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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 NTRS1991

Robotics in space-age manufacturing

Robotics technologies are developed to improve manufacturing of space hardware. The following applications of robotics are covered: (1) welding for the space shuttle and space station Freedom programs; (2) manipulation of high-pressure water for shuttle solid rocket booster refurbishment; (3) automating the application of insulation materials; (4) precision application of sealants; and (5) automation of inspection procedures. Commercial robots are used for these development programs, but they are teamed with advanced sensors, process controls, and computer simulation to form highly productive manufacturing systems. Many of the technologies are also being actively pursued in private sector manufacturing operations.

Jones, Chip↗

NASA NTRS1991

NASA/ASEE Summer Faculty Fellowship Program. 1991 Research Reports

Reports from the NASA/ASEE Summer Faculty Fellowship Program are presented. The editors are responsible for selecting appropriately qualified faculty to address some of the many problems of current interest to NASA Kennedy. Some representative titles are as follows: Development of an Accelerated Test Method for the Determination of Susceptibility to Atmospheric Corrosion; Hazardous Gas Leak Analysis in the Space Shuttle; Modeling and Control of the Automated Radiator Inspection Device; Study of the Finite Element Software Packages at KSC; Multispectral Image Processing for Plants; Algorithms for Contours Depicting Static Electric Fields during Adverse Weather Conditions; Transient Study of a Cryogenic Hydrogen Filling System; and Precision Cleaning Verification of Nonvolatile Residues by using Water, Ultrasonics, and Turbidity Analyses.

Hosler, E. Ramon↗

NASA NTRS1991

Generic Techniques for the Calibration of Robots with Application of the 3-D Fixtures and Statistical Technique on the PUMA 500 and ARID Robots

A relatively simple, inexpensive, and generic technique that could be used in both laboratories and some operation site environments is introduced at the Robotics Applications and Development Laboratory (RADL) at Kennedy Space Center (KSC). In addition, this report gives a detailed explanation of the set up procedure, data collection, and analysis using this new technique that was developed at the State University of New York at Farmingdale. The technique was used to evaluate the repeatability, accuracy, and overshoot of the Unimate Industrial Robot, PUMA 500. The data were statistically analyzed to provide an insight into the performance of the systems and components of the robot. Also, the same technique was used to check the forward kinematics against the inverse kinematics of RADL's PUMA robot. Recommendations were made for RADL to use this technique for laboratory calibration of the currently existing robots such as the ASEA, high speed controller, Automated Radiator Inspection Device (ARID) etc. Also, recommendations were made to develop and establish other calibration techniques that will be more suitable for site calibration environment and robot certification.

Tawfik, Hazem↗

NASA NTRS2016

Remote Strain Sensing of CFRP Using Microwave Frequency Domain Reflectometry

NASA's Advanced Composites Project is investigating technologies that increase automated remote inspection of aircraft composite structures. Therefore, microwave Frequency Domain Reflectometry (FDR) is being investigated as a method of enabling rapid remote measurement of strain occurring at the first ply of a composite fiber reinforced polymer (CFRP) structure using Radio Frequency (RF) Electro-Magnetic (EM) radiation. While microwave reflectometry has been used to detect disbonds in CFRP structures, its use in detecting strain has been limited. This work will present data demonstrating the measurement of the reactance changes due to loading conditions that are indicative of strain in a CFRP structure. In addition, the basic EM signature will be presented along with an analysis of temperature and humidity effects.

