SEARCH · Search NASA

Results for “mass production method”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 91 records · Page 5

All sources NASA NTRS DOE OSTI

DOE OSTI2020

Energy Efficient Thermoplastic Composite Manufacturing

The objective of the project was to establish an effective and affordable method to lay-up and consolidate/join large thermoplastic composite aerospace structure with cycle times measured in minutes rather than hours. Composite airplane designs have proven efficient and effective however future potential product production rates are challenging what the current systems can efficiently produce due to material lay-down constraints and extended thermal cycle times. The ability to lay-up then rapidly heat, consolidate, and cool large complex composite structures plus very accurately tool them (i.e. matching CTE of composite materials) along with very precise thermal control is a difficult challenge. Current systems such as autoclave processing of thermoset materials require long cycle times due to method of heating and the large associated thermal masses. These extended cycle times inhibit the ability to meet higher rate production scenarios due to the need for multiple sets of equipment and tools. Thermoplastic composite materials were used to facilitate more rapid cycle times via the elimination of a need for a cure dwell at temperature. Also, utilized induction heating along with smart susceptors to enable the quick cycle times needed while providing precise intrinsic thermal control. The intrinsic control of the induction heating process via the smart susceptors along with the use of laser assisted fiber placement were the key innovations areas developed. The ability to rapidly heat and then precisely control the temperature of the consolidation component was paramount to the success of this project. It is this unique processing attribute coupled with the thermoplastic material characteristics along with rapid lay-up methods that are novel and advantageous. While many requirements and influencing factors decide the materials and processes utilized for future airplane construction, the forecast of accelerated production rates and the recent performance successes of composites in airplane construction provide an opportunity for this processing technology to have significant influence. During the course of this project a number of key accomplishments were completed. They are as follows: The needed laser assisted fiber placement capabilities have been developed and validated on a component of meaningful scale and complexity. Subsequently, a thermoplastic preform of the part scale-up part design was laser assisted fiber placed and made availalbe for consolidation. An induction consolidation system was sized, designed, and fabricated resulting in the full capability to consolidate the scale-up component. The tool for induction consolidating of the scale-up component was designed and fabricated. An aluminum pressure bladder was welded and formed for use as the pressurization membrane to perform the needed application of pressure on the part at temperature to achieve consolidation. The induction consolidation system consisting of the restraint, induction power supply, induction tool with integrated induction coils and smart susceptor liners, along with the aluminum bladder were successfully used to consolidate a large thermoplastic skin. The capability of accomplishing rapid heat-up rates and cool down rates for consolidation of large thermoplastic skins with precise thermal control and even pressure application at the consolidation temperature was validated. The general conclusion is that the use of induction consolidation with smart susceptors is an effective method to rapidly and efficiently consolidate large thermoplastic composite components and enable affordable high rate manufacturing of composites. More specific conclusions generated by this project are as follows: A restraint type induction consolidation system provides an affordable option over the standard press when using the induction consolidation processing method. Aluminum bladders can be formed to the complex shapes needed and supply uniform pressure for consolidation and co-consolidation of thermoplastic composite materials. Straightforward modifications can be made to existing fiber placement robotic systems to enable their use for thermoplastic lay-up applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Measurement of the 230 Th( p ,2n)Pa229 and 230 Th( p ,3n)Pa228 reaction cross sections from 14.1 to 16.9 MeV

Actinium-225 is of interest for medical isotope production and there is on-going research into methods of producing Ac 225 , either directly or via the decay of its parent isotopes ( Th 229 , Pa 229 , and Ra 225 ). One method that has been suggested is the Th 230 ( p , 2 n ) Pa 229 reaction. However, there is no available cross-section data for this reaction in the literature. Purpose: Measure the Th 230 ( p , 2 n ) and Th 230 ( p , 3 n ) reaction cross sections in the energy range where the ( p , 2 n ) reaction is predicted to peak to determine the feasibility of Ac 225 production via the Th 230 ( p , 2 n ) reaction. Methods: Targets naturally enriched in Th 230 were irradiated at the Center for Accelerator Mass Spectrometry at Lawrence Livermore National Laboratory with energies ranging from 14.1 to 16.9 MeV. Furthermore, chemical processing was used to separate the protactinium activation products, followed by γ -ray spectroscopy to measure the activities of Pa 228 , 229 , 230 , 232 produced in the irradiation. Results: We find that excitation functions are reported for the first time in the literature for the Th 230 ( p , 2 n ) and Th 230 ( p , 3 n ) reactions in this energy range. The peak measured value of the Th 230 ( p , 2 n ) reaction was found to be 182 ± 12 mb at 14.4 ± 0.1 MeV. The Th 232 ( p , n ) Pa 232 reaction was used to verify the experimental conditions, the measured values are reported and are comparable to the existing literature values. From the γ -ray spectrometry data, the half-life of Pa 229 was measured as 1.5 ± 0.1 days, which is within the error of the half-life reported in the evaluated nuclear data as well as in the recent measurements, and the half-life of Pa 228 was measured as 19.5 ± 0.4 hours. Conclusions: Overall, the Th 230 ( p , 2 n ) Pa 229 reaction could reasonably be used for Ac 225 isotope production, although significant amounts of relatively isotopically pure Th 230 would be needed for significant production because the low alpha-decay branching ratio of Pa 229 and long half-life of Th 229 inhibit the in-growth of significant amounts of Ac 225 .

