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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
All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

Composite fuselage crown panel manufacturing technology

Commercial fuselage structures contain significant challenges in attempting to save manufacturing costs with advanced composite technology. Assembly issues, material costs, and fabrication of elements with complex geometry are each expected to drive the cost of composite fuselage structures. Boeing's efforts under the NASA ACT program have pursued key technologies for low-cost, large crown panel fabrication. An intricate bond panel design and manufacturing concepts were selected based on the efforts of the Design Build Team (DBT). The manufacturing processes selected for the intricate bond design include multiple large panel fabrication with the Advanced Tow Placement (ATP) process, innovative cure tooling concepts, resin transfer molding of long fuselage frames, and utilization of low-cost material forms. The process optimization for final design/manufacturing configuration included factory simulations and hardware demonstrations. These efforts and other optimization tasks were instrumental in reducing cost by 18 percent and weight by 45 percent relative to an aluminum baseline. The qualitative and quantitative results of the manufacturing demonstrations were used to assess manufacturing risks and technology readiness.

Willden, Kurtis↗
NASA NTRS1976

Advanced composite rudders for DC-10 aircraft: Design, manufacturing, and ground tests

Design synthesis, tooling and process development, manufacturing, and ground testing of a graphite epoxy rudder for the DC-10 commercial transport are discussed. The composite structure was fabricated using a unique processing method in which the thermal expansion characteristics of rubber tooling mandrels were used to generate curing pressures during an oven cure cycle. The ground test program resulted in certification of the rudder for passenger-carrying flights. Results of the structural and environmental tests are interpreted and detailed development of the rubber tooling and manufacturing process is described. Processing, tooling, and manufacturing problems encountered during fabrication of four development rudders and ten flight-service rudders are discussed and the results of corrective actions are described. Non-recurring and recurring manufacturing labor man-hours are tabulated at the detailed operation level. A weight reduction of 13.58 kg (33 percent) was attained in the composite rudder.

Lehman, G. M.↗
NASA NTRS1991

Cost studies for commercial fuselage crown designs

Studies were conducted to evaluate the cost and weight potential of advanced composite design concepts in the crown region of a commercial transport. Two designs from each of three design families were developed using an integrated design-build team. A range of design concepts and manufacturing processes were included to allow isolation and comparison of cost centers. Detailed manufacturing/assembly plans were developed as the basis for cost estimates. Each of the six designs was found to have advantages over the 1995 aluminum benchmark in cost and weight trade studies. Large quadrant panels and cobonded frames were found to save significant assembly labor costs. Comparisons of high- and intermediate-performance fiber systems were made for skin and stringer applications. Advanced tow placement was found to be an efficient process for skin lay up. Further analysis revealed attractive processes for stringers and frames. Optimized designs were informally developed for each design family, combining the most attractive concepts and processes within that family. A single optimized design was selected as the most promising, and the potential for further optimization was estimated. Technical issues and barriers were identified.

Walker, T. H.↗
NASA NTRS2016

Multilayer Active Shell Mirrors for Space Telescopes

A novel active mirror technology based on carbon fiber reinforced polymer (CFRP) substrates and replication techniques has been developed. Multiple additional layers are implemented into the design serving various functions. Nanolaminate metal films are used to provide a high quality reflective front surface. A backing layer of thin active material is implemented to provide the surface-parallel actuation scheme. Printed electronics are used to create a custom electrode pattern and flexible routing layer. Mirrors of this design are thin (< 1.0 mm), lightweight (2.7 kg/m2 ), and have large actuation capabilities. These capabilities, along with the associated manufacturing processes, represent a significant change in design compared to traditional optics. Such mirrors could be used as lightweight primaries for small CubeSat-based telescopes or as meter-class segments for future large aperture observatories. Multiple mirrors can be produced under identical conditions enabling a substantial reduction in manufacturing cost and complexity. An overview of the mirror design and manufacturing processes is presented. Predictions on the actuation performance have been made through finite element simulations demonstrating correct abilities on the order of 250−300× for astigmatic modes with only 41 independent actuators. A description of the custom metrology system used to characterize the active mirrors is also presented. The system is based on a Reverse Hartmann test and can accommodate extremely large deviations in mirror figure (> 100 µm PV) down to sub-micron precision. The system has been validated against several traditional techniques including photogrammetry and interferometry. The mirror performance has been characterized using this system, as well as closed-loop figure correction experiments on 150 mm dia. prototypes. The mirrors have demonstrated post-correction figure accuracies of 200 nm RMS (two dead actuators limiting performance).

