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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6

Intelligent processing of intermetallic composite consolidation

Intermetallic composites based upon titanium aluminide matrices and silicon carbide of aluminum oxide fibers are emerging candidates for future hypersonic vehicle airframes and engines. To tailor the properties of these 'engineered' materials for specific application, to increase process yield, and to reduce costs, 'intelligent processing of materials' (IPM) control strategies are being explored for their processing. Recent progress is evaluated in the development of predictive process models, advanced sensors and control methodologies (the components of the IPM approach) for the critical near net-shape consolidation process step of continuous fiber reinforced intermetallic composite manufacture.

Wadley, H. N. G.↗

V-Man Generation for 3-D Real Time Animation

The V-Man project has developed an intuitive authoring and intelligent system to create, animate, control and interact in real-time with a new generation of 3D virtual characters: The V-Men. It combines several innovative algorithms coming from Virtual Reality, Physical Simulation, Computer Vision, Robotics and Artificial Intelligence. Given a high-level task like "walk to that spot" or "get that object", a V-Man generates the complete animation required to accomplish the task. V-Men synthesise motion at runtime according to their environment, their task and their physical parameters, drawing upon its unique set of skills manufactured during the character creation. The key to the system is the automated creation of realistic V-Men, not requiring the expertise of an animator. It is based on real human data captured by 3D static and dynamic body scanners, which is then processed to generate firstly animatable body meshes, secondly 3D garments and finally skinned body meshes.

Nebel, Jean-Christophe↗

IDSE Version 1 User's Manual

The integrated development support environment (IDSE) is a suite of integrated software tools that provide intelligent support for information modelling. These tools assist in function, information, and process modeling. Additional tools exist to assist in gathering and analyzing information to be modeled. This is a user's guide to application of the IDSE. Sections covering the requirements and design of each of the tools are presented. There are currently three integrated computer aided manufacturing definition (IDEF) modeling methodologies: IDEF0, IDEF1, and IDEF2. Also, four appendices exist to describe hardware and software requirements, installation procedures, and basic hardware usage.

Mayer, Richard↗

An IEEE 1451.1 Architecture for ISHM Applications

The IEEE 1451.1 Standard for a Smart Transducer Interface defines a common network information model for connecting and managing smart elements in control and data acquisition networks using network-capable application processors (NCAPs). The Standard is a network-neutral design model that is easily ported across operating systems and physical networks for implementing complex acquisition and control applications by simply plugging in the appropriate network level drivers. To simplify configuration and tracking of transducer and actuator details, the family of 1451 standards defines a Transducer Electronic Data Sheet (TEDS) that is associated with each physical element. The TEDS contains all of the pertinent information about the physical operations of a transducer (such as operating regions, calibration tables, and manufacturer information), which the NCAP uses to configure the system to support a specific transducer. The Integrated Systems Health Management (ISHM) group at NASA's John C. Stennis Space Center (SSC) has been developing an ISHM architecture that utilizes IEEE 1451.1 as the primary configuration and data acquisition mechanism for managing and collecting information from a network of distributed intelligent sensing elements. This work has involved collaboration with other NASA centers, universities and aerospace industries to develop IEEE 1451.1 compliant sensors and interfaces tailored to support health assessment of complex systems. This paper and presentation describe the development and implementation of an interface for the configuration, management and communication of data, information and knowledge generated by a distributed system of IEEE 1451.1 intelligent elements monitoring a rocket engine test system. In this context, an intelligent element is defined as one incorporating support for the IEEE 1451.x standards and additional ISHM functions. Our implementation supports real-time collection of both measurement data (raw ADC counts and converted engineering units) and health statistics produced by each intelligent element. The handling of configuration, calibration and health information is automated by using the TEDS in combination with other electronic data sheets extensions to convey health parameters. By integrating the IEEE 1451.1 Standard for a Smart Transducer Interface with ISHM technologies, each element within a complex system becomes a highly flexible computation engine capable of self-validation and performing other measures of the quality of information it is producing.

