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NASA NTRS1992

Flow behavior in liquid molding

The liquid molding (LM) process for manufacturing polymer composites with structural properties has the potential to significantly lower fabrication costs and increase production rates. LM includes both resin transfer molding and structural reaction injection molding. To achieve this potential, however, the underlying science base must be improved to facilitate effective process optimization and implementation of on-line process control. The National Institute of Standards and Technology (NIST) has a major program in LM that includes materials characterization, process simulation models, on-line process monitoring and control, and the fabrication of test specimens. The results of this program are applied to real parts through cooperative projects with industry. The key feature in the effort is a comprehensive and integrated approach to the processing science aspects of LM. This paper briefly outlines the NIST program and uses several examples to illustrate the work.

Hunston, D.↗

NASA NTRSDate not supplied

The Additive Manufacturing Moment Measure - A Parallel Computation Technique for Determining Build Variance in the Laser Powder Bed Fusion Process

Additive manufacturing (AM) has unique process attributes that facilitate the creation of optimized, complex, and unique parts for aerospace applications. However, the multi-scale and complicated building process for AM parts can cause unexpected build conditions that result in microstructural variability within the deposited material. The need for richer datasets and computational modeling capabilities to improve AM process reliability is a consequence of this microstructural variability. A computational approach, referred to as the Additive Manufacturing Moment Measure (AM3), addresses this need by leveraging the way AM processes fuse material in precise, incremental steps. During the layering sequence, each previous step contributes to the condition of the current step at the center of the heat source. The precise steps can be selected to systematically create a time-space point field with co-located machine input and in-situ sensor data. The sequential nature of the AM process, coupled with nearest neighbor calculations, allows for a fully parallel computation for part-scale build profile analysis. The AM3 concept introduced here enables part-scale assessment directly from build files and in-situ process monitoring sensors alike. The AM moment measures were calculated for build point fields and compared with co-located in-situ and ex-situ nondestructive evaluation and optical microscopy observations. These comparisons permit a better understanding of how the sequential process actions can affect the quality of a laser powder bed fusion (LPBF) build. Details of the AM3technique will be discussed and compared to measured LPBF part characteristics. The AM3 results indicate a strong potential to advance the qualification process for aerospace applications.

Additive Manufacturing↗

NASA NTRS1997

Exterior and Interior Polar Cusps: Observations from Hawkeye

Hawkeye plasma, magnetic field, and plasma wave instruments directly sampled the throat of the northern polar cusp as the orientation of the Interplanetary Magnetic Field (IMF) changed from southward to northward on July 3, 1974. Two distinct regions in the polar cusp were identified based on magnetic field, plasma flow and magnetic and electric noise: the interior and exterior cusps. The observations show highly variable flows in the exterior portion of the cusp and constantly strong dawn-dusk flows in the interior portion during periods of strong IMF By component. Results of a minimum variance analysis of the magnetic field at each cusp interface crossing provides evidence that the magnetopause surface normal deviated highly from empirical models. During intervals of relatively steady solar wind dynamic pressure, the motion of the cusp relative to the slow moving spacecraft was modulated by the varying IMF clock angle as observed by IMP 8 in the upstream solar wind. The motion did not show a correlation with internal processes monitored by the A E index. We propose that observed plasma flow patterns and cusp motion are results of reconnection between the IMF and the magnetospheric magnetic field. Flow velocity observed in the interior cusp is consistent with stress balance for a reconnection process. This unique interval provides an opportunity for detailed studies of the plasma, magnetic field, and plasma wave properties in both the exterior and interior cusp.

Chen, S.-H.↗

NASA NTRSDate not supplied

Additive Manufacturing Model-Based Process Metrics: Reduced Order Modeling of the Laser Powder Bed Fusion Process

The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. In this work, we describe a fully parallel reduced order modeling approach that has been developed to evaluate the evolution of AM processes, termed the AM moment measure method. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology and terminology of the approach will be described, and computed build maps will be calculated and compared for various laser powder bed fusion (LPBF) builds of Ti-6Al-4V. Such comparative results develop understanding of how the sequential process actions can affect the LPBF-AM build quality and microstructure variability.

Laser Powder Bed Fusion↗

NASA NTRS2001

Real-Time Optical Monitoring of Flow Kinetics and Gas Phase Reactions Under High-Pressure OMCVD Conditions

This contribution addresses the real-time optical characterization of gas flow and gas phase reactions as they play a crucial role for chemical vapor phase depositions utilizing elevated and high pressure chemical vapor deposition (HPCVD) conditions. The objectives of these experiments are to validate on the basis of results on real-time optical diagnostics process models simulation codes, and provide input parameter sets needed for analysis and control of chemical vapor deposition at elevated pressures. Access to microgravity is required to retain high pressure conditions of laminar flow, which is essential for successful acquisition and interpretation of the optical data. In this contribution, we describe the design and construction of the HPCVD system, which include access ports for various optical methods of real-time process monitoring and to analyze the initial stages of heteroepitaxy and steady-state growth in the different pressure ranges. To analyze the onset of turbulence, provisions are made for implementation of experimental methods for in-situ characterization of the nature of flow. This knowledge will be the basis for the design definition of experiments under microgravity, where gas flow conditions, gas phase and surface chemistry, might be analyzed by remote controlled real-time diagnostics tools, developed in this research project.

