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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.

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NASA NTRS1990

Conservative buffering of approximate nonlinear constraints

In engineering design practice behavior is usually predicted based on some known nominal design. However, when the design is fabricated it will differ from the nominal design because of manufacturing tolerances. In order to generate nominal designs that will still satisfy behavior constraints in the presence of manufacturing tolerances, engineers resort to the use of safety factors, over and above those introduced to account for other uncertainties (e.g., in load conditions, material properties, analysis modeling). The accurate selection of the values of these manufacturing tolerances safety factors is dependent on the capability of the engineer to determine the sensitivity of the critical constraints to changes in the design variables. This process usually leads to overly conservative designs. The task of choosing safety factors is much more difficult in structural synthesis because: (1) it is not known which constraints will be active at the final design, (2) as the design changes during the synthesis process the sensitivities of the constraints with respect to the design variables also change, and (3) the imposition of the safety factors themselves may change the set of critical constraints. These difficulties can be overcome with the approximation concepts approach to structural synthesis by buffering the approximate constraints with quantities that are related to the design variable tolerances and the accurate sensitivities of the constraints with respect to the design variable. Designs generated by this approach tend to be feasible but not overly conservative.

Thomas, H. L.↗

NASA NTRS1999

SPARCLE Optical System Design and Operational Characteristics

The SPAce Readiness Coherent Lidar Experiment (SPARCLE) is the first demonstration of a coherent Doppler wind lidar in space. SPARCLE will be flown aboard a space shuttle In the middle part of 2001 as a stepping stone towards the development and deployment of a long-life-time operational instrument in the later part of next decade. SPARCLE is an ambitious project that is intended to evaluate the suitability of coherent lidar for wind measurements, demonstrate the maturity of the technology for space application, and provide a useable data set for model development and validation. This paper describes the SPARCLE's optical system design, fabrication methods, assembly and alignment techniques, and its anticipated operational characteristics. Coherent detection is highly sensitive to aberrations in the signal phase front, and to relative alignment between the signal and the local oscillator beams. Consequently, the performance of coherent lidars is usually limited by the optical quality of the transmitter/receiver optical system. For SPARCLE having a relatively large aperture (25 cm) and a very long operating range (400 km), compared to the previously developed 2-micron coherent lidars, the optical performance requirements are even more stringent. In addition with stringent performance requirements, the physical and environment constraints associated with this instrument further challenge the limit of optical fabrication technologies.

Amzajerdian, Farzin↗

NASA NTRS1979

Space fabrication demonstration system, technical volume

The automatic beam builder ABB was developed, fabricated, and demonstrated within the established contract cost and schedule constraints. The ABB demonstrated the feasibility of: producing lightweight beams automatically within the required rate of 1 to 5 ft of completed beam per minute and producing structurally sound beams with axial design load of 5538 N based on the Grumman photovoltaic satellite solar power system design reference structure.

Source record↗

NASA NTRS1982

Development of an LSI maximum-likelihood convolutional decoder for advanced forward error correction capability on the NASA 30/20 GHz program

The particular coding option identified as providing the best level of coding gain performance in an LSI-efficient implementation was the optimal constraint length five, rate one-half convolutional code. To determine the specific set of design parameters which optimally matches this decoder to the LSI constraints, a breadboard MCD (maximum-likelihood convolutional decoder) was fabricated and used to generate detailed performance trade-off data. The extensive performance testing data gathered during this design tradeoff study are summarized, and the functional and physical MCD chip characteristics are presented.

Clark, R. T.↗

NASA NTRS1980

Economical space power systems

A commercial approach to design and fabrication of an economical space power system is investigated. Cost projections are based on a 2 kW space power system conceptual design taking into consideration the capability for serviceability, constraints of operation in space, and commercial production engineering approaches. A breakdown of the system design, documentation, fabrication, and reliability and quality assurance estimated costs are detailed.