Reverse Hartmann↗
NASA NTRS2010

Propulsion Design With Freeform Fabrication (PDFF)

The nation is challenged to decrease the cost and schedule to develop new space transportation propulsion systems for commercial, scientific, and military purposes. Better design criteria and manufacturing techniques for small thrusters are needed to meet current applications in missile defense, space, and satellite propulsion. The requirements of these systems present size, performance, and environmental demands on these thrusters that have posed significant challenges to the current designers and manufacturers. Designers are limited by manufacturing processes, which are complex, costly, and time consuming, and ultimately limited in their capabilities. The PDFF innovation vastly extends the design opportunities of rocket engine components and systems by making use of the unique manufacturing freedom of solid freeform rapid prototype manufacturing technology combined with the benefits of ceramic materials. The unique features of PDFF are developing and implementing a design methodology that uses solid freeform fabrication (SFF) techniques to make propulsion components with significantly improved performance, thermal management, power density, and stability, while reducing development and production costs. PDFF extends the design process envelope beyond conventional constraints by leveraging the key feature of the SFF technique with the capability to form objects with nearly any geometric complexity without the need for elaborate machine setup. The marriage of SFF technology to propulsion components allows an evolution of design practice to harmonize material properties with functional design efficiency. Reduced density of materials when coupled with the capability to honeycomb structure used in the injector will have significant impact on overall mass reduction. Typical thrusters in use for attitude control have 60 90 percent of its mass in the valve and injector, which is typically made from titanium. The combination of material and structure envisioned for use in an SFF thruster design could reduce thruster weight by a factor of two or more. The thrust-to-weight ratios for such designs can achieve 1,000:1 or more, depending on chamber pressure. The potential exists for continued development in materials, size, speed, accuracy of SFF techniques, which can lead to speculative developments of PDFF processes such as fabrication of custom human interface devices like masks, chairs, and clothing, and advanced biomedical application to human organ reconstruction. Other potential applications are: higher fidelity lower cost test fixtures for probes and inspection, disposable thrusters, and ISRU (in situ resource utilization) for component production in space or on Lunar and Martian missions, and application for embedding MEMS (microelectromechanical systems) during construction process of form changing aerostructure/dynamic structures.

Barnes, Daudi↗
NASA NTRS1993

The Gold Rush: A simulated commercial air transportation study

The remotely piloted vehicle (RPV) GoldRush was designed to complete the mission of transporting passengers in AeroWorld at a lower cost per seat per thousand feet (CPSPK) than the competition, the HB-40. There were two major factors which were constant considerations in the design process. The cost of manufacturing was the most important. In light of this, the designs were kept as simple as possible while considering trade-offs in performance. For example, the wing was not tapered so that several ribs could be cut at one time. Also of major importance was the takeoff distance. In order to serve all the cities in AeroWorld it was necessary to maintain a takeoff distance requirement of 24 feet. The takeoff distance proved to be the number one force in driving the design process. The Astro 25 engine and 13 inch propellor, a large wing area, and the high lift Wortmann airfoil were all chosen in order to satisfy this objective.

Clarke, Amanda↗
NASA NTRS1974

Design, fabrication and test of graphite/epoxy metering truss structure components, phase 3

The design, materials, tooling, manufacturing processes, quality control, test procedures, and results associated with the fabrication and test of graphite/epoxy metering truss structure components exhibiting a near zero coefficient of thermal expansion are described. Analytical methods were utilized, with the aid of a computer program, to define the most efficient laminate configurations in terms of thermal behavior and structural requirements. This was followed by an extensive material characterization and selection program, conducted for several graphite/graphite/hybrid laminate systems to obtain experimental data in support of the analytical predictions. Mechanical property tests as well as the coefficient of thermal expansion tests were run on each laminate under study, the results of which were used as the selection criteria for the single most promising laminate. Further coefficient of thermal expansion measurement was successfully performed on three subcomponent tubes utilizing the selected laminate.

