Search NASA⌕ Search

SEARCH · Search NASA

Results for “manufacturing rate”

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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS2024

Advances in Thermoplastic Composites Over Three Decades – A Literature Review

Recently, there has been a renewed interest in thermoplastic composites driven mainly by advances in automation which can lead to significant cost reductions by increasing manufacturing rates while simultaneously reducing the part count and energy consumption relative to the manufacturing of thermoset composites. At the same time, new material systems have been developed and the thermoplastic composites prepreg material quality has improved over time. Additionally, thermoplastic composites have nearly infinite room-temperature shelf life and production scraps can be reused and retired parts can be recycled, providing opportunities for more sustainable operations and downstream markets. These factors have contributed to a strong interest in advancing thermoplastic composites for aerospace, automotive, and other industrial applications. The objective of the present study is to assess the state of the art regarding the maturity and performance of thermoplastic composite materials and to document the advances made in manufacturing and assembly of thermoplastic composite structures. Therefore, more than 200 NASA reports, conference proceedings and journal papers spanning three and a half decades (1986-2022) were reviewed and the findings summarized. The current study, however, is limited in scope with a focus on the application of thermoplastic composites to aircraft structures. Further, the study does not provide a comprehensive assessment of the available literature but rather offers an overview of past and present research being conducted in the field of thermoplastic composites. The information provided may be used to identify gaps and help guide future research and development. In this report, the opportunities offered by the use of thermoplastic composites in general and challenges encountered in particular are presented first. Second, an overview of thermoplastic materials is presented, manufacturing methods are discussed, and new methods for fastener-less assembly such as welding are introduced. Third, tests that have been performed on different levels of the building block, ranging from coupon to structural level, are presented. In particular, fracture toughness results for different thermoplastic composite materials are used to demonstrate their performance compared to state-of-the-art thermoset composites. Fourth, several examples of analyses are discussed including process modelling and progressive damage analysis (PDA). An extensive list of references and appendices with tables support the narrative. Lastly, a brief summary with outlook and recommendations for future research is provided.

composites↗
NASA NTRSDate not supplied

Manufacturing Trials of Integrally Stiffened Panels for Flight Applications

Reduced weight is an ever-increasing demand within the aerospace industry, and non-traditional means of achieving this demand are increasingly being considered. There is also a desire to reduce the manual labor involved in attaching thousands of parts together with rivets and other fasteners. Using advanced stiffener concepts can avoid the weight of fasteners and streamline fabrication by reducing the part count, while still providing the mandatory strength requirements for flight certification. Described herein is a set of manufacturing trials that were completed at NASA Langley Research Center to investigate the feasibility of various integrated stiffener concepts. Fully composite stiffeners that can be integrated or attached by other means, either through bonding or interleaving them within the skin, can remove the fasteners and still maintain a rapid manufacturing rate. This study contains these advanced stiffener concepts, and the lessons learned and design iterations that resulted from the series of manufacturing trials. Each set of trials was completed with an end goal of using tow-steered integral stiffeners for flight structure in composite aircraft wings.

Composite↗
NASA NTRSDate not supplied

Closed-Loop Control of Laser Surface Treatment via Laser Induced Breakdown Spectroscopy

Current composite manufacturing rates need to be improved to meet the projected demand of on-demand mobility (ODM) and commercial aircraft transports. Some processes in the composite manufacturing chain require touch labor such as manual sanding of surfaces prior to bonding and installing thousands of mechanical fasteners in bonded primary structures to achieve Federal Aviation Administration (FAA) certification. The consequences are insufficient repeatability in bond quality resulting in increased manufacturing time. The FAA has indicated that robust process control is one potential means of certifying bondlines in primary structure. This work describes an integrated closed-loop control system between a laser machining system and laser induced breakdown spectroscopy (LIBS) instrumentation as a means of assuring bond performance and achieving certified composite bondlines. Preliminary results from in-situ treatment and inspection are presented. Results indicate that LIBS inspection and laser treatment can be conducted simultaneously to achieve high quality, reliable adhesive bonds.