Morris, Jon A.↗

Precision Casting via Advanced Simulation and Manufacturing

A two-year program was conducted to develop and commercially implement selected casting manufacturing technologies to enable significant reductions in the costs of castings, increase the complexity and dimensional accuracy of castings, and reduce the development times for delivery of high quality castings. The industry-led R&D project was cost shared with NASA's Aerospace Industry Technology Program (AITP). The Rocketdyne Division of Boeing North American, Inc. served as the team lead with participation from Lockheed Martin, Ford Motor Company, Howmet Corporation, PCC Airfoils, General Electric, UES, Inc., University of Alabama, Auburn University, Robinson, Inc., Aracor, and NASA-LeRC. The technical effort was organized into four distinct tasks. The accomplishments reported herein. Task 1.0 developed advanced simulation technology for core molding. Ford headed up this task. On this program, a specialized core machine was designed and built. Task 2.0 focused on intelligent process control for precision core molding. Howmet led this effort. The primary focus of these experimental efforts was to characterize the process parameters that have a strong impact on dimensional control issues of injection molded cores during their fabrication. Task 3.0 developed and applied rapid prototyping to produce near net shape castings. Rocketdyne was responsible for this task. CAD files were generated using reverse engineering, rapid prototype patterns were fabricated using SLS and SLA, and castings produced and evaluated. Task 4.0 was aimed at developing technology transfer. Rocketdyne coordinated this task. Casting related technology, explored and evaluated in the first three tasks of this program, was implemented into manufacturing processes.

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Parametric Mechanism Design Through Numerical Optimization and Physics Simulation

Design-Build-Test approaches for developing spaceflight hardware are prohibitively time and cost intensive and often lead to suboptimal mechanism designs. Approaches that couple machine learning and high-fidelity physics simulation could eliminate the need for hardware prototyping and dramatically accelerate the engineering design cycle, ultimately reducing cost. This work presents a modular NASA-developed toolchain to optimize hardware mechanisms in a virtual environment using numerical optimization and multi-body physics simulation. The toolchain enables multi-objective optimization, generates parametric CAD files that can be further post-processed by an end user, and can be expanded to optimize full systems and non-mechanical parameters such as feedback control variables. We demonstrate the toolchain through an independently verifiable design problem that optimizes wheel radius to achieve a desired linear velocity in a rigid-body physics environment when the wheel rotates at a constant angular speed, and then post-process the parametric CAD file of the optimal design generated by the tool before ultimately manufacturing it via 3D printing. We end with a discussion of how the toolchain can incorporate other analysis tools, including finite element analysis, computational fluid dynamics, and granular media simulations.

Optimization↗

An Optimization-Based Toolchain for Parametric Mechanism Design

Design-Build-Test approaches for developing spaceflight hardware are prohibitively time and cost intensive and often lead to suboptimal mechanism designs. Approaches that couple machine learning and high-fidelity physics simulation could eliminate the need for hardware prototyping and dramatically accelerate the engineering design cycle, ultimately reducing cost. This work presents a modular NASA-developed toolchain to optimize hardware mechanisms in a virtual environment using numerical optimization and multi-body physics simulation. The toolchain enables multi-objective optimization, generates parametric CAD files that can be further post-processed by an end user, and can be expanded to optimize full systems and non-mechanical parameters such as feedback control variables. We demonstrate the toolchain through an independently verifiable design problem that optimizes wheel radius to achieve a desired linear velocity in a rigid-body physics environment when the wheel rotates at a constant angular speed, and then post-process the parametric CAD file of the optimal design generated by the tool before ultimately manufacturing it via 3D printing. We end with a discussion of how the toolchain can incorporate other analysis tools, including finite element analysis, computational fluid dynamics, and granular media simulations.

Optimization↗

Neutron Characterization for Additive Manufacturing

Oak Ridge National Laboratory (ORNL) is leveraging decades of experience in neutron characterization of advanced materials together with resources such as the Spallation Neutron Source (SNS) and the High Flux Isotope Reactor (HFIR) shown in Fig. 1 to solve challenging problems in additive manufacturing (AM). Additive manufacturing, or three-dimensional (3-D) printing, is a rapidly maturing technology wherein components are built by selectively adding feedstock material at locations specified by a computer model. The majority of these technologies use thermally driven phase change mechanisms to convert the feedstock into functioning material. As the molten material cools and solidifies, the component is subjected to significant thermal gradients, generating significant internal stresses throughout the part (Fig. 2). As layers are added, inherent residual stresses cause warping and distortions that lead to geometrical differences between the final part and the original computer generated design. This effect also limits geometries that can be fabricated using AM, such as thin-walled, high-aspect- ratio, and overhanging structures. Distortion may be minimized by intelligent toolpath planning or strategic placement of support structures, but these approaches are not well understood and often "Edisonian" in nature. Residual stresses can also impact component performance during operation. For example, in a thermally cycled environment such as a high-pressure turbine engine, residual stresses can cause components to distort unpredictably. Different thermal treatments on as-fabricated AM components have been used to minimize residual stress, but components still retain a nonhomogeneous stress state and/or demonstrate a relaxation-derived geometric distortion. Industry, federal laboratory, and university collaboration is needed to address these challenges and enable the U.S. to compete in the global market. Work is currently being conducted on AM technologies at the ORNL Manufacturing Demonstration Facility (MDF) sponsored by the DOE's Advanced Manufacturing Office. The MDF is focusing on R&D of both metal and polymer AM pertaining to in-situ process monitoring and closed-loop controls; implementation of advanced materials in AM technologies; and demonstration, characterization, and optimization of next-generation technologies. ORNL is working directly with industry partners to leverage world-leading facilities in fields such as high performance computing, advanced materials characterization, and neutron sciences to solve fundamental challenges in advanced manufacturing. Specifically, MDF is leveraging two of the world's most advanced neutron facilities, the HFIR and SNS, to characterize additive manufactured components.

