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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 NTRSDate not supplied

In-Situ Consolidation Automated Fiber Placement of Thermoplastic Composites for High-Rate Aircraft Manufacturing

The National Aeronautics and Space Administration (NASA) initiated the Hi-Rate Composites Aircraft Manufacturing (HiCAM) project in 2021 with the goal of significantly increasing composite structures manufacturing rate in the commercial aircraft industry. The technologies currently under investigation include resin infusion and automated fiber placement (AFP) of novel thermoset materials and thermoplastic composites. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA is particularly focused on assessing composite structure manufacturing utilizing an in-situ consolidation AFP of thermoplastics (ICAT) process employing a recently developed laser heating system. Two semi-crystalline polyaryletherketone thermoplastic tape materials were characterized to ascertain the ICAT process parameters at AFP placement speeds approaching 423 mm/s. The required laser power settings were determined at Electroimpact, measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. An overview of the HiCAM project as well as initial data from ICAT process characterizations are described.

thermoplastic composites↗

NASA NTRS2022

In-Situ Consolidation Automated Fiber Placement of Thermoplastic Composites for High-Rate Aircraft Manufacturing

laser heating↗

NASA NTRS2019

Optimization of Aluminum-Tin Ink Composition and Sintering in Atmospheric Conditions

This study will focus on the basics of generating an aluminum-tin ink that can sinter in air and exhibits properties near that of a solid aluminum-tin alloy. Sintering temperatures will also be assessed in this study. Once the optimal aluminum ink composition is determined, the optimal ink thickness for homogeneous sintering must be determined by additional experimentation. Additive manufacturing is a rapidly developing and growing manufacturing process and has proven successful in many different ways. Processes, such as extrusion three-dimensional (3D) printing and selective laser melting (SLM), have proven to work but have limitations, such as material capabilities or density issues. SLM is a revolutionary process for additive manufacturing of metals but cannot be used in outer space due to the need for metallic powder which would diffuse into the atmosphere in a zero-gravity environment. For this reason, metallic ink additive manufacturing is a potential solution. Work is being done on metallic ink additive manufacturing in a vacuum for electrical applications. This project has focused on developing an aluminum-tin metallic ink that can sinter without the need of a vacuum or inert gas-purged atmosphere in order to prevent oxidation of the aluminum by adding flux. Once a potential ink composition has been determined through sintering of small disks and thin layers of ink, the ink may be studied with a multimaterial 3D printer at NASA Marshall Space Flight Center (MSFC) in future experiments. If successful, this aluminum-tin ink will be capable for use on the International Space Station to make replacement parts quickly. Along with its zero-gravity advantages, this ink may also have applications on Earth because it may be extruded on a substrate with precise ceramic tips in a 3D printing process. This would allow the fabrication of precise, complex shapes and may generate a much faster and more efficient printing process as compared with traditional powder bed additive manufacturing processes. The process would not be limited by a small building volume because the system would not require an enclosed chamber.

Courtright, Z. S.↗

NASA NTRSDate not supplied

Automated Probabilistic Finite Element Model Calibration Tool Based on Uncertainty Quantification and Machine Learning

Qualification and certification of safety critical parts is a hurdle to the adoption of metallic additively manufactured components for aerospace vehicle applications. Challenges include variability in part properties due to inconsistent defect distribution and microstructure. Understanding of the process through finite element modeling (FEM), and process control through in-situ monitoring, may result in significant improvements; however, solutions useful to manufacturers will require large volumes of data and automated data utilization. Toward this end, a generalizable automated FEM calibration paradigm is developed. This paradigm leverages existing and novel tools from machine learning and uncertainty quantification to enable the automatic calibration of FEMs without requiring prior knowledge of the model performance across input parameter space, including meshing and solver settings, which can require time consuming manual model probing or cause noisy and inconsistent predictions. The result is a probabilistic distribution of calibrated and validated FEM input parameters targeting measured data.