Rodolfo Ledesma↗
NASA NTRSDate not supplied

Closed-Loop Control of Laser Surface Treatment via Laser Induced Breakdown Spectroscopy

Current composite manufacturing rates need to be improved to meet the projected demand of on-demand mobility (ODM) and commercial aircraft transports. Some processes in the composite manufacturing chain require touch labor such as manual sanding of surfaces prior to bonding and installing thousands of mechanical fasteners in bonded primary structures to achieve Federal Aviation Administration (FAA) certification. The consequences are insufficient repeatability in bond quality resulting in increased manufacturing time. The FAA has indicated that robust process control is one potential means of certifying bondlines in primary structure. This work describes an integrated closed-loop control system between a laser machining system and laser induced breakdown spectroscopy (LIBS) instrumentation as a means of assuring bond performance and achieving certified composite bondlines. Preliminary results from in-situ treatment and inspection are presented. Results indicate that LIBS inspection and laser treatment can be conducted simultaneously to achieve high quality, reliable adhesive bonds.

Rodolfo Ledesma↗
NASA NTRS2021

Machine Learning to Predict Joint Performance in Epoxy Composites Based on Process Parameters

Polymer matrix composites are gaining popularity in the aerospace industry due to their high specific strength, fatigue properties, and processability. However, based on current FAA certification guidelines, manufacturers utilizing current state-of-the-art composites made with adhesive bonds commonly install redundant fasteners to guarantee the strength of these adhesively bonded composite parts. The number of fasteners in a single-aisle commercial transport aircraft is typically on the order of 105, which reduces manufacturing rate, increases cost tremendously, and reduces the advantage of the specific strength composites provide. Due to this, the Adhesive Free Bonding of Composites (AERoBOND) project at NASA Langley Research Center has developed a novel assembly process to manufacture complex composite parts without the use of adhesives and fasteners. However, optimization of the process is currently challenging due to the complex and interdependent process parameters. To assist with the optimization, four machine learning algorithms utilizing gradient boosting decision trees were created to provide predictions for the mechanical and characterization properties of the composite parts. Approximately 200 random states from each algorithm were tested, and the models from each state were isolated and analyzed based on their accuracy, a validation process, and their feature importance. This analysis concluded that the models created from the machine learning algorithms could accelerate a parametric study for the AERoBOND process by rapidly optimizing process parameters to achieve desired performance characteristics.

Brennen Michael Middleton↗
NASA NTRSDate not supplied

Machine Learning to Predict Joint Performance in Epoxy Composites Based on Process Parameters

Polymer matrix composites are gaining popularity in the aerospace industry due to their high specific strength, fatigue properties, and processability. However, based on current FAA certification guidelines, manufacturers utilizing current state-of-the art composites made with adhesive bonds commonly install redundant fasteners to guarantee the strength of these adhesively bonded composite parts.1,2 The number of fasteners in a single-aisle commercial transport aircraft is typically on the order of 105, which reduces manufacturing rate, increases cost tremendously, and reduces the advantage of the specific strength composites provide. Due to this, the Adhesive Free Bonding of Composites (AERoBOND) project at NASA Langley Research Center has developed a novel assembly process to manufacture complex composite parts without the use of adhesives and fasteners.1 However, optimization of the process is currently challenging due to the complex and interdependent process parameters. To assist with the optimization, four machine learning algorithms utilizing gradient boosting decision trees were created to provide predictions for the mechanical and characterization properties of the composite parts. Approximately 200 random states from each algorithm were tested, and the models from each state were isolated and analyzed based on their accuracy, a validation process, and their feature importance. This analysis concluded that the models created from the machine learning algorithms could accelerate a parametric study for the AERoBOND process by rapidly optimizing process parameters to achieve desired performance characteristics.

