SEARCH · Search NASA

Results for “assembly processes”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 433 records · Page 24

All sources NASA NTRS DOE OSTI

NASA NTRSDate not supplied

Maturation of In-space Welding in Reduced Gravity and Reduced Pressure Environments Through Progression to Suborbital Flight Experiments

Development of in-space welding (ISW) is a key and enabling manufacturing technology as welding is currently involved in producing approximately 90% of durable goods, and this trend is expected to hold for in-space manufacturing as well. ISW is critical to a sustainable space economy. To mature in-space welding, numerous gaps must be closed since NASA has not made a weld in space in 50 years. Advancing laser beam welding (LBW) towards a suborbital flight demonstration will help mature the process for in-space assembly & manufacturing (ISAM) through demonstration in relevant environments and achieving technology readiness milestones. LBW technologies and science improved by this work will benefit in-space manufacturing, long-term sustainability of space structures & operations, and the overall space economy. Ground-based welding of aerospace hardware requires an Edisonian approach to qualify a welding process; however, this approach is infeasible for ISW qualification due to mass, volume, logistic, and cost challenges inherent to the space environment. To address this challenge, we are conducting ground and suborbital tests with partners performing parabolic flights to gather data on LBW processes and infuse them into NASA & partner missions. This progression from ground to flight experiments will elucidate relevant physics during LBW: 1) reduced gravity, 2) reduced pressure, and 3) extreme temperature. Data from post-flight evaluation and in situ instrumentation will feed integrated computational materials engineering (ICME) tools to reduce the burden of ISW infusion by establishing a link between space and terrestrial environments, ultimately accelerating the qualification of LBW in space.

in-space welding↗

NASA NTRS1995

Backward assembly planning with DFA analysis

An assembly planning system that operates based on a recursive decomposition of assembly into subassemblies, and analyzes assembly cost in terms of stability, directionality, and manipulability to guide the generation of preferred assembly plans is presented. The planning in this system incorporates the special processes, such as cleaning, testing, labeling, etc. that must occur during the assembly, and handles nonreversible as well as reversible assembly tasks through backward assembly planning. In order to increase the planning efficiency, the system avoids the analysis of decompositions that do not correspond to feasible assembly tasks. This is achieved by grouping and merging those parts that can not be decomposable at the current stage of backward assembly planning due to the requirement of special processes and the constraint of interconnection feasibility. The invention includes methods of evaluating assembly cost in terms of the number of fixtures (or holding devices) and reorientations required for assembly, through the analysis of stability, directionality, and manipulability. All these factors are used in defining cost and heuristic functions for an AO* search for an optimal plan.

Lee, Sukhan↗

NASA NTRS1980

A study of poultry processing plant noise characteristics and potential noise control techniques

The noise environment in a typical poultry processing plant was characterized by developing noise contours for two representative plants: Central Soya of Athens, Inc., Athens, Georgia, and Tip Top Poultry, Inc., Marietta, Georgia. Contour information was restricted to the evisceration are of both plants because nearly 60 percent of all process employees are stationed in this area during a normal work shift. Both plant evisceration areas were composed of tile walls, sheet metal ceilings, and concrete floors. Processing was performed in an assembly-line fashion in which the birds travel through the area on overhead shackles while personnel remain at fixed stations. Processing machinery was present throughout the area. In general, the poultry processing noise problem is the result of loud sources and reflective surfaces. Within the evisceration area, it can be concluded that only a few major sources (lung guns, a chiller component, and hock cutters) are responsible for essentially all direct and reverberant sound pressure levels currently observed during normal operations. Consequently, any effort to reduce the noise problem must first address the sound power output of these sources and/or the absorptive qualitities of the room.

