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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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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1997

Technology Needs for Reduced Design and Manufacturing Cost of Commercial Transport Engines

The objective of the study was to assess the needs in the design and manufacturing processes and identify areas where technology could impact in cost and cycle-time reduction. At the highest level, the team first identified the goals that were in line with long-range needs of the aeropropulsion industry, and to which technology and process improvements would be required to contribute. These goals are to reduce the time and costs in the development cycle of aircraft engines by a factor of two, reduce production cycle time by a factor of four, and to reduce production costs by 25%. Also, it was the intent of the team to identify the highest impact technologies that could be developed and demonstrated in five years.

Rohn, Douglas A.↗
NASA NTRS1984

Present capabilities and future requirements for computer-aided geometric modeling in the design and manufacture of gas turbine

Gas turbine engine design requires the ability to rapidly develop complex structures which are subject to severe thermal and mechanical operating loads. As in all facets of the aerospace industry, engine designs are constantly driving towards increased performance, higher temperatures, higher speeds, and lower weight. The ability to address such requirements in a relatively short time frame has resulted in a major thrust towards integrated design/analysis/manufacturing systems. These computer driven graphics systems represent a unique challenge, with major payback opportunities if properly conceived, implemented, and applied.

Caille, E.↗
NASA NTRS1999

High Reynolds Number Hybrid Laminar Flow Control (HLFC) Flight Experiment: Suction System Design and Manufacture - Report 4

This document describes the design of the leading edge suction system for flight demonstration of hybrid laminar flow control on the Boeing 757 airplane. The exterior pressures on the wing surface and the required suction quantity and distribution were determined in previous work. A system consisting of porous skin, sub-surface spanwise passages ("flutes"), pressure regulating screens and valves, collection fittings, ducts and a turbocompressor was defined to provide the required suction flow. Provisions were also made for flexible control of suction distribution and quantity for HLFC research purposes. Analysis methods for determining pressure drops and flow for transpiration heating for thermal anti-icing are defined. The control scheme used to observe and modulate suction distribution in flight is described.

Source record↗
NASA NTRS2001

An Assessment of the State-of-the-Art in the Design and Manufacturing of Large Composite Structures for Aerospace Vehicles

An assessment of the State-of-the-Art in the design and manufacturing of large composite structures has been conducted. The focus of the assessment is large structural components in commercial and military aircraft. Applications of composites are reviewed for commercial transport aircraft, general aviation aircraft, rotorcraft, and military aircraft.

Harris, Charles E.↗
NASA NTRS2003

Liner-less Tanks for Space Application - Design and Manufacturing Considerations

Composite pressure vessels, used extensively for gas and fuel containment in space vehicles, are generally constructed with a metallic liner, while the fiber reinforcement carries the major portion of the pressure-induced load. The design is dominated by the liner s low strain at yield since the reinforcing fibers cannot operate at their potential load-bearing capability without resorting to pre-stressing (or autofrettaging). An ultra high-efficiency pressure vessel, which operates at the optimum strain capability of the fibers, can be potentially achieved with a liner-less construction. This paper discusses the design and manufacturing challenges to be overcome in the development of such a pressure vessel. These include: (1) gas/liquid containment and permeation, (2) design and structural analysis, and (3) manufacturing process development. The paper also presents the development and validation tests on a liner-less pressure vessel developed by Kaiser Compositek Inc. (KCI). It should be noted that KCI s liner-less tank exhibits a highly controlled leak-before-burst mode. This feature results in a structure having the highest level of safety.