Wilson, William C.↗

NASA NTRS2016

Carbon Fiber TOW Angle Determination Using Microwave Reflectometry

Wilson, William C.↗

NASA NTRSDate not supplied

Seeker 1.0 GNC Flight Performance (presentation)

Seeker is an automated extravehicular inspection spacecraft that was designed and built in-house at the NASA Johnson Space Center (JSC) over approximate-ly 18 months with a budget of $1.8 million. This first version of Seeker is in-tended to be an incremental development towards an advanced inspection ca-pability. Seeker launched onboard the NG-11 Cygnus mission in 2019 and de-ployed from Cygnus on September 16, 2019. Downlinked telemetry, imagery from the chaser and target spacecraft, and onboard engineering data logs are used to provide an analysis of the systemâ€™s performance. This paper reviews the performance of the Seeker vehicle with a focus on the guidance, navigation, and control (GNC) system. The results are presented with a discussion of the re-lated system design to highlight how decisions and applied methods culminated in the observed performance.

Sam Pedrotty↗

NASA NTRSDate not supplied

Development and Demonstration of a Digital NDE Pipeline for Streamlined Analysis of Ultrasonic Data

Currently when nondestructive evaluation (NDE) is performed on composite structures, the results, although recorded digitally are often manually interpreted and indicated (drawn) on the part being inspected by hand. Following this, a determination must be made on how to disposition that part. This decision could be based on engineering guidelines and best practices, rule-of-thumb, expert opinion or finite-element analysis of the part with some approximate representation of the damage. In order to streamline this process for ultrasonic inspection an effort was undertaken as part of NASA Advanced Composites Project to develop the Digital NDE Pipeline. The Digital NDE Pipeline is an integrated tool suite and associated framework that streamlines the inspection and defect disposition process through model-assisted inspection optimization, automated defect analysis of NDE data, and mapping of NDE data into finite element analysis software. This paper will provide an overview of the Digital NDE Pipeline and provide details of the individual tools developed along with the results of applying these tools to a demonstration test case.

Composites↗

NASA NTRS2026

Fatigue Life of Flow-Formed Aluminum 2195 and 6061 Alloys

The successful design and fabrication of metallic cryotanks for commercial aviation applications require lightweight, durable materials capable of withstanding high pressures and cryogenic temperatures through tens of thousands of thermomechanical refueling cycles. Flow forming is an advanced manufacturing technique that offers high-rate production and scalability for fabricating integrally stiffened cylinders suitable for cryotank applications. This work establishes the durability of flow-formed aluminum alloys by characterizing their fatigue life performance under conditions that mimic cryotank refueling cycles. Residual stresses in flow-formed aluminum-lithium (Al-Li) 2195-T6 cylinders were assessed using the contour method and found to be minimal. Fatigue life testing was conducted on flow-formed Al-Li 2195-T6 at room temperature and cryogenic temperatures (-321°F [-196°C]), with wrought Al-Li 2195-T6 serving as a baseline for comparison. Results showed that flow-formed materials exhibited fatigue performance comparable to or better than wrought materials, with no statistically significant differences observed between different specimen orientations relative to processing directions. Fractography revealed reduced delaminations in the flow-formed Al-Li 2195 samples as compared to wrought, indicating potential improvement to the microstructure that could result in improved service properties. Texture analysis using electron backscattered diffraction (EBSD) indicated recrystallization during heat treatment, potentially contributing to reduced delamination susceptibility. These findings demonstrating flow-formed material durability coupled with the high manufacturing efficiency of flow forming, makes flow forming an attractive process to produce aircraft cryotanks.

EBF3↗

NASA NTRS2019

Machine Learning Based AFP Inspection: A Tool for Characterization and Integration

Automated Fiber Placement (AFP) has become a standard manufacturing technique in the creation of large scale composite structures due to its high production rates. However, the associated rapid layup that accompanies AFP manufacturing has a tendency to induce defects. We forward an inspection system that utilizes machine learning (ML) algorithms to locate and characterize defects from profilometry scans coupled with a data storage system and a user interface (UI) that allows for informed manufacturing. A Keyence LJ-7080 blue light profilometer is used for fast 2D height profiling. After scans are collected, they are process by ML algorithms, displayed to an operator through the UI, and stored in a database. The overall goal of the inspection system is to add an additional tool for AFP manufacturing. Traditional AFP inspection is done manually adding to manufacturing time and being subject to inspector errors or fatigue. For large parts, the inspection process can be cumbersome. The proposed inspection system has the capability of accelerating this process while still keeping a human inspector integrated and in control. This allows for the rapid capability of the automated inspection software and the robustness of a human checking for defects that the system either missed or misclassified.

