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At least 91 records · Page 5

Concept of Operations Visualization for Ares I Production

Establishing Computer Aided Design models of the Ares I production facility, tooling and vehicle components and integrating them into manufacturing visualizations/simulations allows Boeing and NASA to collaborate real time early in the design/development cycle. This collaboration identifies cost effective and lean solutions that can be easily shared with Ares stakeholders (e.g., other NASA Centers and potential science users). These Ares I production visualizations and analyses by their nature serve as early manufacturing improvement precursors for other Constellation elements to be built at the Michoud Assembly Facility such as Ares V and the Altair Lander. Key to this Boeing and Marshall Space Flight Center collaboration has been the use of advanced virtual manufacturing tools to understand the existing Shuttle era infrastructure and trade potential modifications to support Ares I production. These approaches are then used to determine an optimal manufacturing configuration in terms of labor efficiency, safety and facility enhancements. These same models and tools can be used in an interactive simulation of Ares I and V flight to the Space Station or moon to educate the human space constituency (e.g., government, academia, media and the public) in order to increase national and international understanding of Constellation goals and benefits.

Chilton, Jim↗

A study of internal structure in components made by additive manufacturing process using 3 D X-ray tomography

Additive manufacturing methods are gaining increasing popularity for rapidly and efficiently manufacturing parts and components in the industrial context, as well as for domestic applications. However, except when used for prototyping or rapid visualization of components, industries are concerned with the load carrying capacity and strength achievable by additive manufactured parts. In this paper, the wire-arc additive manufacturing (AM) process based on gas tungsten arc welding (GTAW) has been examined for the internal structure and constitution of components generated by the process. High-resolution 3D X-ray tomography is used to gain cut-views through wedge-shaped parts created using this GTAW additive manufacturing process with titanium alloy materials. In this work, two different control conditions for the GTAW process are considered. The studies reveal clusters of porosities, located in periodic spatial intervals along the sample cross-section. Such internal defects can have a detrimental effect on the strength of the resulting AM components, as shown in destructive testing studies. Closer examination of this phenomenon shows that defect clusters are preferentially located at GTAW traversal path intervals. These results highlight the strong need for enhanced control of process parameters in ensuring components with minimal defects and higher strength.

36 MATERIALS SCIENCE↗

Experimental Analysis of Advanced Turbine for Supercritical CO2 Power Cycle

An advanced first stage high pressure turbine blade for a supercritical CO2 power cycle is tested in the Big Rig for Aerothermal Stationary Turbine Analysis (BRASTA) annular cascade at the Purdue Experimental Turbine Aerothermal Laboratory (PETAL) high pressure blow down facility alongside a baseline blade for comparison of aerodynamic performance. Both geometries are tested simultaneously using a novel off-axis rig design to allow for the blade geometries to be scaled up to achieve higher Reynolds numbers. The off-axis design necessitates the use of discrete sectors of airfoils, which are designed and additively manufactured in house using an mSLA printer. Printing the blades allows for unique routing of passage for blade surface static pressure taps that contour to the blade shape instead of requiring a straight line view from surface tap to egress, allowing all instrumentation for 15%, 50%, and 85% span to exist in the same passage. A flow conditioning gauze [1] is placed upstream of the blade passages to impart pressure, Mach, and swirl profiles to mimic the rotor relative frame inlet conditions to the blade. Downstream, a sonic valve is used to alter the backpressure to achieve different pressure ratios for different blowdown setpoints. The design of the rig, sonic wheel, and instrumentation are discussed along with the manufacturing and GD&T of the blades with respect to the build-up of this novel experimental apparatus. Initial commissioning data is obtained from inlet total pressure and temperature rakes, blade static pressure taps, and exit total pressure rakes. Oil visualization is performed using a silicone oil mixture containing titanium dioxide and pigmented for contrast of the blade suction side surface with the hub and shroud endwalls. The viscosity of the oil is tuned so that the oil does not fully thin and blow away during the time of the test, and endoscopic cameras are placed in the rig for live monitoring and recording. The preliminary oil visualization and rake profiles are presented, showcasing the operability of this additively manufactured off-axis flow path design.

