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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

Implementing Geometric Surface Imperfections into Sandwich Composite Cylinder Finite Element Method Models

The buckling responses of certain cylindrical shell structures are extremely sensitive to geometric imperfections. The NASA Engineering and Safety Center (NESC) Shell Buckling Knockdown Factor Project (SBKF) is conducting research to develop analysis-based buckling design recommendations. Experiments are used to verify the analysis-based factors, but the sensitivity of the test articles to geometric imperfections requires implementing as-manufactured imperfections into high-fidelity finite element method (FEM) models. Geometry measurement methods such as structured light scanning are used for all geometric surface data used in this work. Common preprocessing and visualization steps used in SBKF are discussed, and steps of how surface scans are prepared for implementation into a finite element model is described. The Python Tool for Implementing Geometric Imperfections in Reduced Structures (Py_TIGIRS), written specifically for the use with SBKF, is briefly described and uses eight functions to extract, modify, and write geometric imperfections into Abaqus input files. Results of the preprocessing methods and results from Py_TIGIRS are provided and compared for Composite Test Articles (CTA) 8.2, 8.2B, and 8.3. Excellent agreement between the visualized scan data and the FEM-extracted geometry is demonstrated. A brief example of why geometric surface imperfections are significant in nonlinear numerical analyses for thin cylinders in axial compression is provided as motivation to use tools such as Py_TIGIRS. Future developments of Py_TIGIRS including expansion to structures of arbitrary geometry is planned.

Geometric imperfections↗
NASA NTRS2015

Cleaning and Cleanliness Measurement of Additive Manufactured Parts

The successful acquisition and utilization of piece parts and assemblies for contamination sensitive applications requires application of cleanliness acceptance criteria. Contamination can be classified using many different schemes. One common scheme is classification as organic, ionic and particulate contaminants. These may be present in and on the surface of solid components and assemblies or may be dispersed in various gaseous or liquid media. This discussion will focus on insoluble particle contamination on the surface of piece parts and assemblies. Cleanliness of parts can be controlled using two strategies, referred to as gross cleanliness and precision cleanliness. Under a gross cleanliness strategy acceptance is based on visual cleanliness. This approach introduces a number of concerns that render it unsuitable for controlling cleanliness of high technology products. Under the precision cleanliness strategy, subjective, visual assessment of cleanliness is replaced by objective measurement of cleanliness. When a precision cleanliness strategy is adopted there naturally arises the question: How clean is clean enough? The six commonly used methods for establishing objective cleanliness acceptance limits will be discussed. Special emphasis shall focus on the use of multiple extraction, a technique that has been demonstrated for additively manufactured parts.

Welker, Roger W.↗
NASA NTRS1982

Aircraft geometry verification with enhanced computer-generated displays

A method for visual verification of aerodynamic geometries using computer-generated, color-shaded images is described. The mathematical models representing aircraft geometries are created for use in theoretical aerodynamic analyses and in computer-aided manufacturing. The aerodynamic shapes are defined using parametric bi-cubic splined patches. This mathematical representation is then used as input to an algorithm that generates a color-shaded image of the geometry. A discussion of the techniques used in the mathematical representation of the geometry and in the rendering of the color-shaded display is presented. The results include examples of color-shaded displays, which are contrasted with wire-frame-type displays. The examples also show the use of mapped surface pressures in terms of color-shaded images of V/STOL fighter/attack aircraft and advanced turboprop aircraft.

Cozzolongo, J. V.↗
NASA NTRS1990

Space-Spurred Metallized Materials

Spurred R&D toward improved vacuum metallizing techniques led to an extensive line of commercial products, from insulated outdoor garments to packaging for foods, from wall coverings to window shades, from life rafts to candy wrappings, reflective blankets to photographic reflectors. Metallized Products, Inc. (MPI) was one of the companies that worked with NASA in development of the original space materials. MPI markets its own metallized products and supplies materials to other manufacturers. One of the most widely used MPI products is TXG laminate. An example is a reflective kite, the S.O.S. Signal Kite that can be flown as high as 200 feet to enhance radar and visual detectability. It offers a boon to campers, hikers, mountain climbers and boaters. It is produced by Solar Reflections, Inc. The company also markets a solar reflective hat. Another example is by Pro-Tektion, Inc. to provide protection for expensive musical equipment that have sensitive electronic components subject to damage from the heat of stage lights, dust, or rain at outdoor concerts. MP supplied the material and acceptance of the covers by the sound industry has been excellent.

