic is covered in three main categories: site selection; mining; and beneficiation. It will also include (in less detail) in-situ processes. The text described mining technology ranging from simple diggings and hauling vehicles (the strawman) to more specialized technology including underground excavation methods. The section of beneficiation emphasizes dry separation techniques and methods of sorting the ore by particle size. In-situ processes, chemical and thermal, are identified to stimulate further thinking by future researchers.
Chamberlain, Peter G.↗
In-situ integrated processing and characterization of thin films of high temperature superconductors, dielectrics and semiconductors by MOCVD
In this strategy of depositing the basic building blocks of superconductors, semiconductors, and dielectric having common elements, researchers deposited superconducting films of Y-Ba-Cu-O, semiconductor films of Cu2O, and dielectric films of BaF2 and Y2O3 by metal oxide chemical vapor deposition (MOCVD). By switching source materials entering the chamber, and by using direct writting capability, complex device structures like three-terminal hybrid semiconductors/superconductors transistors can be fabricated. The Y-Ba-Cu-O superconducting thin films on BaF2/YSZ substrates show a T(sub c) of 80 K and are textured with most of the grains having their c-axis or a-axis perpendicular to the substrate. Electrical characteristics as well as structural characteristics of superconductors and related materials obtained by x-ray defraction, electron microscopy, and energy dispersive x-ray analysis are discussed.
Singh, R.↗
In-situ integrated processing and characterization of thin films of high temperature superconductors, dielectrics and semiconductors by MOCVD
In this strategy of depositing the basic building blocks of superconductors, semiconductors, and dielectrics having common elements, researchers deposited superconducting films of Y-Ba-Cu-O, semiconductor films of Cu2O, and dielectric films of BaF2 and Y2O3 by metal oxide chemical vapor deposition (MOCVD). By switching source materials entering the chamber, and by using direct writing capability, complex device structures like three terminal hybrid semiconductor/superconductor transistors can be fabricated. The Y-Ba-Cu-O superconducting thin films on BaF2/YSZ substrates show a T(sub c) of 80 K and are textured with most of the grains having their c-axis or a-axis perpendicular to the substrate. Electrical characteristics as well as structural characteristics of superconductors and related materials obtained by x-ray deffraction, electron microscopy, and energy dispersive x-ray analysis are discussed.
Singh, R.↗
Processing of Superconductor-Normal-Superconductor Josephson Edge Junctions
The electrical behavior of epitaxial superconductor-normal-superconductor (SNS) Josephson edge junctions is strongly affected by processing conditions. Ex-situ processes, utilizing photoresist and polyimide/photoresist mask layers, are employed for ion milling edges for junctions with Yttrium-Barium-Copper-Oxide (YBCO) electrodes and primarily Co-doped YBCO interlayers.
photoresist polyimide process interlayer materials↗
Powder Bed Fusion Laser Beam Metals Additive Manufacturing: Process Monitoring Approaches for Qualification and Certification
The use of in-situ process monitoring is of interest to lower the cost of inspection for the qualification of powder bed fusion laser beam metal (PBF-LB/M) additively manufactured (AM) parts. Precise monitoring of the PBF-LB/M AM build process constitutes a multi-scale and multi-discipline task. There are several significant challenges to the in-situ approach: the synchronization of sensor signals to process steps; the physical interpretation and classification of sensor signals; managing very large datasets; and comparing the inputs with the observed monitoring signals. At NASA Langley Research Center, a configurable architecture additive testbed has been developed to monitor the build process with synchronized sensors. The philosophy and method adopted for the synchronization of the cameras with laser power and position throughout a complex PBF-LB/M AM build will be described. The synchronized in-situ monitoring signals are compared with ex-situ nondestructive inspection, x-ray computed tomography (XCT). Such comparisons permit a better understanding of how the sequential process actions of LPBF-AM can affect build quality. The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. This presentation will describe an additive manufacturing model-based process metric (AM-PM) computational method that is a fully parallel reduced order modeling approach developed to evaluate the evolution of AM processes. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology of the approach will be described and mapped to the porosity observed from XCT for a complex PBF-LB/M build. Such comparative results develop understanding of how the sequential process actions can affect the PBF-LB/M AM build quality and microstructure variability.