Tuite, Logan [Purdue University]↗

FY2017 annual report: Roll-to-Roll Advanced Materials Manufacturing DOE Laboratory Consortium Project

The following report provides a description of the program structure and technical accomplishments made during FY 2017 to overcome challenges for expanding use of R2R technologies and processing for clean energy applications. Technologies are under development that enable enhanced manufacturing of battery electrodes, fuel cells and water separation membranes that take advantage of advancements in new functional materials. Data mining, visualization, modeling and simulation for the materials, technologies and processes being developed allow for improvements in R2R manufacturing applications. This report documents the research conducted by four DOE national laboratories as a consortium in collaboration with industry partnerships. The research is directly applicable to AMM strategies that apply the National Science and Technology Council’s Materials Genome Initiative (NSTC 2011) approach to enhance the performance of battery, fuel cell and water membrane materials. This effort supports building the foundation of technologies, processes and a U.S. manufacturing base that will enable an order of magnitude in shorter process development cycles with the pathway for initial commercialization within months instead of years.

36 MATERIALS SCIENCE↗

Thermal tomography 3D imaging of additively manufactured metallic structures

Thermal tomography is a computational method for heat diffusion-based imaging of solids, which provides 3D visualization of data from flash thermography measurements. We investigate thermal tomography imaging and nondestructive evaluation of stainless steel and nickel super alloy metallic structures produced with the laser powder bed fusion (LPBF) additive manufacturing (AM) process. Metallic structures produced with LPBF contain defects, and there are limited capabilities to evaluate these structures non-destructively. Thermal tomography reconstruction of 3D apparent spatial effusivity provides information about AM structure geometry and internal material flaws. We study performance of thermal tomography in imaging of metallic structures through COMSOL computer simulations of transient heat transfer and through reconstruction of data obtained from experimental measurements. Thermal tomography reconstructions of structure shape and dimensions are shown for the Inconel 718 AM structure which has variations in the horizontal plane but is uniform along the depth dimension. Reconstruction of internal defects is investigated using a stainless steel 316L specimen with flat bottom hole (FBH) indentations, and the Inconel 718 plate is produced with the LPBF method, which contains imprinted hemispherical shape low density regions containing non-sintered metallic powder. The FBHs have the same sizes as the imprinted defects in the LPBF specimens but offer better imaging contrast. Thermal tomography reconstructions provide visualizations of internal defects and allow for estimation of their sizes and locations. Results of this study demonstrate that thermal tomography can be used for visualization and quality control in AM.

36 MATERIALS SCIENCE↗

Quantitative comparison of noise texture across CT scanners from different manufacturers

Purpose: To quantitatively compare noise texture across computed tomography (CT) scanners from different manufacturers using the noise power spectrum (NPS). Methods: The American College of Radiology CT accreditation phantom (Gammex 464, Gammex, Inc., Middleton, WI) was imaged on two scanners: Discovery CT 750HD (GE Healthcare, Waukesha, WI), and SOMATOM Definition Flash (Siemens Healthcare, Germany), using a consistent acquisition protocol (120 kVp, 0.625/0.6 mm slice thickness, 250 mAs, and 22 cm field of view). Images were reconstructed using filtered backprojection and a wide selection of reconstruction kernels. For each image set, the 2D NPS were estimated from the uniform section of the phantom. The 2D spectra were normalized by their integral value, radially averaged, and filtered by the human visual response function. A systematic kernel-by-kernel comparison across manufacturers was performed by computing the root mean square difference (RMSD) and the peak frequency difference (PFD) between the NPS from different kernels. GE and Siemens kernels were compared and kernel pairs that minimized the RMSD and |PFD| were identified. Results: The RMSD (|PFD|) values between the NPS of GE and Siemens kernels varied from 0.01 mm{sup 2} (0.002 mm{sup -1}) to 0.29 mm{sup 2} (0.74 mm{sup -1}). The GE kernels 'Soft,''Standard,''Chest,' and 'Lung' closely matched the Siemens kernels 'B35f,''B43f,''B41f,' and 'B80f' (RMSD < 0.05 mm{sup 2}, |PFD| < 0.02 mm{sup -1}, respectively). The GE 'Bone,''Bone+,' and 'Edge' kernels all matched most closely with Siemens 'B75f' kernel but with sizeable RMSD and |PFD| values up to 0.18 mm{sup 2} and 0.41 mm{sup -1}, respectively. These sizeable RMSD and |PFD| values corresponded to visually perceivable differences in the noise texture of the images. Conclusions: It is possible to use the NPS to quantitatively compare noise texture across CT systems. The degree to which similar texture across scanners could be achieved varies and is limited by the kernels available on each scanner.