Source record↗
NASA NTRS2010

Effects of Hydrocarbon-Based Grease on Rapid Prototype Material Used for Grease Retention Shrouds

Effects of hydrocarbon-based greases on specific rapid prototype (RP) materials used to fabricate grease retention shrouds (GRS) were explored in this study. Grease retention shrouds are being considered as a way to maintain adequate grease lubrication at the gear mesh in a prototype research transmission system. Due to their design and manufacturing flexibility, rapid prototype materials were chosen for the grease retention shrouds. In order to gain a better understanding of the short and long term effects grease pose on RP materials, research was conducted on the interaction of hydrocarbon-based grease with RP materials. The materials used in this study were durable polyamide (nylon), acrylonitrile butadiene styrene (ABS), and WaterClear 10120. Testing was conducted using Mobilgrease 28 and Syn-Tech 3913G grease (gear coupling grease). These greases were selected due to their regular use with mechanical components. To investigate the effect that grease has on RP materials, the following methods were used to obtain qualitative and quantitative data: Fourier transform infrared spectroscopy (FT-IR), interference profilometer measurements, digital camera imaging, physical shape measurement, and visual observations. To record the changes in the RP materials due to contact with the grease, data was taken before and after the grease application. Results showed that the WaterClear 10120 RP material provided the best resistance to grease penetration as compared to nylon and ABS RP materials. The manufacturing process, and thus resulting surface conditions of the RP material, played a key role in the grease penetration properties and resilience of these materials.

Zakrajsek, Andrew J.↗
NASA NTRS2003

Visual and x-ray inspection characteristics of eutectic and lead free assemblies

For high reliability applications, visual inspection has been the key technique for most conventional electronic package assemblies. Now, the use of x-ray technique has become an additional inspection requirement for quality control and detection of unique defects due to manufacturing of advanced electronic array packages such as ball grid array (BGAs) and chip scale packages (CSPs).

x-ray↗
NASA NTRS1979

Manufacture of low carbon astroloy turbine disk shapes by hot isostatic pressing. Volume 2, project 1

The performance of a hot isotatic pressed disk installed in an experimental engine and exposed to realistic operating conditions in a 150-hour engine test and a 1000 cycle endurance test is documented. Post test analysis, based on visual, fluorescent penetrant and dimensional inspection, revealed no defects in the disk and indicated that the disk performed satisfactorily.

Eng, R. D.↗
NASA NTRS1996

Cardiac Monitor

Under contract to Johnson Space Center, the University of Minnesota developed the concept of impedance cardiography as an alternative to thermodilution to access astronaut heart function in flight. NASA then contracted Space Labs, Inc. to construct miniature space units based on this technology. Several companies then launched their own impedance cardiography, including Renaissance Technologies, which manufactures the IQ System. The IQ System is 5 to 17 times cheaper than thermodilution, and features the signal processing technology called TFD (Time Frequency Distribution). TFD provides three- dimensional distribution of the blood circulation force signals, allowing visualization of changes in power, frequency and time.