Source record↗
NASA NTRS1990

A light-trapping solar cell coverglass

A novel method of reducing surface reflectivity which eliminates the need to texturize the surface of the cell is presented. A double light pass is achieved by using a light-trapping coverglass which redirects reflected light back to the cell surface by total internal reflection. This technique allows low-reflectance surfaces to be used on planar solar cells, including GaAs and InP, with the benefit of increasing the possible short-circuit current (and hence the efficiency) by 6 to 10 percent with no additional steps added to the cell manufacturing process. The coverglass design also has applications to reduction of grid shadowing and to light trapping within the cell.

Landis, Geoffrey A.↗
NASA NTRS1993

Space propulsion

Lewis Research Center is developing broad-based new technologies for space chemical engines to satisfy long-term needs of ETO launch vehicles and other vehicles operating in and beyond Earth orbit. Specific objectives are focused on high performance LO2/LH2 engines providing moderate thrusts of 7,5-200 klb. This effort encompasses research related to design analysis and manufacturing processes needed to apply advanced materials to subcomponents, components, and subsystems of space-based systems and related ground-support equipment. High-performance space-based chemical engines face a number of technical challenges. Liquid hydrogen turbopump impellers are often so large that they cannot be machined from a single piece, yet high stress at the vane/shroud interface makes bonding extremely difficult. Tolerances on fillets are critical on large impellers. Advanced materials and fabricating techniques are needed to address these and other issues of interest. Turbopump bearings are needed which can provide reliable, long life operation at high speed and high load with low friction losses. Hydrostatic bearings provide good performance, but transients during pump starts and stops may be an issue because no pressurized fluid is available unless a separate bearing pressurization system is included. Durable materials and/or coatings are needed that can demonstrate low wear in the harsh LO2/LH2 environment. Advanced materials are also needed to improve the lifetime, reliability and performance of other propulsion system elements such as seals and chambers.

Kazaroff, John M.↗
NASA NTRS1999

Alternatives to Silicon Rubber Thermal Barrier in RSRM Nozzle Joints

Thiokol Propulsion encountered a situation where gas path can form in the Filler material in joints between the phenolic in the Space Shuttle Reusable Solid Rocket Motor nozzle. An investigation determined that the method for injecting the filler material into the joint created a pressurized pocket of air that forced its way to the surface while the filler was curing. The path that the air took remained open some situations leaving a path for hot gas to get deep into the joint. The condition that created the gas path has been corrected by modifications to the manufacturing process, but a design solution that would reduce processing time is being pursued. A strip of open cell installed deep into the joint, can serve as a barrier to the Filler material. Testing indicates that the foam eliminates the pressure pocket, and does not prevent detection of leakage of the o-ring seals during leak test. Open cell foam does not have thermal resistance capability and mechanical structure, which would be required in the event of a gas path. A replacement to open cell foam is now being considered. Braided carbon fiber rope has the permeability characteristics of foam and it has thermal resistance characteristics as well. Braided carbon fiber rope (BCFR) has been tested in simulated joints in subscale rocket motor. Results of the testing indicate that braided carbon fiber rope can significantly reduce gas temperature by as much es 3000 F in a nozzle joint configuration. BCFR can be installed as a barrier to stop the joint filler material or it can used as the thermal barrier alone.