Jones, Brian H.↗
NASA NTRS1994

Integrated design and manufacturing for the high speed civil transport

In June 1992, the School of Aerospace Engineering at Georgia Tech was awarded a three year NASA University Space Research Association (USRA) Advanced Design Program (ADP) grant to address issues associated with the Integrated Design and Manufacturing of High Speed Civil Transport (HSCT) configurations in its graduate Aerospace Systems Design courses. This report provides an overview of the on-going Georgia Tech initiative to address these design/manufacturing issues during the preliminary design phases of an HSCT concept. The new design methodology presented here has been incorporated in the graduate aerospace design curriculum and is based on the concept of Integrated Product and Process Development (IPPD). The selection of the HSCT as a pilot project was motivated by its potential global transportation payoffs; its technological, environmental, and economic challenges; and its impact on U.S. global competitiveness. This pilot project was the focus of each of the five design courses that form the graduate level aerospace systems design curriculum. This year's main objective was the development of a systematic approach to preliminary design and optimization and its implementation to an HSCT wing/propulsion configuration. The new methodology, based on the Taguchi Parameter Design Optimization Method (PDOM), was established and was used to carry out a parametric study where various feasible alternative configurations were evaluated. The comparison criterion selected for this evaluation was the economic impact of this aircraft, measured in terms of average yield per revenue passenger mile ($/RPM).

Lee, Jae Moon↗
NASA NTRS2001

An Assessment of the State-of-the-Art in the Design and Manufacturing of Large Composite Structures for Aerospace Vehicles

The results of an assessment of the state-of-the-art in the design and manufacturing of large composite structures are described. The focus of the assessment is on the use of polymeric matrix composite materials for large airframe structural components. such as those in commercial and military aircraft and space transportation vehicles. Applications of composite materials for large commercial transport aircraft, general aviation aircraft, rotorcraft, military aircraft. and unmanned rocket launch vehicles are reviewed. The results of the assessment of the state-of-the-art include a summary of lessons learned, examples of current practice, and an assessment of advanced technologies under development. The results of the assessment conclude with an evaluation of the future technology challenges associated with applications of composite materials to the primary structures of commercial transport aircraft and advanced space transportation vehicles.

Harris, Charles E.↗
NASA NTRS2009

Design and Manufacture of Structurally Efficient Tapered Struts

Composite materials offer the potential of weight savings for numerous spacecraft and aircraft applications. A composite strut is just one integral part of the node-to-node system and the optimization of the shut and node assembly is needed to take full advantage of the benefit of composites materials. Lockheed Martin designed and manufactured a very light weight one piece composite tapered strut that is fully representative of a full scale flight article. In addition, the team designed and built a prototype of the node and end fitting system that will effectively integrate and work with the full scale flight articles.

Brewster, Jebediah W.↗
NASA NTRS2014

America's Next Great Ship: Space Launch System Core Stage Transitioning from Design to Manufacturing

The Space Launch System (SLS) Program is essential to achieving the Nation's and NASA's goal of human exploration and scientific investigation of the solar system. As a multi-element program with emphasis on safety, affordability, and sustainability, SLS is becoming America's next great ship of exploration. The SLS Core Stage includes avionics, main propulsion system, pressure vessels, thrust vector control, and structures. Boeing manufactures and assembles the SLS core stage at the Michoud Assembly Facility (MAF) in New Orleans, LA, a historical production center for Saturn V and Space Shuttle programs. As the transition from design to manufacturing progresses, the importance of a well-executed manufacturing, assembly, and operation (MA&O) plan is crucial to meeting performance objectives. Boeing employs classic techniques such as critical path analysis and facility requirements definition as well as innovative approaches such as Constraint Based Scheduling (CBS) and Cirtical Chain Project Management (CCPM) theory to provide a comprehensive suite of project management tools to manage the health of the baseline plan on both a macro (overall project) and micro level (factory areas). These tools coordinate data from multiple business systems and provide a robust network to support Material & Capacity Requirements Planning (MRP/CRP) and priorities. Coupled with these tools and a highly skilled workforce, Boeing is orchestrating the parallel buildup of five major sub assemblies throughout the factory. Boeing and NASA are transforming MAF to host state of the art processes, equipment and tooling, the most prominent of which is the Vertical Assembly Center (VAC), the largest weld tool in the world. In concert, a global supply chain is delivering a range of structural elements and component parts necessary to enable an on-time delivery of the integrated Core Stage. SLS is on plan to launch humanity into the next phase of space exploration.