Source record↗
NASA NTRS2015

Color Changing Hydrogen Sensors

During the Space Shuttle Program, one of the most hazardous operation that occurred was the loading of liquid hydrogen (LH2) during fueling operations of the spacecraft. Due to hydrogen's low explosive limit, any amount leaked could lead to catastrophic event. Hydrogen's chemical properties make it ideal as a rocket fuel; however, the fuel is deemed unsafe for most commercial use because of the inability to easily detect the gas leaking. The increased use of hydrogen over traditional fossil fuels would reduce greenhouse gases and America's dependency on foreign oil. Therefore a technology that would improve safety at NASA and in the commercial sector while creating a new economic sector would have a huge impact to NASA's mission. The Chemochromic Detector for sensing hydrogen gas leakage is a color-changing detector that is useful in any application where it is important to know not only the presence but also the location of the hydrogen gas leak. This technology utilizes a chemochromicpigment and polymer matrix that can be molded or spun into rigid or pliable shapes useable in variable temperature environments including atmospheres of inert gas, hydrogen gas, or mixtures of gases. A change in color of the detector material indicates where gaseous hydrogen leaks are occurring. The irreversible sensor has a dramatic color change from beige to dark grey and remains dark grey after exposure. A reversible pigment changes from white to blue in the presence of hydrogen and reverts back to white in the presence of oxygen. Both versions of the sensor's pigments were comprised of a mixture of a metal oxide substrate and a hydro-chromic compound (i.e., the compound that changed color in the presence of hydrogen) and immediately notified the operator of the presence of low levels of hydrogen. The detector can be used in a variety of formats including paint, tape, caulking, injection molded parts, textiles and fabrics, composites, and films. This technology brings numerous benefits over the traditional hydrogen sensors: The technology has excellent temperature stability (4K to 373 K), it can be used in cryogenic fluid applications, it is easy to apply and remove; it requires no power to operate; it has a quick response time; the leak points can be detected visually or electronically; it is nonhazardous, thus environmentally friendly; it can be reversible or irreversible; it does not require on-site monitoring; has a long shelf life; the detector is very durable; and the technology is inexpensive to manufacture.

Chemochromic sensor↗
NASA NTRS2007

Experimental Design for the Evaluation of Detection Techniques of Hidden Corrosion Beneath the Thermal Protective System of the Space Shuttle Orbiter

The detection of corrosion beneath Space Shuttle Orbiter thermal protective system is traditionally accomplished by removing the Reusable Surface Insulation tiles and performing a visual inspection of the aluminum substrate and corrosion protection system. This process is time consuming and has the potential to damage high cost tiles. To evaluate non-intrusive NDE methods, a Proof of Concept (PoC) experiment was designed and test panels were manufactured. The objective of the test plan was three-fold: establish the ability to detect corrosion hidden from view by tiles; determine the key factor affecting detectability; roughly quantify the detection threshold. The plan consisted of artificially inducing dimensionally controlled corrosion spots in two panels and rebonding tile over the spots to model the thermal protective system of the orbiter. The corrosion spot diameter ranged from 0.100" to 0.600" inches and the depth ranged from 0.003" to 0.020". One panel consisted of a complete factorial array of corrosion spots with and without tile coverage. The second panel consisted of randomized factorial points replicated and hidden by tile. Conventional methods such as ultrasonics, infrared, eddy current and microwave methods have shortcomings. Ultrasonics and IR cannot sufficiently penetrate the tiles, while eddy current and microwaves have inadequate resolution. As such, the panels were interrogated using Backscatter Radiography and Terahertz Imaging. The terahertz system successfully detected artificially induced corrosion spots under orbiter tile and functional testing is in-work in preparation for implementation.

Kemmerer, Catherine C.↗
NASA NTRS1998

Analysis of a Memory Device Failure

The recent failure of a vintage memory device presented a unique challenge to failure analysts. Normally device layouts, fabrication parameters and other technical information were available to assist the analyst in the analysis. However, this device was out of production for many years and the manufacturer was no longer in business, so the information was not available. To further complicate this analysis, the package leads were all but removed making additional electrical testing difficult. Under these conditions, new and innovative methods were used to analyze the failure. The external visual exam, radiography, PIND, and leak testing were performed with nominal results. Since electrical testing was precluded by the short lead lengths, the device was delidded to expose the internal structures for microscopic examination. No failure mechanism was identified. The available electrical data suggested an ESD or low level EOS type mechanism which left no visible surface damage. Due to parallel electrical paths, electrical probing on the chip failed to locate the failure site. Two non-destructive Scanning Electron Microscopy techniques, CIVA (Charge Induced Voltage Alteration) and EBIC (Electron Beam Induced Current), and a liquid crystal decoration technique which detects localized heating were employed to aid in the analysis. CIVA and EBIC isolated two faults in the input circuitry, and the liquid crystal technique further localized two hot spots in regions on two input gates. Removal of the glassivation and metallization revealed multiple failure sites located in the gate oxide of two input transistors suggesting machine (testing) induced damage.