Totman, Peter D.↗
NASA NTRS2011

Hybrid Composite Cryogenic Tank Structure

A hybrid lightweight composite tank has been created using specially designed materials and manufacturing processes. The tank is produced by using a hybrid structure consisting of at least two reinforced composite material systems. The inner composite layer comprises a distinct fiber and resin matrix suitable for cryogenic use that is a braided-sleeve (and/or a filamentwound layer) aramid fiber preform that is placed on a removable mandrel (outfitted with metallic end fittings) and is infused (vacuum-assisted resin transfer molded) with a polyurethane resin matrix with a high ductility at low temperatures. This inner layer is allowed to cure and is encapsulated with a filamentwound outer composite layer of a distinct fiber resin system. Both inner and outer layer are in intimate contact, and can also be cured at the same time. The outer layer is a material that performs well for low temperature pressure vessels, and it can rely on the inner layer to act as a liner to contain the fluids. The outer layer can be a variety of materials, but the best embodiment may be the use of a continuous tow of carbon fiber (T-1000 carbon, or others), or other high-strength fibers combined with a high ductility epoxy resin matrix, or a polyurethane matrix, which performs well at low temperatures. After curing, the mandrel can be removed from the outer layer. While the hybrid structure is not limited to two particular materials, a preferred version of the tank has been demonstrated on an actual test tank article cycled at high pressures with liquid nitrogen and liquid hydrogen, and the best version is an inner layer of PBO (poly-pphenylenebenzobisoxazole) fibers with a polyurethane matrix and an outer layer of T-1000 carbon with a high elongation epoxy matrix suitable for cryogenic temperatures. A polyurethane matrix has also been used for the outer layer. The construction method is ideal because the fiber and resin of the inner layer has a high strain to failure at cryogenic temperatures, and will not crack or produce leaks. The outer layer serves as more of a high-performance structural unit for the inner layer, and can handle external environments.

DeLay, Thomas↗
NASA NTRS2013

Three-Axis Distributed Fiber Optic Strain Measurement in 3D Woven Composite Structures

Recent advancements in composite materials technologies have broken further from traditional designs and require advanced instrumentation and analysis capabilities. Success or failure is highly dependent on design analysis and manufacturing processes. By monitoring smart structures throughout manufacturing and service life, residual and operational stresses can be assessed and structural integrity maintained. Composite smart structures can be manufactured by integrating fiber optic sensors into existing composite materials processes such as ply layup, filament winding and three-dimensional weaving. In this work optical fiber was integrated into 3D woven composite parts at a commercial woven products manufacturing facility. The fiber was then used to monitor the structures during a VARTM manufacturing process, and subsequent static and dynamic testing. Low cost telecommunications-grade optical fiber acts as the sensor using a high resolution commercial Optical Frequency Domain Reflectometer (OFDR) system providing distributed strain measurement at spatial resolutions as low as 2mm. Strain measurements using the optical fiber sensors are correlated to resistive strain gage measurements during static structural loading. Keywords: fiber optic, distributed strain sensing, Rayleigh scatter, optical frequency domain reflectometry

Castellucci, Matt↗
NASA NTRS2016

Additive Manufacturing, Design, Testing, and Fabrication: A Full Engineering Experience at JSC