Wyvill, J. C.↗

NASA NTRS1991

Lessons learned for composite structures

Lessons learned for composite structures are presented in three technology areas: materials, manufacturing, and design. In addition, future challenges for composite structures are presented. Composite materials have long gestation periods from the developmental stage to fully matured production status. Many examples exist of unsuccessful attempts to accelerate this gestation period. Experience has shown that technology transition of a new material system to fully matured production status is time consuming, involves risk, is expensive and should not be undertaken lightly. The future challenges for composite materials require an intensification of the science based approach to material development, extension of the vendor/customer interaction process to include all engineering disciplines of the end user, reduced material costs because they are a significant factor in overall part cost, and improved batch-to-batch pre-preg physical property control. Historical manufacturing lessons learned are presented using current in-service production structure as examples. Most producibility problems for these structures can be traced to their sequential engineering design. This caused an excessive emphasis on design-to-weight and schedule at the expense of design-to-cost. This resulted in expensive performance originated designs, which required costly tooling and led to non-producible parts. Historically these problems have been allowed to persist throughout the production run. The current/future approach for the production of affordable composite structures mandates concurrent engineering design where equal emphasis is placed on product and process design. Design for simplified assembly is also emphasized, since assembly costs account for a major portion of total airframe costs. The future challenge for composite manufacturing is, therefore, to utilize concurrent engineering in conjunction with automated manufacturing techniques to build affordable composite structures. Composite design experience has shown that significant weight savings have been achieved, outstanding fatigue and corrosion resistance have been demonstrated, and in-service performance has been very successful. Currently no structural design show stoppers exist for composite structures. A major lesson learned is that the full scale static test is the key test for composites, since it is the primary structural 'hot spot' indicator. The major durability issue is supportability of thin skinned structure. Impact damage has been identified as the most significant issue for the damage tolerance control of composite structures. However, delaminations induced during assembly operations have demonstrated a significant nuisance value. The future challenges for composite structures are threefold. Firstly, composite airframe weight fraction should increase to 60 percent. At the same time, the cost of composite structures must be reduced by 50 percent to attain the goal of affordability. To support these challenges it is essential to develop lower cost materials and processes.

Whitehead, R. S.↗

NASA NTRS2005

STS-114: Discovery Tanking Operations for Launch

Jessica Rye from NASA Public Affairs is the narrator for the tanking operations for the launch of the Space Shuttle Discovery. She presents a video of the arrival and processing of the new external tank at the Kennedy Space Center. The external tank is also shown entering the Vehicle Assembly Building (VAB). The external tank underwent new processing resulting from its redesign including inspection of the bipod heater and the external separation camera. The changes to the external tank include: 1) Electric heaters to protect from icing; and 2) Liquid Oxygen feed line bellows to carry fuel from the external tank to the Orbiter. Footage of the external tank processing facility at NASA's Michoud Assembly Facility in New Orleans, La. prior to its arrival at Kennedy Space Center is shown and a video of the three key modifications to the external tank including the bipod, flange and bellows are shown.

Source record↗

NASA NTRS2008

Opto-Mechanics of the Constellation-X SXT Mirrors: Challenges in Mounting and Assembling the Mirror Segments

The Constellation-X Spectroscopy X-Ray Telescopes consists of segmented glass mirrors with an axial length of 200 mm, a width of up to 400 mm, and a thickness of 0.4 mm. To meet the requirement of less than 15 arc-second half-power diameter with the small thickness and relatively large size is a tremendous challenge in opto-mechanics. How shall we limit distortion of the mirrors due to gravity in ground tests, that arises from thermal stress, and that occurs in the process of mounting, affixing and assembling of these mirrors? In this paper, we will describe our current opto-mechanical approach to these problems. We will discuss, in particular, the approach and experiment where the mirrors are mounted vertically by first suspending it at two points.

Chan, Kai-Wing↗

NASA NTRS1980

From inanimate matter to living systems

Since the early part of this century, the Genesis account of the origin and evolution of life has been explained as an extrapolation of astronomical and geochemical processes. The essence of the answer to date is a protoreproductive protocell of much biochemical and cytophysical competance. The processes of its origin, molecular ordering, and its functions are described. A crucial understanding is that of the nonrandomness of evolutionary processes at all stages (with perhaps a minor statistical component). In this way, evolution conflicts with statistical randomness; the latter is a favorite assumption of both scientific and creationistic critics of the proteinoid theory. The principle contribution of the proteinoid theory to the understanding of general biology is to particularize the view that evolutionary direction is rooted in the shapes of molecules, in stereochemistry. After molecules of the right kind first assembled to protocells, life in its various stages of evolution was an inevitable consequence. It is molecules that continue to assemble as part of living process and, in the role of enzymes, continue to direct life cycle of the cell.