Sacco, Christopher↗

NASA NTRS1993

Robotic System Would Inspect Tubes And Fillets

Proposed robotic system inspects arrays of brazed tubes being fabricated for use in heat exchangers and similar objects. Arrays contain coolant tubes mounted in nozzle of main engine of Space Shuttle. Other versions used to inspect components of terrestrial heat exchangers for powerplants, vehicles, and refrigeration equipment. Inspection system provides for automated, complete, objective, and efficient inspection of arrays of coolant tubes. Computer executing image-processing algorithms extracts profiles of tubes and braze fillets and identifies flaws.

Gilbert, Jeffrey L.↗

DOE OSTI2022

Integration of the Kromek D3S Detector and Spot Robot For Secondary Inspections

Inspecting vehicles and containers for the presence of nuclear material is a challenging task for border control and security. When performed manually by inspectors, this task also has an associated risk of exposing the inspectors to unknown radiation. With the advent of agile, easy-to-program, quadruped robots like the Boston Dynamics Spot, automation of secondary inspection can improve the efficiency of the inspection process and alleviates the radiation risks to inspectors. In this project, Brookhaven National Laboratory and the University of Massachussetts at Lowell explored how to automate a simple secondary inspection mission. The Spot robot comes with its own software development kit (SDK) that allows clients/users to write custom code in the Python programming language to control the robot. Spot also has a payload computer called Spot-CORE, which runs the Ubuntu Linux operating system and allows users to integrate external sensors, such as a radiation detector, with Spot. In this study, the Kromek D3S detector has been integrated with Spot via the Spot-CORE, allowing Spot to capture gamma spectra and neutron counts for a specified acquisition period. Two custom routines, search and confirmation, have been developed and executed in this specified order. The search routine directs Spot to go around the nearest obstacle, e.g., vehicle and container, in a preset distance and step to collect gamma and neutron gross counts with the D3S detector. The radiation data and the robot location corresponding to each step are stored and fed to the confirmation routine at the end of the search. The confirmation routine then navigates Spot to the locations of the highest gamma or neutron counts to perform a long, e.g., one minute, measurement, and gives the operators the signature gamma spectra and neutron counts at the hotspots. This paper presents a detailed description of this automated system along with results of the preliminary tests in identifying the location and signature of a 137Cs radiation source in a vehicle.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

NASA NTRS1990

Calibration For On-Machine Inspections

Permanent calibration setup on numerically-controlled machine tool enables fast and reliable calibration of automated probes for inspection of workpieces while still mounted on machine. Setup includes one or more artifacts, dimensions and locations known precisely and stored in memory of computer controlling machine. Before probes used to inspect newly machined part, used to check artifacts. Probe measurements compared with values in memory to determine whether probe readings need adjustment.

Haymaker, Carlton L., Jr.↗

NASA NTRS1994

Automated path planning of the Payload Inspection and Processing System

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.

Byers, Robert M.↗

NASA NTRS1994

Robotic NDE inspection of advanced solid rocket motor casings

The Advanced Solid Rocket Motor program determined the need to inspect ASRM forgings and segments for potentially catastrophic defects. To minimize costs, an automated eddy current inspection system was designed and manufactured for inspection of ASRM forgings in the initial phases of production. This system utilizes custom manipulators and motion control algorithms and integrated six channel eddy current data acquisition and analysis hardware and software. Total system integration is through a personal computer based workcell controller. Segment inspection demands the use of a gantry robot for the EMAT/ET inspection system. The EMAT/ET system utilized similar mechanical compliancy and software logic to accommodate complex part geometries. EMAT provides volumetric inspection capability while eddy current is limited to surface and near surface inspection. Each aspect of the systems are applicable to other industries, such as, inspection of pressure vessels, weld inspection, and traditional ultrasonic inspection applications.