60 APPLIED LIFE SCIENCES↗

Standardized nomenclature for photovoltaic connectors

Photovoltaic (PV) systems rely on discrete connectors for the efficient and safe flow of power from module to module and from strings to combiner boxes and inverters. Despite their functional importance, no common nomenclature for PV connectors currently exists, resulting in confusion and miscommunication. Misunderstood terms like "MC4 compatible", "cross-mating", "intermating", "female", and "male" can lead to installation and maintenance errors and compromise system reliability. We believe a standardized terminology will reduce confusion, help support installation best practices, aid in maintenance and repair, inform next-generation designs, and provide a technical basis for improved codes and standards. To that end, we are proposing a standardized glossary for 4 mm PV connectors (the most common type of connector used in PV applications) based on, and validated by, a Sandia National Laboratories' investigation that included the following sources: 1) a comprehensive review of official documents from 20 connector manufacturers, including schematics, datasheets, installation manuals, and catalogs, as well as relevant patents; 2) two rounds of surveys distributed to stakeholders, including connector manufacturers, engineers, asset owners, test labs, and researchers; and 3) visual examination of 25 different models of 4 mm single-pole DC PV connectors to document variations in design and functionality. This work provides a foundation for establishing a clear and consistent terminology for PV connectors that will in turn enable progress toward greater reliability and collaboration across the industry.

14 SOLAR ENERGY↗

High speed X-ray phase contrast imaging of energetic composites under dynamic compression

Fracture of crystals and subsequent frictional heating are associated with formation of hot spots in energetic composites such as polymer bonded explosives (PBXs). Traditional high speed optical imaging methods cannot be used to study the dynamic sub-surface deformation and fracture behavior of such materials due to their opaque nature. In this study, high speed synchrotron X-ray experiments are conducted to visualize the in situ deformation and fracture mechanisms in PBXs manufactured using octahydro-1,3,5,7-tetranitro-1,3,5,7-tetrazocine (HMX) crystals and hydroxyl-terminated polybutadiene (HTPB) binder. A modified Kolsky bar apparatus was used to apply controlled dynamic compression on the PBX specimens, and a high speed synchrotron X-ray phase contrast imaging (PCI) setup was used to record the in situ deformation and failure in the specimens. The experiments show that synchrotron X-ray PCI provides a sufficient contrast between the HMX crystals and the doped binder, even at ultrafast recording rates. Under dynamic compression, most of the cracking in the crystals was observed to be due to the tensile stress generated by the diametral compression applied from the contacts between the crystals. Tensile stress driven cracking was also observed for some of the crystals due to the transverse deformation of the binder and superior bonding between the crystal and the binder. In conclusion, the obtained results are vital to develop improved understanding and to validate the macroscopic and mesoscopic numerical models for energetic composites so that eventually hot spot formation can be predicted.

36 MATERIALS SCIENCE↗

Investigation of durability of optical coatings in highly purified tritium gas

Anti-reflection coated windows are part of Raman spectroscopy systems for tritium analytics in the KATRIN experiment and fusion-related applications. Damages of such windows were observed after three months of expo-sure to highly purified tritium gas in the LOOPINO facility. In this work, the origin of the damages was investigated, identified and eliminated. Coating samples manufactured by various physical vapor deposition methods have been tested for durability by exposure to pure tritium gas and subsequent visual inspection. Electron beam deposited coatings showed indications for damage after 17 days of tritium exposure in contrast to samples manufactured by ion assisted deposition or sputtering. An improved coating layout of the sample cell is presented for reliable long-term monitoring of tritium gas using Raman spectroscopy. (authors)

36 MATERIALS SCIENCE↗

MR-Compatible Surgical Instruments Final Report CRADA No. TSB-0847-94

ITI is a California-based company formed in February 1994 to design, manufacture and market premium quality magnetic resonance imaging (MRI) medical devices and instruments. These products are for use in existing MR irnagers, as well as for emerging applications in reaI-tirne MRI-guided surgery and interventional radiology. Such application require products that are MR biocompatible and in many cases MR visible. In an era of managed health care, purchasing decisions by hospitals, medical centers and insurers emphasize cost-effectiveness. Since minimally invasive therapy reduces surgical costs, shortens hospital stay and post-operative rehabilitation, this segment of the health care industry is expected to grow rapidly. Many experts believe that high-speed MRI-guided therapy offers the best opportunity to maximize the benefits of minimally invasive procedures because MIH enables the clearest differentiation of normal from abnormal tissues. Manufacturers of conventional imagers, including General Electric, Siemens, and Philips, have aleady made substantial investments aid produced prototype high-speed MRI.imagers to permit continuous real-time visualization of tissues during surgical and endovascular procedures. According to forecasts published by the National Electrical Manufacturers Association (1993) and the Medical and Healthcare Marketplace Guide (1992), the average world~wide growth rate of MN installations is expected to be about 7% annually for the next three years, increasing 12-15% annually thereafter as developing countries buy increasing numbers of MM units. The same forecasters project 17,000- 20,000 MRI irnagers world-wide by the year 2000, with a throughput of 2,300-6,000 patients per machine per year, at an.average examination cost.of $560-780-per-patient.