Fox, S. W.↗

NASA NTRS1991

Software Engineering Laboratory (SEL) cleanroom process model

The Software Engineering Laboratory (SEL) cleanroom process model is described. The term 'cleanroom' originates in the integrated circuit (IC) production process, where IC's are assembled in dust free 'clean rooms' to prevent the destructive effects of dust. When applying the clean room methodology to the development of software systems, the primary focus is on software defect prevention rather than defect removal. The model is based on data and analysis from previous cleanroom efforts within the SEL and is tailored to serve as a guideline in applying the methodology to future production software efforts. The phases that are part of the process model life cycle from the delivery of requirements to the start of acceptance testing are described. For each defined phase, a set of specific activities is discussed, and the appropriate data flow is described. Pertinent managerial issues, key similarities and differences between the SEL's cleanroom process model and the standard development approach used on SEL projects, and significant lessons learned from prior cleanroom projects are presented. It is intended that the process model described here will be further tailored as additional SEL cleanroom projects are analyzed.

Green, Scott↗

NASA NTRS2006

Thermal Cycle Reliability of PBGA/CCGA 717 I/Os

Status of thermal cycle test results for a nonfunctional daisy-chained peripheral ceramic column grid array (CCGA) and its plastic ball grid array (PBGA) version. both having 560 I/Os. were presented in last year's conference. Test results included environmental data for three different thermal cycle regimes (-55 C/125 C, -55 C/100 C, and -50 C /75 C). Update information on these - especially failure type for assemblies with high and low solder volumes-were presented. The thermal cycle test procedure followed those recommended IPC-9701 for tin-lead solder joint assemblies. Revision A of this specification covers guideline thermal cycle requirements for Pb-free solder joints. Some background information discussed during release of this specification with its current guideline recommendations were also presented. In a recent reliability investigation a fully populated CCGA with 717 I/Os was also considered for assembly reliability. evaluation. The functional package is a field-programmable gate array that has much higher processing power than its previous version. This new package is smaller in dimension, has no interposer, and has a thinner column wrapped with copper for reliability improvement. This paper will also present thermal cycle test results for this package assembly and its plastic version with 728 I/Os. both of which were exposed to three different cycle regimes. Two cycle profiles were those specified by IPC- 9701A for tin-lead, i.e. -55 to 100 C and -55 to 125 C and one was a cycle profile specified by Mil-Std-883, i.e.. -65 C/150 C which is generally used for ceramic hybrid packages. Per IPC-9701 A, test vehicles were built using daisy chain packages and were continuously monitored. The effects of many process and assembly variables-including corner staking commonly used for improving resistance to mechanical loading such as drop and vibration loads--were also considered as part of the test matrix. Optical photomicrographs were taken at various thermal cycle intervals to document damage progress and behavior. Representative samples of these along with cross-sectional photomicrographs at higher magnification taken by scanning electron microscopy (SEM) to determine crack propagation and failure analyses for packages are also presented.

staking↗

NASA NTRS1996

Attitude Determination Improvements for GOES

In this paper, a summary of the basic simulation parameters and results of a new study for the Geostationary Operational Environmental Satellite (GOES) is shown. The study for GOES involves the simulation of minor modifications to the current spacecraft, so that the relative performance of these modifications can be analyzed. The first modification studies requires the placement of a baseline inertial reference unit, such as the Dry Rotor Inertial Reference Unit or the Hemispherical Resonator Gyro onto the spacecraft. The imager/sounder assembly is currently used to obtain landmark and/or star observations in order to compensate for spacecraft motion and external disturbances through ground processing. The study uses the imager/sounder assembly as another attitude sensor for on-board attitude determination. Also the addition of star trackers is used to provide precise attitude knowledge.