Watkins, Thomas↗

NASA space station automation: AI-based technology review

Research and Development projects in automation for the Space Station are discussed. Artificial Intelligence (AI) based automation technologies are planned to enhance crew safety through reduced need for EVA, increase crew productivity through the reduction of routine operations, increase space station autonomy, and augment space station capability through the use of teleoperation and robotics. AI technology will also be developed for the servicing of satellites at the Space Station, system monitoring and diagnosis, space manufacturing, and the assembly of large space structures.

Firschein, O.↗

Sensor Validation Software

Under a Small Business Innovation Research contract from Lewis Research Center, Expert Microsystems, Inc. developed SureSense, real-time sensor data validation software. This ultra-reliable control and sensing system product was produced through a partnership in 1994 between Expert Microsystems and Intelligent Software Associates, Inc. SureSense was created in response to a NASA need for verifying the reliability of sensor input that operated advanced automation and control systems. The immediate applications included improving the safety and reliability of Space Shuttle Main Engine operations. The company has structured the software to enable application to virtually any process control environment, such as computer integrated manufacturing, power plants, and hazardous gas sensing and control systems.

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A Program in Air Transportation Technology (Joint University Program)

The Joint University Program on Air Transportation Technology was conducted at Princeton University from 1971 to 1995. Our vision was to further understanding of the design and operation of transport aircraft, of the effects of atmospheric environment on aircraft flight, and of the development and utilization of the National Airspace System. As an adjunct, the program emphasized the independent research of both graduate and undergraduate students. Recent principal goals were to develop and verify new methods for design and analysis of intelligent flight control systems, aircraft guidance logic for recovery from wake vortex encounter, and robust flight control systems. Our research scope subsumed problems associated with multidisciplinary aircraft design synthesis and analysis based on flight physics, providing a theoretical basis for developing innovative control concepts that enhance aircraft performance and safety. Our research focus was of direct interest not only to NASA but to manufacturers of aircraft and their associated systems. Our approach, metrics, and future directions described in the remainder of the report.

Stengel, Robert F.↗

Intelligent Processing Equipment Research and Development Programs of the Department of Commerce

The intelligence processing equipment (IPE) research and development (R&D) programs of the Department of Commerce are carried out within the National Institute of Standards and Technology (NIST). This institute has had work in support of industrial productivity as part of its mission since its founding in 1901. With the advent of factory automation these efforts have increasingly turned to R&D in IPE. The Manufacturing Engineering Laboratory (MEL) of NIST devotes a major fraction of its efforts to this end while other elements within the organization, notably the Material Science and Engineering Laboratory, have smaller but significant programs. An inventory of all such programs at NIST and a representative selection of projects that at least demonstrate the scope of the efforts are presented.

Simpson, J. A.↗

Advanced Manufacturing and Value-added Products from US Agriculture

An objective of the US Department of Agriculture (USDA) Agriculture Research Service (ARS) is to develop technology leading to a broad portfolio of value-added marketable products. Modern scientific disciplines such as chemical engineering are brought into play to develop processes for converting bulk commodities into high-margin products. To accomplish this, the extremely sophisticated processing devices which form the basis of modern biotechnology, namely, genes and enzymes, can be tailored to perform the required functions. The USDA/ARS is a leader in the development of intelligent processing equipment (IPE) for agriculture in the broadest sense. Applications of IPE are found in the production, processing, grading, and marketing aspects of agriculture. Various biotechnology applications of IPE are discussed.

Villet, Ruxton H.↗

Sixth NASA Glenn Research Center Propulsion Control and Diagnostics (PCD) Workshop

The Intelligent Control and Autonomy Branch at NASA Glenn Research Center hosted the Sixth Propulsion Control and Diagnostics Workshop on August 22-24, 2017. The objectives of this workshop were to disseminate information about research being performed in support of NASA Aeronautics programs; get feedback from peers on the research; and identify opportunities for collaboration. There were presentations and posters by NASA researchers, Department of Defense representatives, and engine manufacturers on aspects of turbine engine modeling, control, and diagnostics.