Brennen M Middleton↗
NASA NTRSDate not supplied

Finite Element Analysis Validation for Stitched, Blade-Stiffened Aerospace Structures

Increased performance and manufacturing rates for aircraft or spacecraft structures may be achieved using stitched and resin infused composite structures. In order to carry out design and analysis of stitched composites, 2-dimensional (2-D) and 3-dimensional (3-D) modeling approaches for stitched and non-stitched carbon fiber vacuum-infused parts were developed. These analysis approaches will be compared with data from previous test specimens tested at the NASA Langley Research Center (LaRC) under tension and bending load conditions. The preliminary results presented herein for the 2-D and 3-D models capture the strain patterns observed in digital image correlation (DIC) data for stitched, blade-stiffened specimens tested in either tension or bending. The analysis method study presented for these specimens is part of a larger analysis development effort planned for stitched composites, with the modeling practices developed here contributing to those that may be applied to a new set of blade- stiffened test specimens that are currently being manufactured for testing as well as the design of a blade stringer pull-off test. These future tests are expected to provide opportunities to validate the developed modeling approaches for predictive purposes, and to provide opportunities for further refinement of the modeling approaches.

HiCAM↗
NASA NTRS1979

The dual-momentum control device for large space systems

The dual-momentum control device being studied for large spacecraft consists of two counter-rotating rings, each designated as an annular momentum control device (AMCD). For large rings, flexibility is appreciable and it becomes necessary to account for the distributed nature of the rings in the design of the magnetic bearing controllers. Also, ring behavior is unpredictably sensitive to ring temperature, spin rate, manufacturing imperfections, and other variables. For that reason, an adaptive control system is being sought for ring stabilization and maneuvering. This paper details an original adaptive control methodology for distributed parameter systems and illustrates this technique by application to AMCD stabilization.

Montgomery, R. C.↗
NASA NTRS1979

Space shuttle solid rocket booster cost-per-flight analysis technique

A cost per flight computer model is described which considers: traffic model, component attrition, hardware useful life, turnaround time for refurbishment, manufacturing rates, learning curves on the time to perform tasks, cost improvement curves on quantity hardware buys, inflation, spares philosophy, long lead, hardware funding requirements, and other logistics and scheduling constraints. Additional uses of the model include assessing the cost per flight impact of changing major space shuttle program parameters and searching for opportunities to make cost effective management decisions.

Forney, J. A.↗
NASA NTRS1979

A distributed system adaptive control strategy

One attitude control device being studied for large spacecraft consists of two counter-rotating rings, each designated as an annular momentum control device (AMCD), that are attached to a spacecraft using several magnetic bearings distributed along the circumference of the rings. For large spacecraft large rings are desirable. Unfortunately, for large rings flexibility is appreciable and it becomes necessary to account for the distributed nature of the rings in the design of the magnetic bearing controllers. Also ring behavior is unpredictably sensitive to ring temperature, spin rate, manufacturing imperfections, and other variables. For that reason a distributed adaptive microcomputer-based control system is being sought for ring stabilization and maneuvering. An original adaptive-control methodology for distributed-parameter systems is detailed and application to spinning ring, i.e., AMCD, stabilization is used as an illustration. The proposed methodology, presented as a step-by-step procedure, combines a lumped-parameter expansion description of distributed parameter systems with a fundamental simultaneous identification and control strategy. Simulations are presented providing preliminary evidence of the capabilities of the proposed procedure.