60 APPLIED LIFE SCIENCES↗

Evaluation of a Head-Worn Display with Ambient Vision Cues for Unusual Attitude Recovery

A Commercial Aviation Safety Team (CAST) study of 18 loss-of-control events determined that a lack of external visual references was a contributing factor in 17 of these events. CAST recommended that manufacturers should develop and implement virtual day-VMC display systems, such as synthetic vision (SV) or equivalent systems (CAST Safety Enhancement, SE-200). In support of this recommended action, CAST has requested studies to define minimum requirements for virtual day-visual meteorological conditions (VMC) displays to improve flight crew awareness of airplane attitude. NASA’s research in Virtual day-VMC displays, known as synthetic vision systems, are intended to support intuitive flight crew attitude awareness similar to a day-VMC-like environment, especially if they could be designed to create visual dominance. A study was conducted to evaluate the utility of ambient vision (AV) cues paired with virtual Head-Up Display (HUD) symbology on a prototype head-worn display (HWD) during recovery from unusual attitudes in a simulated environment. The virtual-HUD component meets the requirement that the HWD may be used as an equivalent display to the HUD. The presence of AV cueing leverages the potential that a HWD has over the HUD for spatial disorientation prevention. The simulation study was conducted as a single-pilot operation, under realistic flight scenarios, with off-nominal events occurring that were capable of inducing unusual attitudes. Independent variables of the experiment included: 1) AV capability (on vs off) 2) AV display opaqueness (transparent vs opaque) and display location (HWD vs traditional head- down displays); AV cues were only present when the HWD was being worn by the subject pilot.

Nicholas, Stephanie N.↗

Technical analysis of filter testing at the U.S. Department of Energy Filter Test Facility

The U.S. Department of Energy (DOE) technical standard DOE-STD-3020-2015 requires verification testing at the Filter Test Facility (FTF) of high-efficiency particulate air (HEPA) filters to be installed in nuclear facility (Hazard Category 1, 2, 3, and radiological facilities) confinement ventilation systems, or to be installed in habitability systems (e.g., filters for protection of workers required to act for the control and mitigation of emergency situations). Filters in these applications perform a safety function in accident situations, are designated as important to safety, or are necessary for habitability systems. Different FTFs have operated for decades, and results of tests are available to examine the need for and benefits of continued execution of 100 percent QA verification testing. The objective of this study and resulting report was to assess the need for 100 percent QA testing at the current FTF in Maryland, based on an examination of a database of test results from 2013 to August 2020. Filters that require independent testing per DOE-STD-3020-2015 to be installed in nuclear facilities are sent to the FTF before being shipped to the facilities. The FTF examines the documentation (e.g., certificates of compliance, results of particle penetration and airflow resistance testing by the manufacturers, labels affixed to filters and packages, and other requirements specified in purchase orders by the nuclear facility operators), implements visual inspections of the physical state of the filters, and checks the dimensions of frames. Filters that meet the documentation and visual inspection requirements are subjected to particle penetration and airflow resistance testing. In case of rejections, the filters are shipped back to the manufacturers, at the cost of the manufacturers, for replacement. Filters that pass all tests are shipped to the nuclear facilities.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Potential use of battery packs from NCAP tested vehicles.

Several large electric vehicle batteries available to the National Highway Traffic Safety Administration are candidates for use in future safety testing programs. The batteries, from vehicles subjected to NCAP crashworthiness testing, are considered potentially damaged due to the nature of testing their associated vehicles have been subjected to. Criteria for safe shipping to Sandia is discussed, as well as condition the batteries must be in to perform testing work. Also discussed are potential tests that could be performed under a variety of conditions. The ultimate value of potential testing performed on these cells will rest on the level of access available to the battery pack, i.e. external access only, access to the on board monitoring system/CAN port or internal electrical access to the battery. Greater access to the battery than external visual and temperature monitoring would likely require input from the battery manufacturer.

Lamb, Joshua↗

Disc resonator gyroscope fabrication process requiring no bonding alignment

A method of fabricating a resonant vibratory sensor, such as a disc resonator gyro. A silicon baseplate wafer for a disc resonator gyro is provided with one or more locating marks. The disc resonator gyro is fabricated by bonding a blank resonator wafer, such as an SOI wafer, to the fabricated baseplate, and fabricating the resonator structure according to a pattern based at least in part upon the location of the at least one locating mark of the fabricated baseplate. MEMS-based processing is used for the fabrication processing. In some embodiments, the locating mark is visualized using optical and/or infrared viewing methods. A disc resonator gyroscope manufactured according to these methods is described.