Burkholder, J. H.↗

NASA NTRS1978

Analysis and assessment of film materials and associated manufacturing processes for a solar sail

Candidate resin manufacturers and film producers were surveyed to determine the availability of key materials and to establish the capabilities of fabricators to prepare ultrathin films of these materials within the capacity/cost/time constraints of the Halley program. Infrared spectra of three candidate samples were obtained by pressing each sample against an internal reflection crystal with the polymer sandwiched between the crystal and the metal backing. The sample size was such that less than one-fourth of the surface of the crystal was covered with the sample. This resulted in weak spectra requiring a six-fold expansion. Internal reflection spectra of the three samples were obtained using both a KRS-5 and a Ge internal reflection crystal. Subtracted infrared spectra of the three samples are presented.

Bradbury, E. J.↗

NASA NTRS1978

Spacelab development and its operational verification

This paper gives a brief status report on the current Spacelab program and describes how the results of ground and flight tests will be combined to provide the operational verification of the system. For the on-going project, data on design, testing and fabrication plans are presented. In particular, recent changes to meet the constraints of a 'build-to-cost' project are described. In the operational verification of Spacelab, ground and flight tests which ESA and NASA will perform are addressed. The installation of test instrumentation and the performance of integrated tests will be accomplished in the US. Experiments for the first flight will be integrated into Spacelab racks and pallets and simulated mission tests performed. On-orbit, system thermal surveys are planned and stress data will be obtained during launch and re-entry.

Bignier, M.↗

NASA NTRS2002

The X-ray Mirrors for the Astro-E2 Mission

The X-Ray telescopes (XRT) for the US/Japan collaborative mission Astro-E2 will be of the same basic design as those built for the original Astro-E mission which failed to reach orbit in Feb. 2000. The NASA/GSFC X-ray Astrophysics Branch will again provide the five lightweight, broad-band mirrors for the mission. X-ray calibrations of the mirrors delivered for the original Astro-E instrument showed spatial resolutions characterized by Half-Power Diameters (HPD) in the range of 1.8 - 2.2 minutes of arc, essentially independent of photon energy in the soft X-ray band. For the mission Astro-E2, both funding constraints and management decisions drastically limit any design modifications, so reflector fabrication and assembly procedures have remained largely unchanged. Nevertheless, in view of the importance in scientific return of attaining even a modest improvement in the spatial resolution of these mirrors, we have carefully considered the various sources of spatial error and, whenever possible, incorporated promising modifications. In this paper, we discuss our current understanding of the various error components as well as the small changes we have been able to implement.

Chan, Kai-Wing↗

NASA NTRS2007

Low Velocity Airdrop Tests of an X-38 Backup Parachute Design

The NASA Johnson Space Center's X-38 program designed a new backup parachute system to recover the 25,000 lb X-38 prototype for the Crew Return Vehicle spacecraft. Due to weight and cost constraints, the main backup parachute design incorporated rapid and low cost fabrication techniques using off-the-shelf materials. Near the vent, the canopy was constructed of continuous ribbons, to provide more damage tolerance. The remainder of the canopy was a constructed with a continuous ringslot design. After cancellation of the X-38 program, the parachute design was resized, built, and drop tested for Natick Soldiers Center's Low Velocity Air Drop (LVAD) program to deliver cargo loads up to 22,000 lbs from altitudes as low as 500 feet above the ground. Drop tests results showed that the 500-foot LVAD parachute deployment conditions cause severe skirt inversion and inflation problems for large parachutes. The bag strip occurred at a high angle of attack, causing skirt inversion before the parachute could inflate. The addition of a short reefing line prevented the skirt inversion. Using a lower porosity in the vent area, than is normally used in large parachutes, improved inflation. The drop testing demonstrated that the parachute design could be refined to meet the requirements for the 500-foot LVAD mission.

Stein, Jenny M.↗

NASA NTRS1995

(abstract) Unidirectional Carbon/Carbon for Ion Engine Optics

Conventional ion engine optical grids are made from hydroformed molybdenum. Carbon/carbon has been utilized in place of molybdenum because of its lower sputter yield, which contributes a greatly increased engine life, and for its low cte, which allows more efficient engine operation. The requirements for this material are that it must have high stiffness, very tight dimensional tolerances, and can be optimized for an hexagonal hole pattern with a very high open area friction. The carbon/carbon for this application was fabricated from unidirectional tape prepreg, using pitch fiber, and was processed to a very high temperature. The use of unidirectional tape allowed for a sufficient number of plies to be used to generate a balanced three directional layup within the thickness constraints of the material, as well as providing strength and stiffness over that normally seen with fabric based carbon/carbons.