I worked on several projects this term. While most projects involved additive manufacturing, I was also involved with two design projects, two testing projects, and a fabrication project. The primary mentor for these was Richard Hagen. Secondary mentors were Hai Nguyen, Khadijah Shariff, and fabrication training from James Brown. Overall, my experience at JSC has been successful and what I have learned will continue to help me in my engineering education and profession long after I leave. My 3D printing projects ranged from less than a 1 cubic centimeter to about 1 cubic foot and involved several printers using different printing technologies. It was exciting to become familiar with printing technologies such as industrial grade FDM (Fused Deposition Modeling), the relatively new SLA (Stereolithography), and PolyJet. My primary duty with the FDM printers was to model parts that came in from various sources to print effectively and efficiently. Using methods my mentor taught me and the Stratasys Insight software, I was able to minimize imperfections, hasten build time, improve strength for specific forces (tensile, shear, etc...), and reduce likelihood of a print-failure. Also using FDM, I learned how to repair a part after it was printed. This is done by using a special kind of glue that chemically melts the two faces of plastic parts together to form a fused interface. My first goal with SLA technology was to bring the printer back to operational readiness. In becoming familiar with the Pegasus SLA printer, I researched the leveling, laser settings, and different vats to hold liquid material. With this research, I was successfully able to bring the Pegasus back online and have successfully printed multiple sample parts as well as functional parts. My experience with PolyJet technology has been focused on an understanding of the abilities/limits, costs, and the maintenance for daily use. Still upcoming will be experience with using a composite printer that uses FDM technology to print plastic while laying an internal filament of Kevlar or carbon-fiber inside the printed material. It has been incredible being exposed to this range of technologies and I feel very fortunate to be ready for virtually any kind of printing technology I come across in the future. Design work played a part in my internship this term as well. Working with Hai Nguyen, I was able to design a set of testing tips and a test frame for use with an Arcjet. The testing tips will be made of several different materials that will possibly be used in the heat shield of the Orion space craft. These designs included technical drawings that were presented to the fabrication shop. The frame design was created from 80/20 (a popular brand of frame construction equipment) and included an order form with pricing for fabrication. An independent design was also done for the virtual reality lab. This design was to create a hand-controller based on a previous design. This final design was sent directly to a 3D printer without technical drawings. Overall, my design work has given me experience with using 80/20, helped improve my CAD (Computer Aided Design) proficiency, and increased my knowledge of how to set up technical drawings for fabrication. The final role I have played in this internship has been to assist with testing of the inflatable technology materials working Khadijah Shariff. I began the internship assisting with permeability testing with the initial plan to continue the testing independently after training. Unfortunately, the testing apparatus suffered a technical failure and had funding pulled which cancelled that portion of the project. Further testing with inflatable technology continued with tensile testing of various stitching methods. This testing took place over a two-days and concluded successfully. Final testing was to be more tensile testing but of straps used to connect various inflatable sections. Unfortunately, the needed grips for the tensile tests could not be located and put the testing on hold. It is possible this round of testing will still take place by the end of the internship if the grips can be found. Overall, this portion of the internship has helped me become familiar with one kind of permeability test as well as a popular tensile/compression testing machine. Finally, I also had the chance to be trained using a metal lathe for making very small tips for a soldering iron. These tips will be used to melt threaded brass inserts into 3D printed plastic. Working with James Brown, I was able to successfully machine a brass rod down to as little as 0.064 inches plus or minus 0.001 inches. It was very rewarding to learn how to best use the machine and become familiar with a skill that will undoubtedly be used again in the future. I have been told by several professional engineers that learning to use a lathe and mill will be invaluable skills in the field. This knocks 50 percent of that goal off and I look forward to learning the mill at some point in the future. As is apparent with this list of projects, my internship was not focused on a single over-arching goal. Instead, I was able to gain experience in a myriad of very different areas. I feel like my time here was spent bouncing from one project to the next. Though sometimes difficult to switch gears, it was very rewarding to be a part of so much in so little time. My career and education will be positively impacted by what I have learned at JSC. My experience with 3D printing has improved my ability to handle many issues that may come up in the future with multiple different technologies. The design work I took part in, especially creating technical drawings, will help me better present designs to any engineer or shop I will encounter. My testing experience has helped me become familiar with a popular kind of tensile test machine that will likely be similar to the kinds I will encounter in the future. Finally, my experience with fabrication has given me a rare opportunity, as an engineer, to take part in the fabrication of a part. This experience will help me better tailor my future designs for the manufacturing process and has given me an appreciation for detailed/delicate machining work. My experience at JSC has been successful and will continue to assist me for a long time within the engineering field.

Zusack, Steven↗
NASA NTRS1998

NASA's Participation in the National Computational Grid

Over the last several years it has become evident that the character of NASA's supercomputing needs has changed. One of the major missions of the agency is to support the design and manufacture of aero- and space-vehicles with technologies that will significantly reduce their cost. It is becoming clear that improvements in the process of aerospace design and manufacturing will require a high performance information infrastructure that allows geographically dispersed teams to draw upon resources that are broader than traditional supercomputing. A computational grid draws together our information resources into one system. We can foresee the time when a Grid will allow engineers and scientists to use the tools of supercomputers, databases and on line experimental devices in a virtual environment to collaborate with distant colleagues. The concept of a computational grid has been spoken of for many years, but several events in recent times are conspiring to allow us to actually build one. In late 1997 the National Science Foundation initiated the Partnerships for Advanced Computational Infrastructure (PACI) which is built around the idea of distributed high performance computing. The Alliance lead, by the National Computational Science Alliance (NCSA), and the National Partnership for Advanced Computational Infrastructure (NPACI), lead by the San Diego Supercomputing Center, have been instrumental in drawing together the "Grid Community" to identify the technology bottlenecks and propose a research agenda to address them. During the same period NASA has begun to reformulate parts of two major high performance computing research programs to concentrate on distributed high performance computing and has banded together with the PACI centers to address the research agenda in common.