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

NASA NTRS1976

Estimates of nitric oxide production for lifting spacecraft reentry

An approximate analysis to estimate the quantity of nitric oxide that could be formed in the wake of a reentering lifting spacecraft is reported. Three different approaches are undertaken: two simplified analytical models utilizing the sudden-freezing concept named the 'trailing-edge-freezing' and 'wake-freezing' approximations, and a computer calculation involving numerical integration of chemical rate equations. The three methods predict a maximum nitric oxide production equivalent to 6, 9.5 and 8% of the mass of the spacecraft, respectively. Thus, the amount of nitric oxide expected to be produced by future space activities is negligibly small compared with that produced by the natural processes.

Park, C.↗

NASA NTRS1998

NASA Breakthrough Propulsion Physics Program

In 1996, NASA established the Breakthrough Propulsion Physics program to seek the ultimate breakthroughs in space transportation: propulsion that requires no propellant mass, propulsion that attains the maximum transit speeds physically possible, and breakthrough methods of energy production to power such devices. Topics of interest include experiments and theories regarding the coupling of gravity and electromagnetism, vacuum fluctuation energy, warp drives and worm-holes, and superluminal quantum effects. Because these propulsion goals are presumably far from fruition, a special emphasis is to identify affordable, near-term, and credible research that could make measurable progress toward these propulsion goals. The methods of the program and the results of the 1997 workshop are presented. This Breakthrough Propulsion Physics program, managed by Lewis Research Center, is one part of a comprehensive, long range Advanced Space Transportation Plan managed by Marshall Space Flight Center.

Millis, Marc G.↗

DOE OSTI2020

Inline gamma-spectrometry of fission product elements after rapid high-pressure ion chromatographic separation

Analysis of irradiated material shortly after irradiation can be non-trivial due to highly radioactive activation and fission isotopes increasing dead time in gamma-ray detection systems, often requiring a “cooling-period” between receipt of a sample and the subsequent analysis. A direct separation–detection method has been developed combining ion chromatography and inductively coupled mass spectrometry for rapid, low-level analysis of fission products; it cannot, however, detect certain short-lived species below the detection limit of the system. In this paper we report the implementation of an inline gamma-ray detector, which was added post-separation, pre-analysis, to test the quality and utility of elementally-isolated gamma-ray spectroscopy.

Inline gamma-ray detection↗

DOE OSTI2023

ICP-MS For Analysis of Lithium Isotopic Ratios in Materials Highly Enriched in 7Li - CRADA 626 (Abstract)

The purpose of this project is to develop analytical methods that can be deployed for analysis of lithium isotope enrichment products. One method involves rapid, high-throughput, relatively low precision analysis for direct monitoring of enrichment processes. A second method involves slower, but more precise analysis of final products of the enrichment process. We will use commercially available analytical equipment (quadrupole base inductively coupled plasma mass spectrometry and multi-collector magnetic sector inductively coupled plasma mass spectrometry) so that the analytical methods developed can be applied broadly.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2023

Intact mass spectrometry screening to optimize hydroxyl radical dose for protein footprinting

Hydroxyl radical protein footprinting (HRPF) using synchrotron radiation is a well-validated method to assess protein structure in the native solution state. In this method, X-ray radiolysis of water generates hydroxyl radicals that can react with solvent accessible side chains of proteins, with mass spectrometry used to detect the resulting labeled products. An ideal footprinting dose provides sufficient labeling to measure the structure but not so much as to influence the results. The optimization of hydroxyl radical dose is typically performed using an indirect Alexa488 fluorescence assay sensitive to hydroxyl radical concentration, but full evaluation of the experiment's outcome relies upon bottom-up liquid chromatography mass spectrometry (LC-MS) measurements to directly determine sites and extent of oxidative labeling at the peptide and protein level. A direct evaluation of the extent of labeling to provide direct and absolute measurements of dose and “safe” dose ranges in terms of, for example, average numbers of labels per protein, would provide immediate feedback on experimental outcomes prior to embarking on detailed LC-MS analyses. To this end, we describe an approach to integrate intact MS screening of labeled samples immediately following exposure, along with metrics to quantify the extent of observed labeling from the intact mass spectra. Intact MS results on the model protein lysozyme were evaluated in the context of Alexa488 assay results and a bottom-up LC-MS analysis of the same samples. In conclusion, this approach provides a basis for placing delivered hydroxyl radical dose metrics on firmer technical grounds for synchrotron X-ray footprinting of proteins, with explicit parameters to increase the likelihood of a productive experimental outcome. Further, the method directs approaches to provide absolute and direct dosimetry for all types of labeling for protein footprinting.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1997