Crassidis, John L.↗

NASA NTRSDate not supplied

A Two-Stage Regenerable Filter for Collection and Disposal of Carbon Fines

NASA is investigating the use of the Plasma Pyrolysis Assembly (PPA), which is a methane post-processing technology with the goal to recover hydrogen from the Carbon dioxide Reduction Assembly (CRA) currently onboard the International Space Station (ISS). The PPA can theoretically recover 75% of hydrogen from methane produced by the CRA. During methane processing the PPA creates roughly 40 mg/hr of carbon dust when operating at 4 crew member levels. The unwanted fines need to be removed from the stream to prevent any clogging of downstream components. The Regenerable Carbon Filter (RCF) was designed by Umpqua Research Company to address the carbon particulate created in the PPA. The RCF includes two stages. The first is an electrostatic precipitator designed to collect ultrafine particles. The second is a low pressure drop physical filter. Both filters are made of heat tolerant materials to allow regeneration of the filtration capacity by O2 oxidation of captured carbon. This paper will discuss the RCF hardware and test plans.

Filtration, Environmental Control, Life Support↗

NASA NTRS1986

Space Station ground processing

The architecture of the Station, the system requirements, and the operational capabilities for ground and flight operations are described. The proposed Space Station design is dual keel and the components of the Station are listed. The initial ground processing activities are to reflect the on-orbit assembly sequence; the four phases of the assembly are examined. The planning and analysis for the ground processing of the Station with an emphasis on cost are discussed. The logistics resupply elements aspect of the ground processing sequence is considered. An example testing the capabilities of the ground processing sequence is presented. Diagrams of the Shuttle, its modules, and ground facilities and equipment are provided.

Scully, E. J.↗

NASA NTRS2009

Improved Assembly for Gas Shielding During Welding or Brazing

An improved assembly for inert-gas shielding of a metallic joint is designed to be useable during any of a variety of both laser-based and traditional welding and brazing processes. The basic purpose of this assembly or of a typical prior related assembly is to channel the flow of a chemically inert gas to a joint to prevent environmental contamination of the joint during the welding or brazing process and, if required, to accelerate cooling upon completion of the process.

Gradl, Paul↗

NASA NTRSDate not supplied

The Athena/X-IFU, from Detector Development to Scientific Feasibility Studies via Simulations

The investigation of the physical hot and energetic phenomena in the Universe will further improve our understanding of the assembly of the largest structures and massive halos of galaxies, and of the role of black holes in shaping the Universe as we see it. Spatially resolved X-ray high-resolution spectroscopy will be a crucial tool to achieve these scientific goals. The X-IFU instrument onboard the Athena observatory will provide us with these capabilities through the use of arrays of Transition edge microcalorimeters detectors. These superconducting devices will deliver the required exquisite spectral resolution needed to achieve the core science objectives, such as the characterization of turbulence and bulk motions in the hot gaseous atmospheres of groups and clusters of galaxies in order to unveil the process of large scale structures assembly. I will present the Transition Edge Sensors principle, the status of the instrumental development for the X-IFU instrument, and discuss their performance in view of the scientific objectives of the Athena mission. I will further present the case of a feasibility study and optimisation of the observing strategy for the characterization of the internal dynamics of the intra-cluster medium, through the use of mock simulations of observations with the X-IFU instrument.