Dietz, N.↗

NASA NTRS2002

A Data-Driven Solution for Performance Improvement

Marketed as the "Software of the Future," Optimal Engineering Systems P.I. EXPERT(TM) technology offers statistical process control and optimization techniques that are critical to businesses looking to restructure or accelerate operations in order to gain a competitive edge. Kennedy Space Center granted Optimal Engineering Systems the funding and aid necessary to develop a prototype of the process monitoring and improvement software. Completion of this prototype demonstrated that it was possible to integrate traditional statistical quality assurance tools with robust optimization techniques in a user- friendly format that is visually compelling. Using an expert system knowledge base, the software allows the user to determine objectives, capture constraints and out-of-control processes, predict results, and compute optimal process settings.

Source record↗

NASA NTRS1994

Attention Focusing and Anomaly Detection in Systems Monitoring

systems↗

NASA NTRS1992

Flexible control techniques for a lunar base

The fundamental elements found in every terrestrial control system can be employed in all lunar applications. These elements include sensors which measure physical properties, controllers which acquire sensor data and calculate a control response, and actuators which apply the control output to the process. The unique characteristics of the lunar environment will certainly require the development of new control system technology. However, weightlessness, harsh atmospheric conditions, temperature extremes, and radiation hazards will most significantly impact the design of sensors and actuators. The controller and associated control algorithms, which are the most complex element of any control system, can be derived in their entirety from existing technology. Lunar process control applications -- ranging from small-scale research projects to full-scale processing plants -- will benefit greatly from the controller advances being developed today. In particular, new software technology aimed at commercial process monitoring and control applications will almost completely eliminate the need for custom programs and the lengthy development and testing cycle they require. The applicability of existing industrial software to lunar applications has other significant advantages in addition to cost and quality. This software is designed to run on standard hardware platforms and takes advantage of existing LAN and telecommunications technology. Further, in order to exploit the existing commercial market, the software is being designed to be implemented by users of all skill levels -- typically users who are familiar with their process, but not necessarily with software or control theory. This means that specialized technical support personnel will not need to be on-hand, and the associated costs are eliminated. Finally, the latest industrial software designed for the commercial market is extremely flexible, in order to fit the requirements of many types of processing applications with little or no customization. This means that lunar process control projects will not be delayed by unforeseen problems or last minute process modifications. The software will include all of the tools needed to adapt to virtually any changes. In contrast to other space programs which required the development of tremendous amounts of custom software, lunar-based processing facilities will benefit from the use of existing software technology which is being proven in commercial applications on Earth.

Kraus, Thomas W.↗

NASA NTRS2002

3-D Flow Field Diagnostics and Validation Studies using Stereoscopic Tracking Velocimetry

The measurement of 3-D three-component velocity fields is of great importance in both ground and space experiments for understanding materials processing and fluid physics. Here, we present the investigation results of stereoscopic tracking velocimetry (STV) for measuring 3-D velocity fields. The effort includes diagnostic technology development, experimental velocity measurement, and comparison with analytical and numerical computation. The advantages of STV stems from the system simplicity for building compact hardware and in software efficiency for continual near-real-time process monitoring. It also has illumination flexibility for observing volumetric flow fields from arbitrary directions. STV is based on stereoscopic CCD observations of particles seeded in a flow. Neural networks are used for data analysis. The developed diagnostic tool is tested with a simple directional solidification apparatus using Succinonitrile. The 3-D velocity field in the liquid phase is measured and compared with results from detailed numerical computations. Our theoretical, numerical, and experimental effort has shown STV to be a viable candidate for reliably quantifying the 3-D flow field in materials processing and fluids experiments.

Cha, Soyoung Stephen↗

NASA NTRS2021

Collaborative Communications Between A Human and A Resilient Safety Support System

Successful introductory UAM integration into the NAS will be contingent on resilient safety systems that support reduced-crew flight operations. In this paper, we present a system that performs three functions: 1) monitors an operator’s physiological state; 2) assesses when the operator is experiencing anomalous states; and 3) mitigates risks by a combination of dynamic, context-based unilateral or collaborative dynamic function allocation of operational tasks. The monitoring process receives high data-rate sensor values from eye-tracking and electrocardiogram sensors. The assessment process takes these values and performs a classification that was developed using machine learning algorithms. The mitigation process invokes a collaboration protocol called DFACCto which, based on context, performs vehicle operations that the operator would otherwise routinely execute. This system has been demonstrated in a UAM flight simulator for an operator incapacitation scenario. The methods and initial results as well as relevant UAM and AAM scenarios will be described.