Birkenstock, Benjamin↗
NASA NTRS2013

Composite Design and Manufacturing Development for Human Spacecrafts

The Structural Engineering Division at the NASA Johnson Space Center (JSC) has begun work on lightweight, multi‐functional pressurized composite structures. The first candidate vehicle for technology development is the Multi‐Mission Space Exploration Vehicle (MMSEV) cabin, known as the Gen 2B cabin, which has been built at JSC by the Robotics Division. Of the habitable MMSEV vehicle prototypes designed to date, this is the first one specifically analyzed and tested to hold internal pressure and the only one made out of composite materials. This design uses a laminate base with zoned reinforcement and external stringers, intended to demonstrate certain capabilities, and to prepare for the next cabin design, which will be a composite sandwich panel construction with multi‐functional capabilities. As part of this advanced development process, a number of new technologies were used to assist in the design and manufacturing process. One of the methods, new to JSC, was to build the Gen 2B cabin with Out of Autoclave technology to permit the creation of larger parts with fewer joints. An 8‐ply pre‐preg layup was constructed to form the cabin body. Prior to lay‐up, a design optimization software called FiberSIM was used to create each ply pattern. This software is integrated with Pro/Engineer to allow for customized draping of each fabric ply over the complex tool surface. Slits and darts are made in the software model to create an optimal design that maintains proper fiber placement and orientation. The flat pattern of each ply is then exported and sent to an automated cutting table where the patterns are cut out of graphite material. Additionally, to assist in lay‐up, a laser projection system (LPT) is used to project outlines of each ply directly onto the tool face for accurate fiber placement and ply build‐up. Finally, as part of the OoA process, a large oven was procured to post‐cure each part. After manufacturing complete, the cabin underwent modal and pressure testing (currently in progress at date of writing) and will go on to be outfitted and used for further ops usage.

Litteken, Douglas↗
NASA NTRS1992

A basis for solid modeling of gear teeth with application in design and manufacture

A new approach to modeling gear tooth surfaces is discussed. A computer graphics solid modeling procedure is used to simulate the tooth fabrication process. This procedure is based on the principles of differential geometry that pertain to envelopes of curves and surfaces. The procedure is illustrated with the modeling of spur, helical, bevel, spiral bevel, and hypoid gear teeth. Applications in design and manufacturing are discussed. Extensions to nonstandard tooth forms, to cams, and to rolling element bearings are proposed.

Huston, Ronald L.↗
NASA NTRS1994

A Basis for Solid Modeling of Gear Teeth with Application in Design and Manufacture

This paper discusses a new approach to modeling gear tooth surfaces. A computer graphics solid modeling procedure is used to simulate the tooth fabrication processes. This procedure is based on the principles of differential geometry that pertain to envelopes of curves and surfaces. The procedure is illustrated with the modeling of spur, helical, bevel, spiral bevel and hypoid gear teeth. Applications in design and manufacturing arc discussed. Extensions to nonstandard tooth forms, to cams, and to rolling element hearings are proposed.

Huston, Ronald L.↗
NASA NTRS2000

Portable Infrared Reflectometer Designed and Manufactured for Evaluating Emittance in the Laboratory or in the Field

The optical properties of materials play a key role in spacecraft thermal control. In space, radiant heat transfer is the only mode of heat transfer that can reject heat from a spacecraft. One of the key properties for defining radiant heat transfer is emittance, a measure of how efficiently a surface can reject heat in comparison to a perfect black body emitter. Heat rejection occurs in the infrared region of the spectrum, nominally in the range of 2 to 25 mm. To calculate emittance, one obtains the reflectance over this spectral range, calculates spectral absorptance by difference, and then uses Kirchhoff s Law and the Stefan-Boltzmann equation to calculate emittance. A new portable infrared reflectometer, the SOC 400t, was designed and manufactured to evaluate the emittance of surfaces and coatings in the laboratory or in the field. It was developed by Surface Optics Corporation under a contract with the NASA Glenn Research Center at Lewis Field to replace the Center s aging Gier-Dunkle DB-100 infrared reflectometer. The specifications for the new instrument include a wavelength range of 2 to 25 mm; reflectance repeatability of +/-1 percent; self-calibrating, near-normal spectral reflectance measurements; a full scan measurement time of 3.5 min, a sample size of 1.27 cm (0.5 in.); a spectral resolution selectable from 4, 8, 16, or 32/cm; and optical property characterization utilizing an automatic integration to calculate total emittance in a selectable temperature range.