Sophie Beaumont↗

NASA NTRS2017

In-Space Assembly Capability Assessment for Potential Human Exploration and Science Applications

Human missions to Mars present several major challenges that must be overcome, including delivering multiple large mass and volume elements, keeping the crew safe and productive, meeting cost constraints, and ensuring a sustainable campaign. Traditional methods for executing human Mars missions minimize or eliminate in-space assembly, which provides a narrow range of options for addressing these challenges and limits the types of missions that can be performed. This paper discusses recent work to evaluate how the inclusion of in-space assembly in space mission architectural concepts could provide novel solutions to address these challenges by increasing operational flexibility, robustness, risk reduction, crew health and safety, and sustainability. A hierarchical framework is presented to characterize assembly strategies, assembly tasks, and the required capabilities to assemble mission systems in space. The framework is used to identify general mission system design considerations and assembly system characteristics by assembly strategy. These general approaches are then applied to identify potential in-space assembly applications to address each challenge. Through this process, several focus areas were identified where applications of in-space assembly could affect multiple challenges. Each focus area was developed to identify functions, potential assembly solutions and operations, key architectural trades, and potential considerations and implications of implementation. This paper helps to identify key areas to investigate were potentially significant gains in addressing the challenges with human missions to Mars may be realized, and creates a foundation on which to further develop and analyze in-space assembly concepts and assembly-based architectures.

Jefferies, Sharon A.↗

NASA NTRS2016

Selection of a Brine Processor Technology for NASA Manned Missions

The current ISS Water Recovery System (WRS) reclaims water from crew urine, humidity condensate, and Sabatier product water. Urine is initially processed by the Urine Processor Assembly (UPA) which recovers 75% of the urine as distillate. The remainder of the water is present in the waste brine which is currently disposed of as trash on ISS. For future missions this additional water must be reclaimed due to the significant resupply penalty for missions beyond Low Earth Orbit (LEO). NASA has pursued various technology development programs for a brine processor in the past several years. This effort has culminated in a technology down-select to identify the optimum technology for future manned missions. The technology selection is based on various criteria, including mass, power, reliability, maintainability, and safety. Beginning in 2016 the selected technology will be transitioned to a flight hardware program for demonstration on ISS. This paper summarizes the technology selection process, the competing technologies, and the rationale for the technology selected for future manned missions.

Carter, Donald L.↗

NASA NTRS2004

Stress, Cognition, and Human Performance: A Literature Review and Conceptual Framework

The following literature review addresses the effects of various stressors on cognition. While attempting to be as inclusive as possible, the review focuses its examination on the relationships between cognitive appraisal, attention, memory, and stress as they relate to information processing and human performance. The review begins with an overview of constructs and theoretical perspectives followed by an examination of effects across attention, memory, perceptual-motor functions, judgment and decision making, putative stressors such as workload, thermals, noise, and fatigue and closes with a discussion of moderating variables and related topics. In summation of the review, a conceptual framework for cognitive process under stress has been assembled. As one might imagine, the research literature that addresses stress, theories governing its effects on human performance, and experimental evidence that supports these notions is large and diverse. In attempting to organize and synthesize this body of work, I was guided by several earlier efforts (Bourne & Yaroush, 2003; Driskell, Mullen, Johnson, Hughes, & Batchelor, 1992; Driskell & Salas, 1996; Haridcock & Desmond, 2001; Stokes & Kite, 1994). These authors should be credited with accomplishing the monumental task of providing focused reviews in this area and their collective efforts laid the foundation for this present review. Similarly, the format of this review has been designed in accordance with these previous exemplars. However, each of these previous efforts either simply reported general findings, without sufficient experimental illustration, or narrowed their scope of investigation to the extent that the breadth of such findings remained hidden from the reader. Moreover, none of these examinations yielded an architecture that adequately describes or explains the inter-relations between information processing elements under stress conditions.

Stress↗

NASA NTRS2010

Hydrogen peroxide catalytic decomposition

Nitric oxide in a gaseous stream is converted to nitrogen dioxide using oxidizing species generated through the use of concentrated hydrogen peroxide fed as a monopropellant into a catalyzed thruster assembly. The hydrogen peroxide is preferably stored at stable concentration levels, i.e., approximately 50%-70% by volume, and may be increased in concentration in a continuous process preceding decomposition in the thruster assembly. The exhaust of the thruster assembly, rich in hydroxyl and/or hydroperoxy radicals, may be fed into a stream containing oxidizable components, such as nitric oxide, to facilitate their oxidation.

Parrish, Clyde F.↗