Johnson, C. R., Jr.↗
NASA NTRS1981

Adaptive control system for large annular momentum control device

A dual momentum vector control concept, consisting of two counterrotating rings (each designated as an annular momentum control device), was studied for pointing and slewing control of large spacecraft. In a disturbance free space environment, the concept provides for three axis pointing and slewing capabilities while requiring no expendables. The approach utilizes two large diameter counterrotating rings or wheels suspended magnetically in many race supports distributed around the antenna structure. When the magnets are energized, attracting the two wheels, the resulting gyroscopic torque produces a rate along the appropriate axis. Roll control is provided by alternating the radiative rotational velocity of the two wheels. Wheels with diameters of 500 to 800 m and with sufficient momentum storage capability require rims only a few centimeters thick. The wheels are extremely flexible; therefore, it is necessary to account for the distributed nature of the rings in the design of the bearing controllers. Also, ring behavior is unpredictably sensitive to ring temperature, spin rate, manufacturing imperfections, and other variables. An adaptive control system designed to handle these problems is described.

Montgomery, R. C.↗
NASA NTRS1987

A comparison of Stirling engines for use with a 25 kW dish-electric conversion system

Two designs for an advanced Stirling conversion system (ASCS) are described. The objective of the ASCS is to generate about 25 kW of electric power to an electric utility grid at an engine/alternator target cost of $300.00/kW at the manufacturing rate of 10,000 unit/yr. Both designs contain a free-piston Stirling engine (FPSE), a heat transport system, solar receiver, a means to generate electric power, the necessary auxiliaries, and a control system. The major differences between the two concepts are: one uses a 25 kWe single-piston FPSE which incorporates a linear alternator to directly convert the energy to electricity on the utility grid; and in the second design, electrical power is generated indirectly using a hydraulic output to a ground based hydraulic motor coupled to a rotating alternator. Diagrams of the two designs are presented.

Shaltens, Richard K.↗
NASA NTRS2004

Silicon Carbide Diodes Characterization at High Temperature and Comparison With Silicon Devices

Commercially available silicon carbide (SiC) Schottky diodes from different manufacturers rated at 200, 300, 600, and 1200 V, were electrically tested and characterized as a function of temperature up to 300 C. Electrical tests included both steady state and dynamic tests. Steady state tests produced forward and reverse I-V characteristic curves. Transient tests evaluated the switching performance of the diodes in either a hard-switched DC to DC buck converter or a half-bridge boost converter. For evaluation and comparison purposes, the same tests were performed with current state-of-the-art ultra fast silicon (Si) pn-junction diodes of similar ratings and also a Si Schottky diode. The comparisons made were forward voltage drop at rated current, reverse current at rated voltage, and turn-off peak reverse recovery current and reverse recovery time. In addition, efficiency measurements were taken for the buck DC to DC converter using both the SiC Schottky diodes and the Si pn-junction diodes at different temperatures and frequencies. The test results showed that at high temperature, the forward voltage drop for SiC Schottky diodes is higher than the forward drop of the ultra fast Si pn-junction diodes. As the temperature increased, the forward voltage drop of the SiC Schottky increased while for the ultra fast Si pn-junction diodes, the forward voltage drop decreased as temperature increased. For the elevated temperature steady state reverse voltage tests, the SiC Schottky diodes showed low leakage current at their rated voltage. Likewise, for the transient tests, the SiC Schottky diodes displayed low reverse recovery currents over the range of temperatures tested. Conversely, the Si pn-junction diodes showed increasing peak reverse current values and reverse recovery times with increasing temperature. Efficiency measurements in the DC to DC buck converter showed the advantage of the SiC Schottky diodes over the ultra fast Si pn-junction diodes, especially at the higher temperatures and higher frequencies.

