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New method devised for generating welding-tool paths; parts of off-line-programmed test trajectories of computer-controlled welding robot. Reduces time necessary to set up simulation of welding process and eliminates some errors by reducing amount of repetition. Provides visual feedback similar to graphical simulation used in off-line-programming process after development of model.
Researchers at NASA Langley Research Center have been developing the Electron Beam Freeform Fabrication (EBF3) metal additive manufacturing process for the past 15 years. In this process, an electron beam is used as a heat source to create a small molten pool on a substrate into which wire is fed. The electron beam and wire feed assembly are translated with respect to the substrate to follow a predetermined tool path. This process is repeated in a layer-wise fashion to fabricate metal structural components. In-process imaging has been integrated into the EBF3 system using a near-infrared (NIR) camera. The images are processed to provide thermal and spatial measurements that have been incorporated into a closed-loop control system to maintain consistent thermal conditions throughout the build. Other information in the thermal images is being used to assess quality in real time by detecting flaws in prior layers of the deposit. NIR camera incorporation into the system has improved the consistency of the deposited material and provides the potential for real-time flaw detection which, ultimately, could lead to the manufacture of better, more reliable components using this additive manufacturing process.
This work presents an approach to modeling the dynamic spreading and curing behavior of thermosets in nozzle-based extrusions. Thermosets cover a wide range of materials, some of which permit low-temperature processing with subsequent high-temperature and high-strength working properties. Extruding thermosets may overcome the limited working temperatures and strengths of conventional thermoplastic materials used in additive manufacturing. This project aims to produce technology for the fabrication of thermoset-based structures leveraging advances made in nozzle-based extrusion, such as fused deposition modeling (FDM), material jetting, and direct writing. Understanding the synergistic interactions between spreading and fast curing of extruded thermosetting materials will provide essential insights for applications that require accurate dimensional controls, such as additive manufacturing [1], [2] and centrifugal coating/forming [3]. Two types of thermally curing thermosets -- one being a soft silicone (Ecoflex 0050) and the other being a toughened epoxy (G/Flex) -- served as the test materials in this work to obtain models for cure kinetics and viscosity. The developed models align with extensive measurements made with differential scanning calorimetry (DSC) and rheology. DSC monitors the change in the heat of reaction, which reflects the rate and degree of cure at different crosslinking stages. Rheology measures the change in complex viscosity, shear moduli, yield stress, and other properties dictated by chemical composition. By combining DSC and rheological measurements, it is possible to establish a set of models profiling the cure kinetics and chemorheology without prior knowledge of chemical composition, which is usually necessary for sophisticated mechanistic modeling. In this work, we conducted both isothermal and dynamic measurements with both DSC and rheology. With the developed models, numerical simulations yielded predictions of diameter and height of droplets, along with width and height of extruded lines cured at varied temperatures. Experimental results carried out on a goniometric platform and a nozzle-based 3D printer showed agreement with the numerical simulations. Finally, this presentation will show how the models are adaptable to the planning of tool paths and designs in additive manufacturing.
The Moon-to-Mars Planetary Autonomous Construction Technology (MMPACT) project, under NASA’s Game Changing Division (GCD) aims to research, develop, and demonstrate lunar surface construction capabilities[1].A fundamental step in lunar infrastructure development is to quantify the geotechnical properties of lunar regolith, such as shear strength (Mohr-Coulomb cohesion and angle of internal friction), com-pression and bearing properties, and angle of re-pose. Knowledge of these geotechnical properties enables the prediction of forces and displacements associated with lunar infrastructure development processes including excavation and constructing landing pads, habitats, shelters, and roadways. Through ground-based testing of autonomous lunar systems performed using relevant hardware (e.g., robotic arms) in appropriate lunar regolith simulants, the developed hardware/technology and tool paths can be validated. Such testing also generates data to give insight into the geotechnical regolith properties on the lunar surface.
NASA’s Moon-To-Mars Planetary Autonomous Construction Technology (MMPACT) project seeks to research, develop, and demonstrate lunar surface construction capabilities. Quantification of lunar regolith’s geotechnical properties allows for effective prediction of forces and displacement during excavation and construction and is critical to facilitating regolith sintering capabilities all of which benefit lunar infrastructure plans. Knowledge of shear strength, Mohr-Coulomb cohesion, angle of internal friction, bearing strength, bulk density, etc. is needed. The use of ground-based testing of various lunar simulants with relevant hardware (e.g., robotic arm tools) enables validation of technology choices, tool paths, and lunar surface construction activities. In addition, the use of Taguchi methods will minimize the number of needed experiments to explore critical input parameters.