Laser Powder Bed Fusion↗
Progress in the Multijunction Solar Cell Mantech Program
In September, 1995, the joint Wright Laboratory/Phillips Laboratory/NASA Lewis Multijunction Solar Cell Manufacturing Technology (ManTech) Program began to improve multijunction cell performance and scale them up to production size and quantity to support Air Force and commercial satellite programs. The first milestone of the program has been reached and the purpose of this paper is to present the results of the program so far. The objectives of the Multijunction Solar Cell ManTech Program are to increase the GaInP2/GaAs/Ge lot average cell efficiency to 24-26%, increase the cell size to > or equal to 16 sq cm while maintaining high efficiency, and limit the per cell costs to < or equal to 1.15X state of the art GaAs/Ge cells. Advanced manufacturing technology and process control techniques such as in-situ process monitoring and real time process feedback are being used to optimize multijunction solar cell growth processes to achieve these goals. This paper will discuss progress made in Phase I of the program and give an overview of Phase II but will focus on side-by-side testing results collected by Phillips Laboratory and NASA Lewis on Phase I deliverable cells from both vendors. Cell performance, pre- and post radiation, and temperature coefficient results on initial production multijunction solar cells will be presented and discussed. The data shows that this technology meets the objectives of the program, and that, in the interim before a new solar simulation standard becomes widely available, the measurement techniques being used by the major space solar cell manufacturers are providing adequate testing results for solar array design.
Keener, David N.↗
Ultrasonic Inspection During Autoclave Cure of Reflowable-Interface Composite Joints
In structural bonds, the interface between adherend and adhesive is nearly two-dimensional making the interface susceptible to minute quantities of contamination, which can cause weak bonds. Regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded primary-structures due to uncertainty in bond performance. To address this issue, the NASA Convergent Aeronautics Solutions (CAS): Adhesive Free Bonding of Composites (AERoBOND) project is investigating reformulated aerospace epoxy-matrix resins to enable reflow and diffusion of the resin at the joint interface during a secondary bonding and cure process that can eliminate the material discontinuity at the interface. Implementing in-situ process monitoring enables assessing the bond quality during processing rather than waiting for post-fabrication mechanical testing to be completed. In this paper, an in-situ ultrasonic inspection system is used to monitor the joining of three composite laminates assembled using the AERoBOND technique. For each panel, the amplitude of the wave reflection at the joint was measured throughout the cure cycle. The results indicate the timing and extent of reflow and cure of the epoxy resin at the joint. Factors indicating end of cure were ascertained and a metric was developed to qualitatively predict acceptable mode-II fracture toughness based on the ultrasonic amplitude at the joint line during cure. In addition, since the inspection system scans an area of the joint, high-resolution localized results can be obtained across the joint.
Tyler B Hudson↗
Lunar Excavator Mission Operations using Dynamic Movement Primitives
To support sustainable infrastructure on the Moon, NASA must leverage robots to extract lunar resources for in-situ processing and construction. As part of this effort, NASA is launching the in-situ resource utilization (ISRU) Pilot Excavator later this decade to validate a robotic regolith excavator based on the Regolith Advanced Surface Systems Operations Robot (RASSOR). RASSOR is designed to extract and transport regolith to meet the needs of ISRU architectures. During its mission, Pilot Excavator will be tasked with driving in test patterns to demonstrate the operational concept. One of these tests is a circular trajectory around the lander while avoiding miscellaneous surface hazards such as lunar rocks. To this end, we utilize dynamic movement primitives to represent navigation sequences as primitive trajectories. Here, we introduce a novel obstacle avoidance parameter, which is configured to avoid rocks throughout testing exercises. We demonstrate the effectiveness our method in a newly developed simulation tool called the Simulated Excavation Environment for Lunar Operations (SEELO) using models based on the NASA RASSOR 2.0 excavator. After making key changes to the obstacle avoidance formulation, our results show that the robot is able to safety and robustly navigate the lunar surface with densely populated rock obstacles while retaining the desired circle pattern behavior.
Space Robotics and Automation↗