ion engine carbon/carbon unidirectional tape prepr↗

NASA NTRS1978

Design and test of a squeeze-film damper for a flexible power transmission shaft

For a flexible shaft designed to pass through a number of bending critical speeds, a squeeze-film damper has been designed and tested. The damper properties were selected to provide control of all critical speeds, while meeting additional constraints of high power transmission requirements and damper simplicity. The damper was fabricated and installed and its ability to control flexible shaft vibrations was demonstrated by the comparison of vibration amplitudes both with and without the damper.

Darlow, M. S.↗

NASA NTRS2003

AM03-AM121-115 Hard X-Ray Optics Development at MSFC

We have developed the electroformed-nickel replication process to enable us to fabricate light-weight hard-x-ray region. Two projects currently utilizing this technology are the production of over 250 r from 5 to 10 cm, for our HERO balloon payload, and 15- and 23-cm-diameter shells for a prototype module. The challenge for the former is to fabricate, mount, align and fly a large number of high-r constraints of a modest budget. For the latter, the challenge is to maintain high angular resolution shell thicknesses (100 micron) which make the shells extremely sensitive to electroforming stresses process does not degrade the ultra-smooth surface finish (approx. 3 A required for eventual multilayer c on these two programs.

Ramsey, Brian↗

NASA NTRS2012

Toward Active X-ray Telescopes II

In the half century since the initial discovery of an astronomical (non-solar) x-ray source, the sensitivity for detection of cosmic x-ray sources has improved by ten orders of magnitude. Largely responsible for this dramatic progress has been the refinement of the (grazing-incidence) focusing x-ray telescope. The future of x-ray astronomy relies upon the development of x-ray telescopes with larger aperture areas (greater than 1 m2) and finer angular resolution (less than 1.). Combined with the special requirements of grazing-incidence optics, the mass and envelope constraints of space-borne telescopes render such advances technologically challenging.requiring precision fabrication, alignment, and assembly of large areas (greater than 100 m2) of lightweight (approximately 1 kg m2 areal density) mirrors. Achieving precise and stable alignment and figure control may entail active (in-space adjustable) x-ray optics. This paper discusses relevant programmatic and technological issues and summarizes progress toward active x-ray telescopes.

O'Dell, Stephen L.↗

NASA NTRS2014

Investigation of Spiral Bevel Gear Condition Indicator Validation Via AC-29-2C Using Damage Progression Tests

This report documents the results of spiral bevel gear rig tests performed under a NASA Space Act Agreement with the Federal Aviation Administration (FAA) to support validation and demonstration of rotorcraft Health and Usage Monitoring Systems (HUMS) for maintenance credits via FAA Advisory Circular (AC) 29-2C, Section MG-15, Airworthiness Approval of Rotorcraft (HUMS) (Ref. 1). The overarching goal of this work was to determine a method to validate condition indicators in the lab that better represent their response to faults in the field. Using existing in-service helicopter HUMS flight data from faulted spiral bevel gears as a "Case Study," to better understand the differences between both systems, and the availability of the NASA Glenn Spiral Bevel Gear Fatigue Rig, a plan was put in place to design, fabricate and test comparable gear sets with comparable failure modes within the constraints of the test rig. The research objectives of the rig tests were to evaluate the capability of detecting gear surface pitting fatigue and other generated failure modes on spiral bevel gear teeth using gear condition indicators currently used in fielded HUMS. Nineteen final design gear sets were tested. Tables were generated for each test, summarizing the failure modes observed on the gear teeth for each test during each inspection interval and color coded based on damage mode per inspection photos. Gear condition indicators (CI) Figure of Merit 4 (FM4), Root Mean Square (RMS), +/- 1 Sideband Index (SI1) and +/- 3 Sideband Index (SI3) were plotted along with rig operational parameters. Statistical tables of the means and standard deviations were calculated within inspection intervals for each CI. As testing progressed, it became clear that certain condition indicators were more sensitive to a specific component and failure mode. These tests were clustered together for further analysis. Maintenance actions during testing were also documented. Correlation coefficients were calculated between each CI, component, damage state and torque. Results found test rig and gear design, type of fault and data acquisition can affect CI performance. Results found FM4, SI1 and SI3 can be used to detect macro pitting on two more gear or pinion teeth as long as it is detected prior to progressing to other components or transitioning to another failure mode. The sensitivity of RMS to system and operational conditions limit its reliability for systems that are not maintained at steady state. Failure modes that occurred due to scuffing or fretting were challenging to detect with current gear diagnostic tools, since the damage is distributed across all the gear and pinion teeth, smearing the impacting signatures typically used to differentiate between a healthy and damaged tooth contact. This is one of three final reports published on the results of this project. In the second report, damage modes experienced in the field will be mapped to the failure modes created in the test rig. The helicopter CI data will then be re-processed with the same analysis techniques applied to spiral bevel rig test data. In the third report, results from the rig and helicopter data analysis will be correlated. Observations, findings and lessons learned using sub-scale rig failure progression tests to validate helicopter gear condition indicators will be presented.