NASA’s Moon-To-Mars Planetary Autonomous Construction Technology (MMPACT) project seeks to research, develop, and demonstrate lunar surface construction capabilities - Quantification of lunar regolith’s geotechnical properties allows for effective prediction of forces and displacement during excavation and construction and is critical to facilitating regolith sintering capabilities all of which benefit lunar infrastructure plans - Knowledge of shear strength, Mohr-Coulomb cohesion, angle of internal friction, bearing strength, bulk density, etc. is needed - Ground-based testing of various lunar simulants with relevant hardware (e.g., robotic arm tools) enables validation of technology choices, tool paths, and lunar surface construction activities - Use of Taguchi methods [1] will minimize the number of needed experiments to explore critical input parameter
- NASA’s Moon-To-Mars Planetary Autonomous Construction Technology (MMPACT) project seeks to research, develop, and demonstrate lunar surface construction capabilities. - Quantification of lunar regolith’s geotechnical properties allows for effective prediction of forces and displacement during excavation and construction and is critical to facilitating regolith sintering capabilities all of which benefit lunar infrastructure plans. - Knowledge of shear strength, Mohr-Coulomb cohesion, angle of internal friction, bearing strength, bulk density, etc. is needed. - The use of ground-based testing of various lunar simulants with relevant hardware (e.g., robotic arm tools) enables validation of technology choices, tool paths, and lunar surface construction activities. - In addition, the use of Taguchi methods [1] will minimize the number of needed experiments to explore critical input parameters. - The Jet Propulsion Lab is preparing to fly the COLDarm payload on a CLPS lunar mission with a geotechnical measurement scoop
The space-faring capabilities of humans are dependent on the ability to interact with plan-etary surfaces safely and efficiently and utilize local re-sources. Since planetary regolith will be the primary feedstock for in situ resource utilization (ISRU) and infrastructure development activities [1,2], the site-specific geomechanical properties must be understood to optimize excavation operations [3]. Excavating planetary regolith is challenging due to its unique geomechanical properties, 1/6th G reduced gravity extreme conditions, and limited energy resources. Therefore, it is critical to develop technologies that reduce excavation force requirements and minimize tool path inefficiencies to save time and energy during planetary re-source acquisition and infrastructure development [3]. There have been several experimental investigations of methods to optimize planetary excavations [4,5], but none developed predictive capabilities. This abstract presents a simple analytical method that will be used to model laboratory and mission excavation data. Future work will build on the simple analytical method here to include high-fidelity numerical simulations of planetary excavation mechanics.
Existing slicing software for additive manufacturing typically requires a triangulated mesh as its input. Triangulated meshes are approximate representations of exact CAD models. Despite the loss in dimensional accuracy, triangulated meshes are used because they are computationally easier to cross-section and offset than the exact geometry in CAD format. When a triangulated object is prepared, the resulting machine instructions include only linear motion commands. Numerous modern motion controllers can move in arc and spline motions; however, the absence of slicing software that supports curvature prevents these commands from being leveraged. To address this limitation, this paper presents a method for the hybrid reconstruction of arcs and splines as a post-processing step to traditional slicing. This method can greatly reduce the number of motion commands required to construct an object by printing smooth curved surfaces. This concise representation of tool-pathing allows for more even extrusion and is computed without a major impact on slicing time.
Three post-mold operations performed in wind blade manufacturing include: trimming, to remove excess flashing; grinding, to shape the leading edge; and sanding, to prepare the are for bonding of over-lamination or paint. This work focuses on automating these three operations. Each operation scans the blade to build a point cloud, plans a tool path for the operation, and executes the toolpath using an industrial robot arm. The results are analyzed to determine the operational speed and the finish quality.
As part of its commitment to advancing safety and reliability assessment methodologies, Argonne National Laboratory pioneered the use of an evaluation method called the Success Path Method (SPM) to improve risk management for offshore oil and gas operations. The development of the SPM at Argonne has been driven by the need to improve existing risk assessment methodologies by focusing on the steps necessary for success rather than failure modes alone. This is particularly important for industrial environments like offshore facilities that perform multiple functions under a continuously evolving set of operational conditions – such as water depth and temperature, currents, and weather conditions. In these dynamic environments, the traditional Probabilistic Risk Assessment (PRA) approach is far too complex as it focuses on what can go wrong – which comprises an infinite failure space that must be fully explored and understood. By shifting the focus to a finite space of success paths, the SPM enables operators and decision makers to prioritize a manageable number of steps that must go right to ensure success. Building on its five decades of experience in safety assessments for the nuclear industry, Argonne made major adaptations to existing risk assessment methods utilizing features similar to fault trees that are traditionally used in PRA to map all pathways in which the system can malfunction. In contrast, SPM identifies the components and processes that must function correctly to achieve specific outcomes – such as preventing the uncontrolled release of hydrocarbons during drilling operations. The SPM framework integrates equipment, procedures, software, processes, and human actions to ensure that physical barriers meet critical safety functions in dynamic operational conditions. This approach helps identify failure modes and improve operational risk management by narrowing the focus to key success elements, which in turn reduces uncertainty and helps users understand, manage, and respond to failures.
In large complex structures, with several major sound transmission paths and high levels of background noise, it can be a complex task to locate and rank the contribution of an individual sound transmission path. The two microphone acoustic intensity techniques are investigated as a tool for path identification. Laboratory tests indicate that, if the intensity transmitted through a particular section of the fuselage is measured in the presence and absence of flanking paths using the face to face and side by side microphone arrangements, then no significant difference exists between the two measured intensities if the face to face microphone arrangement is used. However, if the side by side arrangement is used, then considerable difference exists between the two measured intensities.