Jaworske, Donald A.↗
NASA NTRS2002

Design and Manufacture of Elastically Tailored Tow Placed Plates

Elastic stiffness tailoring of laminated composite panels by allowing the fibers to curve within the plane of the laminate is a relatively novel design concept that has been demonstrated to be both beneficial and practical. In particular, for structures with highly non-uniform stress states, such as the case of a flat panel with a central hole subjected to in-plane loading, the concept is likely to provide substantial improvements in load carrying capability. The objective of the present study is to determine the effectiveness of stiffness tailoring through the use of curvilinear fibers to reduce stress concentrations around the hole and improve the load carrying capability of panels with holes. In this study software was created that translates standard finite element models with traditional laminate definitions into ones that possess stacking sequences with curvilinear fiber paths that are directly manufacturable using an advanced tow placement machine. Preliminary designs for the manufacturing and testing phase were determined through rudimentary design studies for flat plates without holes under axial compression. These candidate designs were then analyzed using finite element models that accurately reflect the test conditions and geometries in order to select final designs for testing. A total of six large panels, measuring three feet by six feet, each of which are used to produce four specimens with or without holes, were fabricated and delivered to NASA for machining and testing.

Tatting, Brain F.↗
NASA NTRS2026

Smart Process Planning for Automated Fiber Placement

Many industries, including aerospace, automotive, wind energy, maritime, and sporting goods, rely on strong, lightweight materials called composites. These materials are made by layering fibers, which can come in the form of narrow strips or wider sheets, and setting them in a polymer matrix. One of the most advanced ways to make these parts is through automated fiber placement, where a machine lays down the fibers in precise patterns. This method can create very efficient and strong designs, but it is complex, expensive, and often depends heavily on the experience of skilled engineers. Today, the design, manufacturing, and inspection stages of composite production are usually handled separately. This separation means that important information, such as how a part will be built or what defects might occur, is not always shared between stages. As a result, parts may not be as lightweight, strong, or defect-free as possible, and the process can take longer and cost more. This research develops a smart process planning system that connects design, manufacturing, and inspection into one continuous process. Built as software that works with existing tools, the system can automatically plan how the fibers are placed, predicting and reducing defects while improving both manufacturability and strength. The system optimizes not only individual layers but also how defects are distributed across all layers, preventing them from stacking up in ways that weaken the final part. It also uses inspection results from completed parts to improve future designs, creating a feedback loop where each stage informs the others. The system was tested by designing a composite panel using this new approach and comparing it to a panel made with state-of-the-art manual planning methods. The results showed that the system could intentionally control where defects appeared and increase the efficiency of the planning process. By unifying design, manufacturing, and inspection, this research shows a way to make advanced composite manufacturing more efficient, consistent, and cost-effective. This approach lowers the barrier to using automated fiber placement and opens the door for its wider adoption not only in aerospace but also in industries such as automotive, wind energy, maritime, and sporting goods, where strong and lightweight structures are essential.

Computer-Aided Process Planning↗
NASA NTRS2009

Design and Manufacturing of Tow-Steered Composite Shells Using Fiber Placement

Advanced composite shells that may offer the potential to improve the structural performance of future aircraft fuselage structures were developed under this joint NASA-industry collaborative effort. Two cylindrical shells with tailored, tow-steered layups and continuously varying fiber angle orientations were designed and built at the National Center for Advanced Manufacturing - Louisiana Partnership. The shells were fabricated from unidirectional IM7/8552 graphite-epoxy pre-preg slit tape material fiber-placed on a constant-diameter mandrel. Each shell had the same nominal 8-ply [plus or minus 45/plus or minus Theta]s layup, where the nominal fiber angle in the tow-steered plies varied continuously from 10 degrees along the crown to 45 degrees on each side, then back to 10 degrees on the keel. One shell was fabricated with all 24 tows placed during each pass of the fiber placement machine, resulting in many tow overlaps on the shell surface. The fiber placement machine's individual tow cut/restart capability was also used to manufacture a second shell with tow drops and a more uniform laminate thickness. This paper presents an overview of the detailed design and manufacturing processes for these shells, and discusses issues encountered during their fabrication and post-cure evaluation. Future plans for structural testing and analyses of the shells are also discussed.

Wu, K. Chauncey↗