gears↗

NASA NTRS1992

Fabrication

What aspects of optical fabrication technology need to be developed so as to facilitate existing planned missions, or enable new ones? Throughout the submillimeter to UV wavelengths, the common goal is to push technology to the limits to make the largest possible apertures that are diffraction limited. At any one wavelength, the accuracy of the surface must be better than lambda/30 (rms error). The wavelength range is huge, covering four orders of magnitude from 1 mm to 100 nm. At the longer wavelengths, diffraction limited surfaces can be shaped with relatively crude techniques. The challenge in their fabrication is to make as large as possible a reflector, given the weight and volume constraints of the launch vehicle. The limited cargo diameter of the shuttle has led in the past to emphasis on deployable or erectable concepts such as the Large Deployable Reflector (LDR), which was studied by NASA for a submillimeter astrophysics mission. Replication techniques that can be used to produce light, low-cost reflecting panels are of great interest for this class of mission. At shorter wavelengths, in the optical and ultraviolet, optical fabrication will tax to the limit the most refined polishing methods. Methods of mechanical and thermal stabilization of the substrate will be severely stressed. In the thermal infrared, the need for large aperture is tempered by the even stronger need to control the telescope's thermal emission by cooled or cryogenic operation. Thus, the SIRTF mirror at 1 meter is not large and does not require unusually high accuracy, but the fabrication process must produce a mirror that is the right shape at a temperature of 4 K. Future large cooled mirrors will present more severe problems, especially if they must also be accurate enough to work at optical wavelengths. At the very shortest wavelengths accessible to reflecting optics, in the x-ray domain, the very low count fluxes of high energy photons place a premium on the collecting area. It is not necessary to reach or even approach the diffraction limit, which would demand subnanometer fabrication and figure control. Replication techniques that produce large very lightweight surfaces are of interest for x-ray optics just as they are for the submillimeter region. Optical fabrication requirements are examined in more detail for missions in each of the three spectral regions of interest in astrophysics.

Angel, Roger↗

NASA NTRS2010

Comparison of Traditional Design Nonlinear Programming Optimization and Stochastic Methods for Structural Design

Structural design generated by traditional method, optimization method and the stochastic design concept are compared. In the traditional method, the constraints are manipulated to obtain the design and weight is back calculated. In design optimization, the weight of a structure becomes the merit function with constraints imposed on failure modes and an optimization algorithm is used to generate the solution. Stochastic design concept accounts for uncertainties in loads, material properties, and other parameters and solution is obtained by solving a design optimization problem for a specified reliability. Acceptable solutions were produced by all the three methods. The variation in the weight calculated by the methods was modest. Some variation was noticed in designs calculated by the methods. The variation may be attributed to structural indeterminacy. It is prudent to develop design by all three methods prior to its fabrication. The traditional design method can be improved when the simplified sensitivities of the behavior constraint is used. Such sensitivity can reduce design calculations and may have a potential to unify the traditional and optimization methods. Weight versus reliabilitytraced out an inverted-S-shaped graph. The center of the graph corresponded to mean valued design. A heavy design with weight approaching infinity could be produced for a near-zero rate of failure. Weight can be reduced to a small value for a most failure-prone design. Probabilistic modeling of load and material properties remained a challenge.