Additive manufacturing model calibration finite el↗

NASA NTRS1974

Program for establishing long-time flight service performance of composite materials in the center wing structure of C-130 aircraft. Phase 3: Fabrication

The manufacturing plan for three C-130 aircraft center wing box test articles, selectively reinforced with boron-epoxy composites, is outlined for the following tasks: (1) tooling; (2) metal parts fabrication: (3) reinforcing laminate fabrication; (4) laminate-to-metal parts bonding; and (5) wing box assembly. The criteria used for reliability and quality assurance are discussed, and several solutions to specific manufacturing problems encountered during fabrication are given. For Vol. 1, see N73-13011; for Vol. 2, see N73-22929.

Harvill, W. E.↗

NASA NTRS1994

Evolution of the NASA long-duration balloon program

The development of long-duration ballooning techniques to support flights of 1-2 ton payloads for periods up to 2 weeks, possibly even longer, offers a near-space scientific mission capability with an order of magnitude improvement over traditional balloon flights. This revolution in scientific research ballooning began with the solution of the manufacturing difficulties that plagued the program in the first half of the 1980's, and it has culminated in the early 1990's with three successive circumnavigations of the Antarctic continent in 9 to 14 day flights. A complementary capablity in the Northern hemisphere, which would approximately double the number of flights that could be supported each year, is needed to accommodate the trend for conventional payloads to be modified, or developed, for long-duration flights. Plans are already underway to employ the order-of-magnitude increased flight time for support of multi-flight research programs that will produce results comparable to some space missions. An overview of the current status and near-term plans for ballooning will be presented, along with a discussion of some major science initiatives that have been enabled.

Jones, W. Vernon↗

NASA NTRS1993

Scheduling Software

Advanced Scheduling Environment is a software product designed and marketed by AVYX, Inc. to provide scheduling solutions for complex manufacturing environments. It can be adapted to specific scheduling and manufacturing processes and has led to substantial cost savings. The system was originally developed for NASA use in scheduling Space Shuttle flights and satellite activities. AVYX, Inc. is an offshoot of a company formed to provide computer-related services to NASA. TREES-plus, the company's initial product became the programming language for the advanced scheduling environment system.

Source record↗

NASA NTRS1993

Cross-calibration of liquid and solid QCT calibration standards: corrections to the UCSF normative data

Quantitative computed tomography (QCT) has been shown to be a precise and sensitive method for evaluating spinal bone mineral density (BMD) and skeletal response to aging and therapy. Precise and accurate determination of BMD using QCT requires a calibration standard to compensate for and reduce the effects of beam-hardening artifacts and scanner drift. The first standards were based on dipotassium hydrogen phosphate (K2HPO4) solutions. Recently, several manufacturers have developed stable solid calibration standards based on calcium hydroxyapatite (CHA) in water-equivalent plastic. Due to differences in attenuating properties of the liquid and solid standards, the calibrated BMD values obtained with each system do not agree. In order to compare and interpret the results obtained on both systems, cross-calibration measurements were performed in phantoms and patients using the University of California San Francisco (UCSF) liquid standard and the Image Analysis (IA) solid standard on the UCSF GE 9800 CT scanner. From the phantom measurements, a highly linear relationship was found between the liquid- and solid-calibrated BMD values. No influence on the cross-calibration due to simulated variations in body size or vertebral fat content was seen, though a significant difference in the cross-calibration was observed between scans acquired at 80 and 140 kVp. From the patient measurements, a linear relationship between the liquid (UCSF) and solid (IA) calibrated values was derived for GE 9800 CT scanners at 80 kVp (IA = [1.15 x UCSF] - 7.32).(ABSTRACT TRUNCATED AT 250 WORDS).

NASA Program Space Physiology and Countermeasures↗

NASA NTRSDate not supplied

TPSAS-NF1676L-31522-DND

Currently, there are limitations in launch capability regarding requisite payload volume and mass for long duration extra-terrestrial missions. In-space additive manufacturing may provide a solution to this challenge and is applicable for articles ranging from large system and subsystem architectures to small consumables and replacement articles. For small articles, additive manufacturing is becoming more feasible through advances in instrumentation and novel manufacturing strategies capable of generating complex shapes. Many approaches, however, utilize feedstock materials that, once consumed, must be replenished before additional architectures can be generated. Thus, although promising, a major challenge with additive manufacturing is the required starting materials to support on-demand article generation. This presentation describes research toward reversibly assembling materials that can revert to the starting material state for subsequent fabrication. Polyimides were synthesized with thermally reversible Diels-Alder reaction functionalities, furan or maleimide moieties. These materials were characterized utilizing typical spectroscopic, thermal, and mechanical techniques. Amine hardener-enriched epoxy microparticles were synthesized for use as a mechanically robust substrate. Integration of these technologies into a single system and application toward generation of secondary structures on a launch vehicle as a means of in-situ resource utilization will be described.