Nicolas, David P.↗
NASA NTRS1993

RighTime: A real time clock correcting program for MS-DOS-based computer systems

A computer program is described which effectively eliminates the misgivings of the DOS system clock in PC/AT-class computers. RighTime is a small, sophisticated memory-resident program that automatically corrects both the DOS system clock and the hardware 'CMOS' real time clock (RTC) in real time. RighTime learns what corrections are required without operator interaction beyond the occasional accurate time set. Both warm (power on) and cool (power off) errors are corrected, usually yielding better than one part per million accuracy in the typical desktop computer with no additional hardware, and RighTime increases the system clock resolution from approximately 0.0549 second to 0.01 second. Program tools are also available which allow visualization of RighTime's actions, verification of its performance, display of its history log, and which provide data for graphing of the system clock behavior. The program has found application in a wide variety of industries, including astronomy, satellite tracking, communications, broadcasting, transportation, public utilities, manufacturing, medicine, and the military.

Becker, G. Thomas↗
NASA NTRS1995

High Performance Parallel Computational Nanotechnology

At a recent press conference, NASA Administrator Dan Goldin encouraged NASA Ames Research Center to take a lead role in promoting research and development of advanced, high-performance computer technology, including nanotechnology. Manufacturers of leading-edge microprocessors currently perform large-scale simulations in the design and verification of semiconductor devices and microprocessors. Recently, the need for this intensive simulation and modeling analysis has greatly increased, due in part to the ever-increasing complexity of these devices, as well as the lessons of experiences such as the Pentium fiasco. Simulation, modeling, testing, and validation will be even more important for designing molecular computers because of the complex specification of millions of atoms, thousands of assembly steps, as well as the simulation and modeling needed to ensure reliable, robust and efficient fabrication of the molecular devices. The software for this capacity does not exist today, but it can be extrapolated from the software currently used in molecular modeling for other applications: semi-empirical methods, ab initio methods, self-consistent field methods, Hartree-Fock methods, molecular mechanics; and simulation methods for diamondoid structures. In as much as it seems clear that the application of such methods in nanotechnology will require powerful, highly powerful systems, this talk will discuss techniques and issues for performing these types of computations on parallel systems. We will describe system design issues (memory, I/O, mass storage, operating system requirements, special user interface issues, interconnects, bandwidths, and programming languages) involved in parallel methods for scalable classical, semiclassical, quantum, molecular mechanics, and continuum models; molecular nanotechnology computer-aided designs (NanoCAD) techniques; visualization using virtual reality techniques of structural models and assembly sequences; software required to control mini robotic manipulators for positional control; scalable numerical algorithms for reliability, verifications and testability. There appears no fundamental obstacle to simulating molecular compilers and molecular computers on high performance parallel computers, just as the Boeing 777 was simulated on a computer before manufacturing it.

Saini, Subhash↗
NASA NTRS1983

Accelerated degradation of silicon metallization systems

Clemson University has been engaged for the past five years in a program to determine the reliability attributes of solar cells by means of accelerated test procedures. The cells are electrically measured and visually inspected and then subjected for a period of time to stress in excess of that normally encountered in use, and then they are reinspected. Changes are noted and the process repeated. This testing has thus far involved 23 different unencapsulated cell types from 12 different manufacturers, and 10 different encapsulated cell types from 9 different manufacturers. Reliability attributes of metallization systems can be classified as major or minor, depending on the severity of the effects observed. As a result of the accelerated testing conducted under the Clemson program, major effects have been observed related to contact resistance and to mechanical adherence and solderability. This paper does not attempt a generalized survey of accelerated test results, but rather concentrates on one particular attribute of metallization that has been observed to cause electrical degradation - increased contact resistance due to Schottky barrier formation. In this example basic semiconductor theory was able to provide an understanding of the electrical effects observed during accelerated stress testing.