Feiereisen, William J.↗
NASA NTRS1990

Systems engineering and integration: Cost estimation and benefits analysis

Space Transportation Avionics hardware and software cost has traditionally been estimated in Phase A and B using cost techniques which predict cost as a function of various cost predictive variables such as weight, lines of code, functions to be performed, quantities of test hardware, quantities of flight hardware, design and development heritage, complexity, etc. The output of such analyses has been life cycle costs, economic benefits and related data. The major objectives of Cost Estimation and Benefits analysis are twofold: (1) to play a role in the evaluation of potential new space transportation avionics technologies, and (2) to benefit from emerging technological innovations. Both aspects of cost estimation and technology are discussed here. The role of cost analysis in the evaluation of potential technologies should be one of offering additional quantitative and qualitative information to aid decision-making. The cost analyses process needs to be fully integrated into the design process in such a way that cost trades, optimizations and sensitivities are understood. Current hardware cost models tend to primarily use weights, functional specifications, quantities, design heritage and complexity as metrics to predict cost. Software models mostly use functionality, volume of code, heritage and complexity as cost descriptive variables. Basic research needs to be initiated to develop metrics more responsive to the trades which are required for future launch vehicle avionics systems. These would include cost estimating capabilities that are sensitive to technological innovations such as improved materials and fabrication processes, computer aided design and manufacturing, self checkout and many others. In addition to basic cost estimating improvements, the process must be sensitive to the fact that no cost estimate can be quoted without also quoting a confidence associated with the estimate. In order to achieve this, better cost risk evaluation techniques are needed as well as improved usage of risk data by decision-makers. More and better ways to display and communicate cost and cost risk to management are required.

Dean, ED↗
NASA NTRS1993

Lithium D-cell study

The purpose of this contract is to evaluate parametrically the effects of various factors including the electrolyte type, electrolyte concentration, depolarizer type, and cell configuration on lithium cell electrical performance and safety. This effort shall allow for the selection and optimization of cell design for future NASA applications while maintaining close ties with WGL's continuous improvements in manufacturing processes and lithium cell design. Taguchi experimental design techniques are employed in this task, and allow for a maximum amount of information to be obtained while requiring significantly less cells than if a full factorial design were employed. Acceptance testing for this task is modeled after the NASA Document EP5-83-025, Revision C, for cell weights, OCV's and load voltages. The performance attributes that are studied in this effort are fresh capacity and start-up characteristics evaluated at two rates and two temperatures, shelf-life characteristics including start-up and capacity retention, and iterative microcalorimetry measurements. Abuse testing includes forced over discharge at two rates with and without diode protection, temperature tolerance testing, and shorting tests at three rates with the measurement of heat generated during shorting conditions.

Size, P.↗
NASA NTRS1986

Manufacturing Systems

Advanced Process Systems designed a portable purge unit for NASA use. The unit is designed to protect flight and ground crews from toxic fumes and to provide a post-landing controlled environment for sensitive electronic equipment. Although the work has future spinoff potential, it has also led to a research and development program in conjunction with several universities.

Source record↗
NASA NTRS1980

National meeting to review IPAD status and goals

A joint NASA/industry project called Integrated Programs for Aerospace-vehicle Design (IPAD) is described, which has the goal of raising aerospace-industry productivity through the application of computers to integrate company-wide management of engineering data. Basically a general-purpose interactive computing system developed to support engineering design processes, the IPAD design is composed of three major software components: the executive, data management, and geometry and graphics software. Results of IPAD activities include a comprehensive description of a future representative aerospace vehicle design process and its interface to manufacturing, and requirements and preliminary design of a future IPAD software system to integrate engineering activities of an aerospace company having several products under simultaneous development.

Fulton, R. E.↗