Christopher J. Wohl↗

NASA NTRSDate not supplied

Convolution-Based Numerical Solutions of Transient Temperature Fields during Powder Bed Fusion Additive Manufacturing: Theory, Accuracy, and Computational Cost

Powder bed fusion (PBF) additive manufacturing has found numerous applications in the aerospace domain. However, components fabricated via PBF have a complex time-temperature history that significantly impacts subsequent mechanical performance. This study examines convolution-based numerical solutions of transient temperature fields that support simulations involving arbitrary beam shapes and paths during PBF. The convolutional approach is verified through comparisons with analytical solutions of the temperature field. The computational speed and accuracy of the method are assessed through comparisons with other explicit and implicit numerical techniques. In addition, the straightforward translation of the approach from a CPU to a GPU implementation and the resultant performance improvement are presented. The role of the technique in predicting microstructure evolution during PBF (for a greater process-structure-property-performance framework) is also demonstrated. This work supports the development of computational materials methods for understanding and controlling the time-temperature history during PBF.

powder bed fusion↗

NASA NTRS1974

Medical benefits from the NASA biomedical applications program

To achieve its goals the NASA Biomedical Applications Program performs four basic tasks: (1) identification of major medical problems which lend themselves to solution by relevant aerospace technology; (2) identification of relevant aerospace technology which can be applied to those problems; (3) application of that technology to demonstrate the feasibility as real solutions to the identified problems; and, (4) motivation of the industrial community to manufacture and market the identified solution to maximize the utilization of aerospace solutions to the biomedical community.

Sigmon, J. L.↗

NASA NTRS1992

Anomalous TWTA output power spikes and their effect on a digital satellite communications system

Several 30 GHz, 60 W traveling wave tube amplifiers (TWTA) were manufactured for the NASA Lewis Research Center's High Burst Rate Link Evaluation Terminal Project. An unusual operating problem characterized by anomalous nonperiodic output power spikes, common to all of the TWTAs proved during testing to significantly affect the performance of a digitally-modulated data transmission test system. Modifications made to the TWTAs significantly curtailed the problem and allowed acceptable system performance to be obtained. This paper presents a discussion of the TWTA output power spike problem, possible causes of the problem, and the solutions implemented by the manufacturer which improved the TWTA performance to an acceptable level. The results of the testing done at NASA Lewis on the TWTAs both before and after the improvement made by Hughes are presented, and the effects of the output power spikes on the performance of the test system are discussed.

May, Brian D.↗

NASA NTRS1972

Research and development of silicon solar cells for low solar intensity and low temperature applications

Problems were identified, using N/P solar cells at low temperature and low intensity; these problems were solved and the solutions incorporated in a manufacturing procedure. Theoretical analysis of the effects of low temperature and low intensity on the various solar cell characteristics indicated that the following behavior might be expected: (1) lower short circuit current,(2) higher open circuit voltage,(3) series resistance becoming less significant, and (4) shunt resistance becoming more critical.

Payne, P. A.↗

NASA NTRS1983

Dispensing Small Measured Volumes of Liquid

Dispensing unit measures, filters, and unloads oil into container. Used in automobile manufacturing to dispense antifreeze solution into radiators or oil into engines, transmissions, or differentials. Uses gaseous nitrogen to control pressure, flow rate, and quality precisely, with minimal contamination from atmosphere.