Real Time Quantitative 3-D Imaging of Diffusion Flame Species

A low-gravity environment, in space or ground-based facilities such as drop towers, provides a unique setting for study of combustion mechanisms. Understanding the physical phenomena controlling the ignition and spread of flames in microgravity has importance for space safety as well as better characterization of dynamical and chemical combustion processes which are normally masked by buoyancy and other gravity-related effects. Even the use of so-called 'limiting cases' or the construction of 1-D or 2-D models and experiments fail to make the analysis of combustion simultaneously simple and accurate. Ideally, to bridge the gap between chemistry and fluid mechanics in microgravity combustion, species concentrations and temperature profiles are needed throughout the flame. However, restrictions associated with performing measurements in reduced gravity, especially size and weight considerations, have generally limited microgravity combustion studies to the capture of flame emissions on film or video laser Schlieren imaging and (intrusive) temperature measurements using thermocouples. Given the development of detailed theoretical models, more sophisticated studies are needed to provide the kind of quantitative data necessary to characterize the properties of microgravity combustion processes as well as provide accurate feedback to improve the predictive capabilities of the computational models. While there have been a myriad of fluid mechanical visualization studies in microgravity combustion, little experimental work has been completed to obtain reactant and product concentrations within a microgravity flame. This is largely due to the fact that traditional sampling methods (quenching microprobes using GC and/or mass spec analysis) are too heavy, slow, and cumbersome for microgravity experiments. Non-intrusive optical spectroscopic techniques have - up until now - also required excessively bulky, power hungry equipment. However, with the advent of near-IR diode lasers, the possibility now exists to obtain reactant and product concentrations and temperatures non-intrusively in microgravity combustion studies. Over the past ten years, Southwest Sciences has focused its research on the high sensitivity, quantitative detection of gas phase species using diode lasers. Our research approach combines three innovations in an experimental system resulting in a new capability for nonintrusive measurement of major combustion species. FM spectroscopy or high frequency Wavelength Modulation Spectroscopy (WMS) have recently been applied to sensitive absorption measurements at Southwest Sciences and in other laboratories using GaAlAs or InGaAsP diode lasers in the visible or near-infrared as well as lead-salt lasers in the mid-infrared spectral region. Because these lasers exhibit essentially no source noise at the high detection frequencies employed with this technique, the achievement of sensitivity approaching the detector shot noise limit is possible.

Kane, Daniel J.↗

DOE OSTI2021

Preshaping clear glass at low temperatures

Advances in available glass chemistries and glass processing methods have accompanied and enabled some of the biggest technology revolutions, from the development and mass production of light bulbs to low-loss fiber optics and durable smartphone touchscreens. An emerging generation of low-temperature processing technologies aims to continue this important trend and make a broader array of glass components mass producible. In the issue, Mader et al. (1) describe one such innovation in glass processing—the use of low-temperature injection molding to preshape silica particle–filled composites that can later be transformed into transparent fused silica glass objects. Traditionally, transparent glass objects are manufactured in high volume from molten or softened glass, which is floated, drawn, blown, cast, or blow-molded to a desired shape (see the figure, top). The glass composition and processing technique dictate the working temperature, which is usually quite high (near 1000°C) and often restricts the choice of compatible equipment or limits the choice of glass composition. Because geometry-specific capital investment is required for production, drastic or frequent component design changes or small batches may be cost prohibitive. Alternatively, transparent glass components can also be shaped at ambient temperature from solid glass by a series of subtractive processes, including cutting or multiple stages of grinding, followed by slower processing steps, such as polishing or etching. This approach is somewhat less amenable to mass production, and certain geometries containing tool-inaccessible regions cannot be fabricated in this way. Several emerging glass-shaping technologies aim to reduce the required manufacturing temperatures and still provide access to a broader range of glass compositions and component geometries (see the figure). These approaches use a three-step process. First, a desired shape is preformed at low temperature from a glass-forming, organic-inorganic composite. Next, the preform is dried, and organic materials used to bind particles are removed. Finally, the preform is heated (sintered) well below the glass-melting temperature to densify to transparent glass. Although the second and third steps do occur at increased temperatures, only standard, geometry-agnostic driers and furnaces are required. This strategy builds on the well-studied sol-gel approach to forming monolithic glass, where silica network–forming chemical solutions are poured into molds, slowly dried, and condensed into dense glass without melting (2). In a departure from the sol-gel process, these new technologies use solvents, cross-linkers, and polymers to formulate organic-inorganic composites tuned for compatibility with a particular shaping process, with formats ranging from photocurable liquids to shear-thickening pastes to solids. The composite inorganic loadings are also typically higher than those in the pure sol-gel approach, which drastically reduces shrinkage in comparison.