Collaboration↗

Planning Complex Projects Automatically

Automated Manifest Planner (AMP) computer program applies combination of artificial-intelligence techniques to assist both expert and novice planners, reducing planning time by orders of magnitude. Gives planners flexibility to modify plans and constraints easily, without need for programming expertise. Developed specifically for planning space shuttle missions 5 to 10 years ahead, with modifications, applicable in general to planning other complex projects requiring scheduling of activities depending on other activities and/or timely allocation of resources. Adaptable to variety of complex scheduling problems in manufacturing, transportation, business, architecture, and construction.

Henke, Andrea L.↗

Physics-Guided Deep Learning for Complex System Health Management and Decision Making

The landscape of complex engineered systems is rapidly evolving, from smart manufacturing facilities to next-generation transportation vehicles. As these systems become increasingly sophisticated and interconnected, the need for advanced health management systems grows ever more critical. These systems must go beyond simple monitoring, actively predicting potential failures before they occur. This paradigm shift from fixed maintenance schedules to condition-based predictions is key to optimizing system performance, enhancing safety, and paving the way for autonomous decision-making across various industries. Whether in industrial processes, energy systems, or advanced transportation, the ability to anticipate and prevent failures is becoming a cornerstone of operational excellence. To accurately predict the future health of any complex system, knowledge of its current health state and future operational conditions is essential. Recent advancements in data-driven algorithms have generated growing interest in artificial intelligence for industrial applications. However, the limitations of pure data-driven methods, particularly in industries where data acquisition is costly and limited, have become apparent. This has led to a focus on blending physics with data-driven algorithms, mitigating the drawbacks of both approaches while emphasizing their respective advantages. This research proposes a novel framework for integrating physics-based performance models with deep learning algorithms for the prognostics of complex safety-critical systems. In this approach, physics-based models serve as a blueprint, capturing fundamental system behaviors, while deep learning algorithms, leveraging real-world sensor data, fill in gaps and identify subtle patterns indicative of potential problems. This hybrid methodology, utilizing techniques such as Physics-Informed Neural Networks (PINNs), offers a powerful solution for predicting system health. By fusing domain knowledge with data-driven insights, this approach promises more accurate, adaptable, and reliable models for health prediction. The resulting framework is versatile, applicable across various sectors including aerospace, manufacturing, and energy systems, ultimately contributing to safer, more efficient operations in our increasingly complex technological landscape.

Diagnostics↗

Characterizing Material Scalability for Ultralight Lattice Design

Stiff yet ultra-light lattice structures constructed using digital materials have many practical applications as the building block for aircraft and other structures. By furthering our understanding of how material configuration affects the structural properties of an ultralight lattice, we can intelligently design these structures based on their intended function. Here we compare the behavior of ultralight lattice structures when fabricated by different materials. The individual unit cells of the lattice structures are referred to as voxels. The stiffness, elastic modulus, and yield strength of the specimens in compression and tension are determined through mechanical testing. Specimens are tested both as single voxel as well as 4x4x4 voxel constructions on an Instron 5982 Universal Testing System until failure. Each voxel is manufactured in bulk through injection molding, with a unit cell pitch of 76.2 mm. Individual voxels are fastened with machine screws and nuts to create assemblies. Four separate materials are used as voxel compositions in this experiment. These include a homogeneous polymer referred to as Ultem 1000, a glass-fiber reinforced polymer referred to as Ultem 2200, a polymer with chopped carbon fibers as 30% of its fill, and homogenous polypropylene. This work compares mechanical behavior, as well as the convergence behavior of the lattice as the size of the lattice assembly increases for various materials. The goal of this study is to characterize the behavior of homogenous lattices such that heterogenous lattices can be designed with different material voxels to achieve target material properties for ultralight space applications.

Sajjadi, Afsheen↗

All-Terrain Intelligent Robot Braves Battlefront to Save Lives

As NASA s lead center for creating robotic spacecraft and rovers, the Jet Propulsion Laboratory (JPL) builds smart machines that can perform very complicated tasks, far, far away from the homeland. JPL s robotic proficiency is making an impact millions of miles away on Mars, where two rovers are presently unlocking the secrets of the Red Planet s rugged terrain, and thousands of miles away in the embattled regions of Iraq and Afghanistan, where robots sown from the seeds of JPL machines have been deployed to be the "eyes and ears" of humans on the front line. This commercial offspring, known as the PackBot Tactical Mobile Robot, is manufactured by iRobot, Inc., of Burlington, Massachusetts.

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