Advanced air mobility↗

NASA NTRSDate not supplied

Collaborative Communications Between a Human and a Resilient Safety Support System

Successful introductory UAM integration into the NAS will be contingent on resilient safety systems that support reduced-crew flight operations. In this paper, we present a system that performs three functions: 1) monitors an operator’s physiological state; 2) assesses when the operator is experiencing anomalous states; and 3) mitigates risks by a combination of dynamic, context-based unilateral or collaborative dynamic function allocation of operational tasks. The monitoring process receives high data-rate sensor values from eye-tracking and electrocardiogram sensors. The assessment process takes these values and performs a classification that was developed using machine learning algorithms. The mitigation process invokes a collaboration protocol called DFACC to which, based on context, performs vehicle operations that the operator would otherwise routinely execute. This system has been demonstrated in a UAM flight simulator for an operator incapacitation scenario. The methods and initial results as well as relevant UAM and AAM scenarios will be described.

Advanced Air Mobility,↗

NASA NTRS1994

Attention focusing and anomaly detection in systems monitoring

Any attempt to introduce automation into the monitoring of complex physical systems must start from a robust anomaly detection capability. This task is far from straightforward, for a single definition of what constitutes an anomaly is difficult to come by. In addition, to make the monitoring process efficient, and to avoid the potential for information overload on human operators, attention focusing must also be addressed. When an anomaly occurs, more often than not several sensors are affected, and the partially redundant information they provide can be confusing, particularly in a crisis situation where a response is needed quickly. The focus of this paper is a new technique for attention focusing. The technique involves reasoning about the distance between two frequency distributions, and is used to detect both anomalous system parameters and 'broken' causal dependencies. These two forms of information together isolate the locus of anomalous behavior in the system being monitored.

Doyle, Richard J.↗

NASA NTRS1994

A Distance Measure for Attention Focusing and Anomaly Detection in Systems Monitoring

Any attempt to introduce automation into the monitoring of complex physical systems must start from a robust anomaly detection capability. This task is far from straightforward, for a single definition of what constitutes an anomaly is difficult to come by. In addition, to make the monitoring process efficient, and to avoid the potential for information overload on human operators, attention focusing must also be addressed. When an anomaly occurs, more often than not several sensors are affected, and the partially redundant information they provide can be confusing, particularly in a crisis situation where a response is needed quickly. Previous results on extending traditional anomaly detection techniques are summarized. The focus of this paper is a new technique for attention focusing.

attention focusing systems monitoring anomaly dete↗

NASA NTRS2005

Encryption for Remote Control via Internet or Intranet

A data-communication protocol has been devised to enable secure, reliable remote control of processes and equipment via a collision-based network, while using minimal bandwidth and computation. The network could be the Internet or an intranet. Control is made secure by use of both a password and a dynamic key, which is sent transparently to a remote user by the controlled computer (that is, the computer, located at the site of the equipment or process to be controlled, that exerts direct control over the process). The protocol functions in the presence of network latency, overcomes errors caused by missed dynamic keys, and defeats attempts by unauthorized remote users to gain control. The protocol is not suitable for real-time control, but is well suited for applications in which control latencies up to about 0.5 second are acceptable. The encryption scheme involves the use of both a dynamic and a private key, without any additional overhead that would degrade performance. The dynamic key is embedded in the equipment- or process-monitor data packets sent out by the controlled computer: in other words, the dynamic key is a subset of the data in each such data packet. The controlled computer maintains a history of the last 3 to 5 data packets for use in decrypting incoming control commands. In addition, the controlled computer records a private key (password) that is given to the remote computer. The encrypted incoming command is permuted by both the dynamic and private key. A person who records the command data in a given packet for hostile purposes cannot use that packet after the public key expires (typically within 3 seconds). Even a person in possession of an unauthorized copy of the command/remote-display software cannot use that software in the absence of the password. The use of a dynamic key embedded in the outgoing data makes the central-processing unit overhead very small. The use of a National Instruments DataSocket(TradeMark) (or equivalent) protocol or the User Datagram Protocol makes it possible to obtain reasonably short response times: Typical response times in event-driven control, using packets sized .300 bytes, are <0.2 second for commands issued from locations anywhere on Earth. The protocol requires that control commands represent absolute values of controlled parameters (e.g., a specified temperature), as distinguished from changes in values of controlled parameters (e.g., a specified increment of temperature). Each command is issued three or more times to ensure delivery in crowded networks. The use of absolute-value commands prevents additional (redundant) commands from causing trouble. Because a remote controlling computer receives "talkback" in the form of data packets from the controlled computer, typically within a time interval < or =1 s, the controlling computer can re-issue a command if network failure has occurred. The controlled computer, the process or equipment that it controls, and any human operator(s) at the site of the controlled equipment or process should be equipped with safety measures to prevent damage to equipment or injury to humans. These features could be a combination of software, external hardware, and intervention by the human operator(s). The protocol is not fail-safe, but by adopting these safety measures as part of the protocol, one makes the protocol a robust means of controlling remote processes and equipment by use of typical office computers via intranets and/or the Internet.