36 MATERIALS SCIENCE↗

NASA NTRS1988

Improved silicon carbide for advanced heat engines

This is the third annual technical report for the program entitled, Improved Silicon Carbide for Advanced Heat Engines, for the period February 16, 1987 to February 15, 1988. The objective of the original program was the development of high strength, high reliability silicon carbide parts with complex shapes suitable for use in advanced heat engines. Injection molding is the forming method selected for the program because it is capable of forming complex parts adaptable for mass production on an economically sound basis. The goals of the revised program are to reach a Weibull characteristic strength of 550 MPa (80 ksi) and a Weibull modulus of 16 for bars tested in 4-point loading. Two tasks are discussed: Task 1 which involves materials and process improvements, and Task 2 which is a MOR bar matrix to improve strength and reliability. Many statistically designed experiments were completed under task 1 which improved the composition of the batches, the mixing of the powders, the sinter and anneal cycles. The best results were obtained by an attritor mixing process which yielded strengths in excess of 550 MPa (80 ksi) and an individual Weibull modulus of 16.8 for a 9-sample group. Strengths measured at 1200 and 1400 C were equal to the room temperature strength. Annealing of machined test bars significantly improved the strength. Molding yields were measured and flaw distributions were observed to follow a Poisson process. The second iteration of the Task 2 matrix experiment is described.

Whalen, Thomas J.↗

NASA NTRS1991

Nonequilibrium radiation and chemistry models for aerocapture vehicle flowfields, volume 2

A technique was developed for predicting the character and magnitude of the shock wave precursor ahead of an entry vehicle and the effect of this precursor on the vehicle flow field was ascertained. A computational method and program were developed to properly model this precursor. Expressions were developed for the mass production rates of each species due to photodissociation and photoionization reactions. Also, consideration was given to the absorption and emission of radiation and how it affects the energy in each of the energy modes of both the atomic and diatomic species. A series of parametric studies were conducted covering a range of entry conditions in order to predict the effects of the precursor on the shock layer and the radiative heat transfer to the body.

Carlson, Leland A.↗

NASA NTRS1989

Improved silicon carbide for advanced heat engines

The development of high strength, high reliability silicon carbide parts with complex shapes suitable for use in advanced heat engines is studied. Injection molding was the forming method selected for the program because it is capable of forming complex parts adaptable for mass production on an economically sound basis. The goals were to reach a Weibull characteristic strength of 550 MPa (80 ksi) and a Weibull modulus of 16 for bars tested in four-point loading. Statistically designed experiments were performed throughout the program and a fluid mixing process employing an attritor mixer was developed. Compositional improvements in the amounts and sources of boron and carbon used and a pressureless sintering cycle were developed which provided samples of about 99 percent of theoretical density. Strengths were found to improve significantly by annealing in air. Strengths in excess of 550 MPa (80 ksi) with Weibull modulus of about 9 were obtained. Further improvements in Weibull modulus to about 16 were realized by proof testing. This is an increase of 86 percent in strength and 100 percent in Weibull modulus over the baseline data generated at the beginning of the program. Molding yields were improved and flaw distributions were observed to follow a Poisson process. Magic angle spinning nuclear magnetic resonance spectra were found to be useful in characterizing the SiC powder and the sintered samples. Turbocharger rotors were molded and examined as an indication of the moldability of the mixes which were developed in this program.

Whalen, Thomas J.↗

NASA NTRS1996

Breakthrough Propulsion Physics Research Program

In 1996, a team of government, university and industry researchers proposed a program to seek the ultimate breakthroughs in space transportation: propulsion that requires no propellant mass, propulsion that can approach and, if possible, circumvent light speed, and breakthrough methods of energy production to power such devices. This Breakthrough Propulsion Physics program, managed by Lewis Research Center, is one part of a comprehensive, long range Advanced Space Transportation Plan managed by Marshall Space Flight Center. Because the breakthrough goals are beyond existing science, a main emphasis of this program is to establish metrics and ground rules to produce near-term credible progress toward these incredible possibilities. An introduction to the emerging scientific possibilities from which such solutions can be sought is also presented.