Lathrop, J. W.↗
NASA NTRS2018

Modeling-Driven Damage Tolerant Design of Graphene Nanoplatelet/Carbon Fiber/Epoxy Hybrid Composite Panels for Full-Scale Aerospace Structures

The objective of this study is to design a new nano graphenecarbon fiberpolymer hybrid composite that can be used for the NASA SLS Composite Exploration Upper Stage (CEUS) forward skirt structure. The new material will improve the resistance to open-hole compression failure of the structure relative to traditional polymer fiber composites. The material is designed rapidly and with little cost using the Integrated Computational Materials Engineering (ICME) approach. Multiscale modeling and experiments are used to synergistically optimize the material design to yield improved properties and performance by controlling key processing parameters for manufacturing nano-enhanced materials. Specifically, the nanocomposite panel showed a 22 reduction in mass relative to the traditional composite panel, while both designs are equal in terms of ease of manufacture. This potential mass savings corresponds to an estimated 45 savings in materials and manufacturing costs. The multiscale ICME workflow developed for this project can be readily applied to the development of nano-enhanced composite materials and large aerospace structures. In addition, all key aspects of ICME were employed to complete this project including multiscale modeling, experimental characterization and visualization, data management, visualization, error and uncertainty quantification, and education. The results presented herein indicate a dramatic level of success, as well as the power and potential of ICME approach and multiscale modeling for composite materials.

computational mechanics↗
NASA NTRS2003

Precise Measurement for Manufacturing

A metrology instrument known as PhaseCam supports a wide range of applications, from testing large optics to controlling factory production processes. This dynamic interferometer system enables precise measurement of three-dimensional surfaces in the manufacturing industry, delivering speed and high-resolution accuracy in even the most challenging environments.Compact and reliable, PhaseCam enables users to make interferometric measurements right on the factory floor. The system can be configured for many different applications, including mirror phasing, vacuum/cryogenic testing, motion/modal analysis, and flow visualization.

Source record↗
NASA NTRS1987

Intelligent laser soldering inspection and process control

Component assembly on printed circuitry keeps making giant strides toward denser packaging and smaller dimensions. From a single layer to multilayer, from through holes to surface mounted components and tape applied bonds, unrelenting progress results in new, difficult problems in assembling, soldering, inspecting and controlling the manufacturing process of the new electronics. Among the major problems are the variables introduced by human operators. The small dimensions and the tight assembly tolerances are now successfully met by machines which are faster and more precise than the human hand. The same is true for soldering. But visual inspection of the solder joints is now so severely limited by the ever shrinking area accessible to the human eye that the inspector's diagnosis cannot be trusted any longer. Solutions to correcting these problems are discussed.

Vanzetti, Riccardo↗
NASA NTRS2021

LMI Automated Air Cargo Operations Market Research and Forecast

Air cargo companies and aircraft manufacturers are making significant investments to enable the movement of cargo via various levels of automated aircraft, such as aircraft with simplified operations requiring a pilot, remotely monitored or piloted aircraft, and fully autonomous aircraft. These investments will enable greater utilization of aircraft while unlocking new air markets traditionally served by ground transportation only. Many cargo companies and aerospace experts envision an operating environment where a single pilot can remotely pilot numerous aircraft for significant increases in aircraft utilization. The future operating environment is also expected to include air cargo companies flying smaller aircraft from airports and distribution centers outside of major U.S. cities directly to city centers, avoiding congested roads and increasing the velocity of cargo shipments, particularly those that are high-value, time-sensitive, and security sensitive (e.g., pharmaceuticals). These are just a few benefits and use cases cargo companies and aerospace experts see with the advancement of automated aircraft. To better understand industry’s direction, NASA asked the LMI team to research the forecasted market, timeline, risks, and opportunities for integrating unmanned air cargo vehicles into the National Airspace System (NAS) for the development and prioritization of the NASA Air Traffic Management Exploration’s research portfolio. To begin the market assessment, we gathered data via numerous interviews with key stakeholders and subject matter experts and literature reviews. We then incorporated the data into a custom-developed systems dynamics model and visualization dashboard. The systems dynamics model classifies the size of the market (e.g., overall fleet size of automated aircraft) for four distinct use cases over the next 20 years. The model projects the year in which various types of automated aircraft will enter the commercial cargo market based on our team’s collective research on when the aircraft will become viable due to manufacturing and certification timelines and the lifespan of current, traditional aircraft in service, to name a few factors. While this report defines our team’s estimated timeline of entry and growth, the model is dynamic—it enables NASA users to change variables based on future-year events. If the necessary technology does not mature in accordance with our assumptions, then NASA can change the entry of service point to a future year to evaluate the changes in market size in the out years. This flexibility will be key to deciding when and how NASA should invest in various areas.

air traffic management↗