The problem domain being addressed by this contractual effort can be summarized by the following list: Automation and Robotics (A&R) technologies appear to be viable alternatives to current, manual operations; Life-cycle cost models are typically judged with suspicion due to implicit assumptions and little associated documentation; and Uncertainty is a reality for increasingly complex problems and few models explicitly account for its affect on the solution space. The objectives for this effort range from the near-term (1-2 years) to far-term (3-5 years). In the near-term, the envisioned capabilities of the modeling tool are annotated. In addition, a framework is defined and developed in the Decision Modelling System (DEMOS) environment. Our approach is summarized as follows: Assess desirable capabilities (structure into near- and far-term); Identify useful existing models/data; Identify parameters for utility analysis; Define tool framework; Encode scenario thread for model validation; and Provide transition path for tool development. This report contains all relevant, technical progress made on this contractual effort.
The Payload Changeout Room Inspection and Processing System (PIPS) is a highly redundant manipulator intended for performing tasks in the crowded and sensitive environment of the Space Shuttle Orbiter payload bay. Its dexterity will be exploited to maneuver the end effector in a workspace populated with obstacles. A method is described by which the end effector of a highly redundant manipulator is directed toward a target via a Lyapunov stability function. A cost function is constructed which represents the distance from the manipulator links to obstacles. Obstacles are avoided by causing the vector of joint parameters to move orthogonally to the gradient of the workspace cost function. A C language program implements the algorithm to generate a joint history. The resulting motion is graphically displayed using the Interactive Graphical Robot Instruction Program (IGRIP) produced by Deneb Robotics. The graphical simulation has the potential to be a useful tool in path planning for the PIPS in the Shuttle Payload Bay environment.
Visible/short-wave infrared spectral data from the Compact Reconnaissance Imaging Spectrometer for Mars (CRISM) show absorptions attributed to hematite at Vera Rubin ridge (VRR), a topographic feature on northwest Mt. Sharp. The goals of this study are to determine why absorptions caused by ferric iron are strongly visible from orbit at VRR, and to improve interpretation of CRISM data throughout lower Mt. Sharp. These goals are achieved by analyzing coordinated CRISM and in situ spectral data along the Curiosity Mars rover’s traverse. VRR bedrock within areas that have the deepest ferric absorptions in CRISM data also have the deepest ferric absorptions measured in situ. This suggests strong ferric absorptions are visible from orbit at VRR because of the unique spectral properties of VRR bedrock. Dust and mixing with basaltic sand additionally inhibit the ability to measure ferric absorptions in bedrock stratigraphically below VRR from orbit. There are two implications of these findings: (1) Ferric absorptions in CRISM data initially dismissed as noise could be real, and ferric phases are more widespread in lower Mt. Sharp than previously reported, (2) Patches with the deepest ferric absorptions in CRISM data are, like VRR, reflective of deeper absorptions in the bedrock. One model to explain this spectral variability is late-stage diagenetic fluids that changed the grain size of ferric phases, deepening absorptions. Curiosity’s experience highlights the strengths of using CRISM data for spectral absorptions and associated mineral detections, and the caveats in using these data for geologic interpretations and strategic path planning tools.
The anticipated application of advanced turboprop propulsion systems and use of composite materials in primary structure is expected to increase the interior noise of future aircraft to unacceptability high levels. The absence of technically and economically feasible noise source-path diagnostic tools has been a primer obstacle in the development of efficient noise control treatments for propeller driven aircraft. A new diagnostic method which permits the separation and prediction of the fully coherent airborne and structureborne components of the sound radiated by plates or thin shells has been developed. Analytical and experimental studies of the proposed method were performed on plates constructed of both conventional and composite materials. The results of the study indicate that the proposed method can be applied to a variety of aircraft materials, could be used in flight, and has fewer encumbrances than the other diagnostic tools currently available. The study has also revealed that the noise radiation of vibrating plates in the low frequency regime due to combined airborne and structureborne inputs possesses a strong synergistic nature. The large influence of the interaction between the airborne and structureborne terms has been hitherto ignored by researchers of aircraft interior noise problems.
The anticipated application of advanced turboprop propulsion systems is expected to increase the interior noise of future aircraft to unacceptably high levels. The absence of technically and economically feasible noise source-path diagnostic tools has been a prime obstacle in the development of efficient noise control treatments for propeller-driven aircraft. A new diagnostic method that permits the separation and prediction of the fully coherent airborne and structureborne components of the sound radiated by plates or thin shells has been developed. Analytical and experimental studies of the proposed method were performed on an aluminum plate. The results of the study indicate that the proposed method could be used in flight, and has fewer encumbrances than the other diagnostic tools currently available.
- Acoustic Validation Goals & Objectives - Overview and Concept of Operations - New Ground Systems Development - State-of-the sonic boom ground recording system - Unattended recording system trigger - X-59 sonic boom flight path planning tool - Real-time sonic boom prediction display - New Airborne Systems Development - Airborne near field probing system - In-flight, full-scale shockwave imagery systems - Real-time relative position pilot display - Acoustic Validation Test Approach