Shcheglov, Kirill V.↗

NASA Tech Briefs, September 2004

Topics covered include: Brazing SiC/SiC Composites to Metals; Composite-Material Tanks with Chemically Resistant Liners; Thermally Conductive Metal-Tube/Carbon-Composite Joints; Improved BN Coatings on SiC Fibers in SiC Matrices; Iterative Demodulation and Decoding of Non-Square QAM; Measuring Radiation Patterns of Reconfigurable Patch Antennas on Wafers; Low-Cutoff, High-Pass Digital Filtering of Neural Signals; Further Improvement in 3DGRAPE; Ground Support Software for Spaceborne Instrumentation; MER SPICE Interface; Simulating Operation of a Planetary Rover; Analyzing Contents of a Computer Cache; Discrepancy Reporting Management System; Silicone-Rubber Microvalves Actuated by Paraffin; Hydraulic Apparatus for Mechanical Testing of Nuts; Heat Control via Torque Control in Friction Stir Welding; Manufacturing High-Quality Carbon Nanotubes at Lower Cost; Setup for Visual Observation of Carbon-Nanotube Arc Process; Solution Preserves Nucleic Acids in Body-Fluid Specimens; Oligodeoxynucleotide Probes for Detecting Intact Cells; Microwave-Spectral Signatures Would Reveal Concealed Objects; Digital Averaging Phasemeter for Heterodyne Interferometry; Optoelectronic Instrument Monitors pH in a Culture Medium; Imaging of gamma-Irradiated Regions of a Crystal; Photodiode-Based, Passive Ultraviolet Dosimeters; Discrete Wavelength-Locked External Cavity Laser; Flexible Shields for Protecting Spacecraft Against Debris; Part 2 of a Computational Study of a Drop-Laden Mixing Layer; Controllable Curved Mirrors Made from Single-Layer EAP Films; and Demonstration of a Pyrotechnic Bolt-Retractor System.

Source record↗

Multivariate Regression of Pyrotechnic Igniter Output

Multivariate multiple regression models are applied to simplified pyrotechnic igniters for the first time to understand how changes in manufactured parameters can affect the output gas dynamic response and the timing of ignition events. The statistical modeling technique is applied to demonstrate quantification of the effects of a set of independent variables measured in the as-fabricated igniters on a set of responses experimentally measured from the functioned igniters. Two independent process variables were intentionally varied following a full factorial experimental design while several other independent variables varied within their normal manufacturing variability range. The four igniter performance responses consisted of the timing of sequential events during igniter function and visual gas dynamic output in the form of shock wave strength observed with high-speed schlieren imaging. Linear regression models built using the measurements throughout the manufacturing processes and the output variance provide insight into the critical device parameters that dominate performance

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

Modeling of reciprocating internal combustion engines for power generation and heat recovery

This paper presents a power generation and heat recovery model for reciprocating internal combustion engines (ICEs). The purpose of the proposed model is to provide realistic estimates of performance/efficiency maps for both electrical power output and useful thermal output for various capacities of engines for use in a preliminary CHP design/simulation process. The proposed model will serve as an alternative to constant engine efficiencies or empirical efficiency curves commonly used in the current literature for simulations of CHP systems. The engine performance/efficiency calculation algorithm has been coded to a publicly distributed FORTRAN Dynamic Link Library (DLL), and a user friendly tool has been developed using Visual Basic programming. Simulation results using the proposed model are validated against manufacturer’s technical data.

combined heat and power, internal combustion engin↗

Development and validation of a piloted simulation of a helicopter and external sling load

A generalized, real time, piloted, visual simulation of a single rotor helicopter, suspension system, and external load is described and validated for the full flight envelope of the U.S. Army CH-54 helicopter and cargo container as an example. The mathematical model described uses modified nonlinear classical rotor theory for both the main rotor and tail rotor, nonlinear fuselage aerodynamics, an elastic suspension system, nonlinear load aerodynamics, and a loadground contact model. The implementation of the mathematical model on a large digital computing system is described, and validation of the simulation is discussed. The mathematical model is validated by comparing measured flight data with simulated data, by comparing linearized system matrices, eigenvalues, and eigenvectors with manufacturers' data, and by the subjective comparison of handling characteristics by experienced pilots. A visual landing display system for use in simulation which generates the pilot's forward looking real world display was examined and a special head up, down looking load/landing zone display is described.

Shaughnessy, J. D.↗