Larson, G.↗

NASA NTRS1996

Welding rework data acquisition and automation

Aluminum-Lithium is a modern material that NASA MSFC is evaluating as an option for the aluminum alloys and other aerospace metals presently in use. The importance of aluminum-lithium is in it's superior weight to strength characteristics. However, aluminum-lithium has produced many challenges in regards to manufacturing and maintenance. The solution to these problems are vital to the future uses of the shuttle for delivering larger payloads into earth orbit and are equally important to future commercial applications of aluminum-lithium. The Metals Processes Branch at MSFC is conducting extensive tests on aluminum-lithium which includes the collection of large amounts of data. This report discusses the automation and data acquisition for two processes: the initial weld and the repair. The new approach reduces the time required to collect the data, increases the accuracy of the data, and eliminates several types of human errors during data collection and entry. The same material properties that enhance the weight to strength characteristics of aluminum-lithium contribute to the problems with cracks occurring during welding, especially during the repair/rework process. The repairs are required to remove flaws or defects discovered in the initial weld, either discovered by x-ray, visual inspection, or some other type of nondestructive evaluation. It has been observed that cracks typically appear as a result of or beyond the second repair. MSFC scientists have determined that residual mechanical stress introduced by the welding process is a primary cause of the cracking. Two obvious solutions are to either prevent or minimize the stress introduced during the welding process, or remove or reduce the stress after the welding process and MSFC is investigating both of these.

Romine, Peter L.↗

NASA NTRS2003

Dry Process for Manufacturing Hybridized Boron Fiber/Carbon Fiber Thermoplastic Composite Materials from a Solution Coated Precursor

An apparatus for producing a hybrid boron reinforced polymer matrix composite from precursor tape and a linear array of boron fibers. The boron fibers are applied onto the precursor tapes and the precursor tape processed within a processing component having an impregnation bar assembly. After passing through variable-dimension forming nip-rollers, the precursor tape with the boron fibers becomes a hybrid boron reinforced polymer matrix composite. A driving mechanism is used to pulled the precursor tape through the method and a take-up spool is used to collect the formed hybrid boron reinforced polymer matrix composite.

Harry L Belvin↗

NASA NTRS2005

Spherical Primary Optical Telescope (SPOT): An Architecture Demonstration for Cost-effective Large Space Telescopes

This paper summarizes efforts underway at the Goddard Space Flight Center to demonstrate a new type of space telescope architecture that builds on the rigid, segmented telescope heritage of the James Webb Space Telescope but that solves several key challenges for future space telescopes. The architecture is based on a cost-effective segmented spherical primary mirror combined with a unique wavefront sensing and control system that allows for continuous phasing of the primary mirror. The segmented spherical primary allows for cost-effective 3-meter class (eg, Midex and Discovery) missions as well as enables 30-meter telescope solutions that can be manufactured in a reasonable amount of time and for a reasonable amount of money. The continuous wavefront sensing and control architecture enables missions in low-earth-orbit and missions that do not require expensive stable structures and thermal control systems. For the 30-meter class applications, the paper discusses considerations for assembling and testing the telescopes in space. The paper also summarizes the scientific and technological roadmap for the architecture and also gives an overview of technology development, design studies, and testbed activities underway to demonstrate it s feasibility.

Feinberg, Lee↗

NASA NTRS2004

Spherical Primary Optical Telescope (SPOT): An Architecture Demonstration for Cost-effective Large Space Telescopes

This paper summarizes efforts underway at the Goddard Space Flight Center to demonstrate a new type of space telescope architecture that builds on the rigid segmented telescope heritage of the James Webb Space Telescope but that solves several key challenges for future space telescopes. The architecture is based on a cost-effective segmented spherical primary mirror combined with a unique wavefront sensing and control system that allows for continuous phasing of the primary mirror. The segmented spherical primary allows for cost-effective 3-meter class (e.g., Midex and Discovery) missions as well as enables 30-meter telescope solutions that can be manufactured in a reasonable amount of time and for a reasonable amount of money. The continuous wavefront sensing and control architecture enables missions in low-earth-orbit and missions that do not require expensive stable structures and thermal control systems. For the 30-meter class applications, the paper discusses considerations for assembling and testing the telescopes in space. The paper also summarizes the scientific and technological roadmap for the architecture and also gives an overview of technology development, design studies, and testbed activities underway to demonstrate its feasibility.

Feinberg, Lee D.↗