Lebron-Velilla, Ramon C.↗
NASA NTRS2016

S&MA Internship to Support Orion and the European Service Module

As a University Space Research Association (USRA) intern for NASA Johnson Space Center (JSC) during the summer 2016 work term, I worked on three main projects for the Space Exploration Division (NC) of the Safety and Mission Assurance (S&MA) Directorate. I worked on all three projects concurrently. One of the projects involved facilitating the status and closure of technical actions that were created during European Service Module (ESM) safety reviews by the MPCV Safety & Engineering Review Panel (MSERP). The two main duties included accurately collecting and summarizing qualitative data, and communicating that information to the European Space Agency (ESA) and Airbus (ESA's prime contractor) in a clear, succinct and precise manner. This project also required that I create a report on the challenges and opportunities of international S&MA. With its heavy emphasis on soft skills, this project taught me how to communicate better, by showing me how to present and share information in an easy-to-read and understandable format, and by showing me how to cooperate with and culturally respect international partners on a technical project. The second project involved working with the Orion Thermal Protection System (TPS) Process Failure Modes and Effects Analysis (PFMEA) Working Group to create the first full version of the Orion TPS PFMEA. The Orion TPS PFMEA Working Group met twice a week to analyze the Avcoat block installation process for failure modes, the failure modes effects, and how such failure modes could be controlled. I was in charge of implementing changes that were discussed in meeting, but were not implemented real time. Another major task included creating a significant portion of the content alongside another team member outside the two weekly meetings. This project caused me to become knowledgeable about TPS, heatshields, space-rated manufacturing, and non-destructive evaluation (NDE). The project also helped me to become better at working with a small team and helped improved my technical communication skills. My main duty for the third project was creating a Safety Verification Tracking Log (SVTL) for the Orbital Maneuvering System Engine (OMS-E), and contacting subject matter experts to close Hazard Report (HR) control verifications. This project also required me to support other OMS-E safety process tasks, like monitoring OMS-E vibration testing for Quality Assurance (QA) purposes. This project helped me become even more proficient in Excel. Throughout the project, I gained knowledge about the OMS-E system and improved my understanding of pressure systems and propellant systems. In terms of education goals, this work term has affirmed my desire to take a few more space-related courses, like orbital mechanics, so that I can have a better understanding of human spaceflight and the industry surrounding it. However, the work term did not persuade me to pursue a master's degree. In terms of career goals, this work term has helped me clarify the direction I would like to head in the future. The perspective of three summer terms working for NASA in S&MA has allowed me to observe that most S&MA employees joined S&MA after working in other NASA directorates, such as Engineering or Flight Operations. It is my belief that it would be advantageous for both NASA and I for me to broaden my knowledge base and technical skill set by completing hands-on technical work on human spaceflight projects, and for me to integrate my safety experience directly into technical work in other directorates. The other significant advantage to this proposed situation is that if I were to eventually return to S&MA, I would be returning with a substantial set of hands-on technical experience and knowledge, which would be a significant resource for S&MA tasks and projects.