Lineberger, Lewis↗

NASA NTRS2010

Electrochemical Detection of Multiple Bioprocess Analytes

An apparatus that includes highly miniaturized thin-film electrochemical sensor array has been demonstrated as a prototype of instruments for simultaneous detection of multiple substances of interest (analytes) and measurement of acidity or alkalinity in bioprocess streams. Measurements of pH and of concentrations of nutrients and wastes in cell-culture media, made by use of these instruments, are to be used as feedback for optimizing the growth of cells or the production of desired substances by the cultured cells. The apparatus is designed to utilize samples of minimal volume so as to minimize any perturbation of monitored processes. The apparatus can function in a potentiometric mode (for measuring pH), an amperometric mode (detecting analytes via oxidation/reduction reactions), or both. The sensor array is planar and includes multiple thin-film microelectrodes covered with hydrous iridium oxide. The oxide layer on each electrode serves as both a protective and electrochemical transducing layer. In its transducing role, the oxide provides electrical conductivity for amperometric measurement or pH response for potentiometric measurement. The oxide on an electrode can also serve as a matrix for one or more enzymes that render the electrode sensitive to a specific analyte. In addition to transducing electrodes, the array includes electrodes for potential control. The array can be fabricated by techniques familiar to the microelectronics industry. The sensor array is housed in a thin-film liquid-flow cell that has a total volume of about 100 mL. The flow cell is connected to a computer-controlled subsystem that periodically draws samples from the bioprocess stream to be monitored. Before entering the cell, each 100-mL sample is subjected to tangential-flow filtration to remove particles. In the present version of the apparatus, the electrodes are operated under control by a potentiostat and are used to simultaneously measure the pH and the concentration of glucose. It is anticipated that development of procedures for trapping more enzymes into hydrous iridium oxide (and possibly into other electroactive metal oxides) and of means for imparting long-term stability to the transducer layers should make it possible to monitor concentrations of products of many enzyme reactions for example, such key bioprocess analytes as amino acids, vitamins, lactose, and acetate.

Rauh, R. David↗

NASA NTRS1977

Instrumentation and data acquisition systems

A comprehensive and integrated measurement system was identified and a design and development effort initiated to meet the criteria imposed by the National Transonic Facility operating environment. Specific measurement areas receiving concentrated attention include: data acquisition, force measurement, pressure instrumentation, flow visualization techniques, model attitude and model deformation measurement, and temperature measurement. The NTF instrument complex will be centered around four 32-bit, 1-microsecond-cycle-time central processing units connected in a multipoint-distributed network configuration. The principal activities to be supported by these computers are: (1) data base management and processing; (2) research measurement data acquisition and display; (3) tunnel and model control; and (4) process monitoring and communication control. The distributed network approach was chosen to modularize the functional software into definable and implementable parts by the various groups involved in the design and to permit use of similar hardware configurations to improve reliability and maintainability.

Guarino, J. F.↗

NASA NTRS1979

Coal mining with a liquid solvent

Study suggests carbonated water can dissolve or suspend coal and carry it to surface. Mixture of carbon dioxide and water may be coal solvent that will make unmanned mining reality. When used with proposed process monitoring coal solubility with conventional strain gage, solvent is basis for rapid cost effective extraction of coal from underground seams.

Lawson, D. D.↗

NASA NTRS1983

Surface and allied studies in silicon solar cells

Two main results are presented. The first deals with a simple method that determines the minority-carrier lifetime and the effective surface recombination velocity of the quasi-neutral base of silicon solar cells. The method requires the observation of only a single transient, and is amenable to automation for in-process monitoring in manufacturing. This method, which is called short-circuit current decay, avoids distortion in the observed transient and consequent inacccuracies that arise from the presence of mobile holes and electrons stored in the p/n junction spacecharge region at the initial instant of the transient. The second main result consists in a formulation of the relevant boundary-value problems that resembles that used in linear two-port network theory. This formulation enables comparisons to be made among various contending methods for measuring material parameters of p/n junction devices, and enables the option of putting the description in the time domain of the transient studies in the form of an infinite series, although closed-form solutions are also possible.

Lindholm, F. A.↗