Millis, Marc G.↗

NASA NTRS2007

Aerogel Insulation Applications for Liquid Hydrogen Launch Vehicle Tanks

Aerogel based insulation systems for ambient pressure environments were developed for liquid hydrogen (LH2) tank applications. Solutions to thermal insulation problems were demonstrated for the Space Shuttle External Tank (ET) through extensive testing at the Cryogenics Test Laboratory. Demonstration testing was performed using a 1/10th scale ET LH2 intertank unit and liquid helium as the coolant to provide the 20 K cold boundary temperature. Cryopumping tests in the range of 20K were performed using both constant mass and constant pressure methods. Long-duration tests (up to 10 hours) showed that the nitrogen mass taken up inside the intertank is reduced by a factor of nearly three for the aerogel insulated case as compared to the un-insulated (bare metal flight configuration) case. Test results including thermal stabilization, heat transfer effectiveness, and cryopumping confirm that the aerogel system eliminates free liquid nitrogen within the intertank. Physisorption (or adsorption) of liquid nitrogen within the fine pore structure of aerogel materials was also investigated. Results of a mass uptake method show that the sorption ratio (liquid nitrogen to aerogel beads) is about 62 percent by volume. A novel liquid nitrogen production method of testing the liquid nitrogen physical adsorption capacity of aerogel beads was also performed to more closely approximate the actual launch vehicle cooldown and thermal stabilization effects within the aerogel material. The extraordinary insulating effectiveness of the aerogel material shows that cryopumping is not an open-cell mass transport issue but is strictly driven by thermal communication between warm and cold surfaces. The new aerogel insulation technology is useful to solve heat transfer problem areas and to augment existing thermal protection systems on launch vehicles. Examples are given and potential benefits for producing launch systems that are more reliable, robust, reusable, and efficient are outlined.

Fesmire, J. E.↗

NASA NTRS2001

Designing Extraterrestrial Plant Growth Habitats With Low Pressure Atmospheres

In-situ resource utilization, provision of human life support requirements by bioregenerative methods, and engineering constraints for construction and deployment of plant growth structures on the surface of Mars all suggest the need for plant growth studies at hypobaric pressures. Past work demonstrated that plants will likely tolerate and grow at pressures at or below 10 kPa. Based upon this premise, concepts are developed for the design of reduced pressure atmospheres in lightweight, inflatable structures for plant growth systems on Mars with the goals of maximizing design simplicity and the use of local resources. A modular pod design is proposed as it could be integrated with large-scale production systems. Atmospheric modification of pod clusters would be based upon a pulse and scrub system using mass flow methods for atmospheric transport. A specific modification and control scenario is developed for a lettuce pod to illustrate the dynamics of carbon dioxide and oxygen exchange within a pod. Considerations of minimal atmospheric crop requirements will aid in the development of engineering designs and strategies for extraterrestrial plant growth structures that employ rarefied atmospheres.

Corey, Kenneth A.↗

NASA NTRS2002

Designing Extraterrestrial Plant Growth Habitats with Low Pressure Atmospheres

Corey, Kenneth A.↗

NASA NTRS2003

Monte Carlo Simulations and Generation of the SPI Response

In this paper we discuss the methods developed for the production of the INTEGRAL/SPI instrument response. The response files were produced using a suite of Monte Carlo simulation software developed at NASA/GSFC based on the GEANT-3 package available from CERN. The production of the INTEGRAL/SPI instrument response also required the development of a detailed computer mass model for SPI. We discuss our extensive investigations into methods to reduce both the computation time and storage requirements for the SPI response. We also discuss corrections to the simulated response based on our comparison of ground and inflight calibration data with MGEANT simulation.

Sturner, S. J.↗

NASA NTRS2003

Monte Carlo Simulations and Generation of the SPI Response

In this paper we discuss the methods developed for the production of the INTEGRAL/SPI instrument response. The response files were produced using a suite of Monte Carlo simulation software developed at NASA/GSFC based on the GEANT-3 package available from CERN. The production of the INTEGRAL/SPI instrument response also required the development of a detailed computer mass model for SPI. We discuss ow extensive investigations into methods to reduce both the computation time and storage requirements for the SPI response. We also discuss corrections to the simulated response based on our comparison of ground and infiight Calibration data with MGEANT simulations.

Sturner, S. J.↗