Hutcheson, Connor↗
NASA NTRSDate not supplied

Genesis Solar Wind Sample Curation Documentation

Introduction: A scientist with experience as a sample science analyst, provider of flight hardware for multiple missions, and senior engineer in an ISO 2000-rated manufacturing plant has described the timeline of key participants in any PI-led sample return mission, the breadth of the organizations involved [1,2], and, of interest to this meeting, choosing the types of data to preserve and issues of future data accessibility. This work broadens that perspective by giving similar lessons from Genesis sample curation point-of-view. Curation participation regarding data gathering was part of the mission review process from the beginning. Genesis’ story illustrates outcome of several choices about types of data to record and preserve. Precision analysis of solar wind atoms captured in pure, ultraclean substrates is the driving science goal; therefore, detailed documentation was captured from all mission and curation phases and from investigator laboratories because these processes affect the final analytical results [3]. Pre-flight: Design and fabrication of the spacecraft. Like many modern small sample return missions, Genesis was a tightly managed team integrated across science, engineering and curation. Communication across the team was excellent, and, for the most part, the hands-on engineering technicians understood the impacts of “small choices” they routinely make, and the eyes-on oversight of manufacturing processes by scientists was mindful of details. The payload was designed by the Jet Propulsion Laboratory and the spacecraft by Lockheed Martin. Solar wind collectors and instruments were fabricated by multiple vendors and laboratories. The main portion of the payload was assembled at JSC. Fabrication procedures and contamination-control data (with witness coupons) were stored primarily at JSC. The original composition, dimensions and configuration of components, results of thermal testing, etc. are still needed for interpretation of analytical data. At times, these must be estimated from secondary information acquired pre-flight. Moreover, some files (e.g., original 3-D models and early Powerpoint) cannot be opened using software. Archived curation data includes 2-D drawings, material usage lists, QA documentation and analyses of consumables used during fabrication. Important chemical information still resides in archived hardware, paints and lubricants, material coupons, cleaning coupons, environmental witness plates and reference materials from manufacturing facilities. Purity and cleanliness of collector substrates. Semi-conductor vendors provided surface cleanliness data and some purity data. Purity for specific elements of interest was verified by science team members in their laboratories [4]. Curation archived procurement and shipping records, analysis reports, and non-proprietary fabrication data. A physical archive of flight collector reference materials is maintained for future use so additional data can be collected as analytical techniques improve. These are of increased value due to the hard landing upon re-entry. Cleaning and cleanliness assessments of flight hardware. Cleaning of the science canister payload was performed at JSC in a dedicated ISO 4 cleanroom using ultrapure water (UPW). The cleanliness of this UPW was monitored throughout processing. The archive for the clean lab also includes airborne particle counts, airborne molecular and inorganic contamination measurements as well as cleanroom construction material coupons and witness coupons. Hardware cleanliness was assessed by particle counts in rinse water batches. This information is recorded in batch cleaning forms and logbooks, and are, perhaps, of decreased value due to the hard landing. Post-flight: Curation-generated data. The curation handling history of each Genesis sample is documented in a typical astromaterials sample database which captures sample location, physical description and characterization data. Samples have a “shelf life”. Crucial to the preservation of samples is ongoing documentation of the sample environment, initially under curatorial control but is now a separate facility function with requires coordination. PI-generated data. Data on sample characterization and cleaning techniques continues to be generated by sample users [5]. These are often captured in LPSC abstracts, but these “engineering” results often are not publishable as stand-alone papers. We are actively looking for ways to make this information more accessible to users. Ion implants into samples have aided science return and can be shared among investigators. These (and similar) materials should be added to the curatorial collection with appropriate process and characterization data generated externally. Summary: Complete data archives for returned astromaterial samples must be broad in types and formats, and inclusive of environmental monitoring.

Genesis↗
NASA NTRSDate not supplied

Spin Formability of High-Strength Aluminum Alloys for Aerospace Applications

Near-net-shape fabrication of launch vehicle tanks and aircraft fuselages is critical for meeting the growing demand for unitized structures in the aerospace industry. Cryogenic tank manufacturing relies on multi-piece construction requiring hundreds of meters of welds that increase both structural weight and inspection time. Currently, fuselages have an immense part count requiring tens of thousands of rivets and long assembly time. NASA is pursuing spin and flow forming technology for manufacturing such structures with minimal assembly. These processes enable domes and stiffened barrels to be fabricated using single-piece construction, offering significant manufacturing rate benefits over conventional methods. However, Al alloys with sufficient formability, such as Al 6061, tend to have insufficient strength for aerospace structural applications. In contrast, alloys with higher strength, such as Al 2139 and Al 2050, exhibit insufficient formability during ambient temperature forming. This study investigates the spin formability of competitive 5xxx and 2xxx series Al alloys, identifies defects impeding formability, and sheds light on future processing routes for successful forming.

Aluminum↗
NASA NTRSDate not supplied

Designed Adhesion - Exploring the Unknown

The ability to design materials and substrates for adhesive properties is highly desirable for the aeronautics industry. This includes the ability to design substrates that have low ice adhesion to increase efficiency of the fleet, as well as the ability to design structural adhesives to improve manufacturing rate. The Designed Adhesion group was chosen during the 2023 Wicked Wild Pitch Event sponsored by CAS and is currently in the discovery phase.

Design↗