Mcneelege, Glenn E.↗

DOE OSTI2023

An Assessment of Machine Learning Applied to Ultrasonic Nondestructive Evaluation

In the United States, the nuclear industry performs inservice inspection (ISI) through nondestructive examination (NDE) methods in accordance with guidelines specified in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section XI, Rules for Inservice Inspection of Nuclear Power Plant Components. Ultrasonic nondestructive testing and evaluation (NDT&E) is one of the more commonly used techniques for inspecting Class 1 structural components in nuclear power systems. As the number of qualified NDE inspectors declines, the nuclear industry is looking to take advantage of advances in automation to enhance inspection capabilities. Advances in computational power, cloud-based computing, and machine learning algorithms make automated data analysis possible. Machine learning (ML) has shown huge potential in automated data analyses for ultrasonic NDE in the context of weld inspections.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1988

CAD-model-based vision for space applications

A pose acquisition system operating in space must be able to perform well in a variety of different applications including automated guidance and inspections tasks with many different, but known objects. Since the space station is being designed with automation in mind, there will be CAD models of all the objects, including the station itself. The construction of vision models and procedures directly from the CAD models is the goal of this project. The system that is being designed and implementing must convert CAD models to vision models, predict visible features from a given view point from the vision models, construct view classes representing views of the objects, and use the view class model thus derived to rapidly determine the pose of the object from single images and/or stereo pairs.

Shapiro, Linda G.↗

DOE OSTI2025

Automated segmentation and analysis of point clouds of pier foundations using Pier Inspection and Evaluation Report (PIER)

Pier foundations are commonly used in locations with unstable soil or where other types of foundations are unsuitable or cost prohibitive. A pier foundation consists of vertical columns to support the structure and elevate it above the ground. Common materials for pier foundations include masonry, concrete, timber, and steel. The methods for accurate placement of pier foundations have remained relatively unchanged for decades. For simple installations, construction chalk lines are used to layout the locations of piers to ensure accurate placement and elevation. For more complex installations, surveying instruments operated by trained professionals are employed to accurately locate piers and assess correct elevation before construction. After installation, another survey may need to be performed to assess the quality of the as-built foundation. However, with the advent of terrestrial laser scanners (TLS), the means now exist for contractors to conduct their own assessments of as-built foundations. The major barrier preventing contractors from performing their own assessments of as-built foundation quality is the segmentation and analysis of point cloud data, a skill that often requires a trained user. The objective of this research is to develop a software tool (PIER: Pier Inspection and Evaluation Report) to enable automated segmentation and analysis of point clouds of pier foundations. In this paper, the automated segmentation and analysis algorithms are detailed. A mockup lay out of pier foundations was built using concrete masonry units, and the algorithms were tested to evaluate performance. Limitations of the current algorithms and future research direction are discussed.

Turki, Amine [ORNL]↗

NASA NTRS1987

Evaluation of an automated karyotyping system for chromosome aberration analysis

Chromosome aberration analysis is a promising complement to conventional radiation dosimetry, particularly in the complex radiation fields encountered in the space environment. The capabilities of a recently developed automated karyotyping system were evaluated both to determine current capabilities and limitations and to suggest areas where future development should be emphasized. Cells exposed to radiometric chemicals and to photon and particulate radiation were evaluated by manual inspection and by automated karyotyping. It was demonstrated that the evaluated programs were appropriate for image digitization, storage, and transmission. However, automated and semi-automated scoring techniques must be advanced significantly if in-flight chromosome aberration analysis is to be practical. A degree of artificial intelligence may be necessary to realize this goal.

Prichard, Howard M.↗