Patnaik, Surya N.↗

NASA NTRS2013

Issues and Strategies in Solving Multidisciplinary Optimization Problems

Optimization research at NASA Glenn Research Center has addressed the design of structures, aircraft and airbreathing propulsion engines. The accumulated multidisciplinary design activity is collected under a testbed entitled COMETBOARDS. Several issues were encountered during the solution of the problems. Four issues and the strategies adapted for their resolution are discussed. This is followed by a discussion on analytical methods that is limited to structural design application. An optimization process can lead to an inefficient local solution. This deficiency was encountered during design of an engine component. The limitation was overcome through an augmentation of animation into optimization. Optimum solutions obtained were infeasible for aircraft and airbreathing propulsion engine problems. Alleviation of this deficiency required a cascading of multiple algorithms. Profile optimization of a beam produced an irregular shape. Engineering intuition restored the regular shape for the beam. The solution obtained for a cylindrical shell by a subproblem strategy converged to a design that can be difficult to manufacture. Resolution of this issue remains a challenge. The issues and resolutions are illustrated through a set of problems: Design of an engine component, Synthesis of a subsonic aircraft, Operation optimization of a supersonic engine, Design of a wave-rotor-topping device, Profile optimization of a cantilever beam, and Design of a cylindrical shell. This chapter provides a cursory account of the issues. Cited references provide detailed discussion on the topics. Design of a structure can also be generated by traditional method and the stochastic design concept. Merits and limitations of the three methods (traditional method, optimization method and stochastic concept) are illustrated. In the traditional method, the constraints are manipulated to obtain the design and weight is back calculated. In design optimization, the weight of a structure becomes the merit function with constraints imposed on failure modes and an optimization algorithm is used to generate the solution. Stochastic design concept accounts for uncertainties in loads, material properties, and other parameters and solution is obtained by solving a design optimization problem for a specified reliability. Acceptable solutions can be produced by all the three methods. The variation in the weight calculated by the methods was found to be modest. Some variation was noticed in designs calculated by the methods. The variation may be attributed to structural indeterminacy. It is prudent to develop design by all three methods prior to its fabrication. The traditional design method can be improved when the simplified sensitivities of the behavior constraint is used. Such sensitivity can reduce design calculations and may have a potential to unify the traditional and optimization methods. Weight versus reliability traced out an inverted-S-shaped graph. The center of the graph corresponded to mean valued design. A heavy design with weight approaching infinity could be produced for a near-zero rate of failure. Weight can be reduced to a small value for a most failure-prone design. Probabilistic modeling of load and material properties remained a challenge.

Patnaik, Surya↗

NASA NTRSDate not supplied

Metal Fused Filament Fabrication of Titanium Alloy for In Space Manufacturing

NASA is developing materials and processes for the in-space manufacturing of many items for the International Space Station (ISS) and future exploration platforms. These new manufacturing processes will require the further development of current 3D printing processes to achieve high-performance metal parts within the power and space constraints of the ISS. Manufacturing Ti-6Al-4V alloy parts with 3D printing using a metal fused filament fabrication (MF3) process is an alternative process to the Direct Metal Laser Sintering (DMLS) of the metal powders additive manufacturing process. Our initial work fabricating Ti-6Al-4V parts from Ti-6Al-4V powder-binder feedstock and processed with the MF3 process has resulted in 95-97% sintered densities. The current development work of optimized sintered properties investigates the effects of variation in sintering time, temperature, and vacuum on the sintered properties of Ti-6Al-4V MF3 printed tensile bars. Sintered properties such as density, hardness, and tensile properties were characterized followed by microstructural and chemical (O/C/N) analysis to understand the role of sintering process on the ensuing material properties. Future development of the MF3 process will also involve investigation of the effects of micro-milling the Ti-64Al-4V powder to nanometer particle sizes and the investigation of laser sintering of the 3D printed devices. This new micro-milling technique will have broad application to other areas that require particle size reduction of hard metallic materials, such as Nuclear Thermal Propulsion and other NASA technologies. Laser sintering in lieu of high temperature thermal sintering should allow for significant power reduction and improved processing speeds.

sintering, alloys, 3D printing↗