Results for “Continuous manufacturing” — Page 9

NASA NTRS1998

Protocol Development for the NASA-JSC Lunar-Mars Life Support Test Project (LMLSTP) Phase 3 Project: A Report on Baseline Studies at KSC for Continuous Salad Production

The Phase 3 Lunar-Mars Life Support Test Project (LMLSTP) was conducted in a 20-foot chamber at Johnson Space Center. The overall objective of the Phase 3 project was to conduct a 90-day regenerative life support system test involving 4 human subjects to demonstrate an integrated biological and physicochemical life support system. A secondary objective of the Phase 3 LMLSTP was to demonstrate the ability to produce salad-type vegetable by integration of a small benchtop growth chamber located within the crew habitat area. This small chamber, commercially manufactured as the Controlled Environment Research Ecosystem (CERES 2010(TM)), functioned as a means to continuously provide fresh lettuce crops for crew members. The CERES 2010(TM) growth chamber utilized hardware components developed for effective plant biomass production in spaceflight applications. These components included: (1) LED lighting; (2) Astroculture(TM) Root Trays; and (3) Zeoponic media. In planning for the LMLSTP Phase 3, a request was put forward for KSC scientists to generate a protocol for successful continuous planting, culturing, and harvesting of the salad-crop, lettuce. By conducting baseline tests with components of the CERES 2010(TM), a protocol was developed.

Goins, G. D.↗

NASA NTRS1979

Advanced manufacturing development of a composite empennage component for L-1011 aircraft

Work on process verification and tooling development continued. The cover process development was completed with the decision to proceed with low resin content prepreg material (34 + or - 3% by weight) in the fabrication of production readiness verification test (PRVT) specimens and the full-scale covers. The structural integrity of the cover/joint design was verified with the successful test of the cover attachment to fuselage ancillary test specimen (H25). Failure occurred, as predicted, in the skin panel away from the fuselage joint at 141 percent of the design ultimate load. With the successful completion of the H25 test, the PRVT cover specimens, which are identical to the H25 ancillary test specimen, were cleared for production. Eight of the twenty cover specimens were fabricated and are in preparation for test. All twenty of the PRVT spar specimens were fabricated and also were prepared for test. The environmental chambers used in the durability test of ten cover and ten spar PRVT specimens were completed and installed in the load reaction frames.

Source record↗

NASA NTRS1979

Advanced manufacturing development of a composite empennage component for L-1011 aircraft

Work in process verification and tooling development continued. The decision was made to redesign the ribs to a more producible design. The bead was eliminated and the truss ribs changed to plain C sections. The solid web rib stiffeners were eliminated as well as the beads and the webs are now reinforced with a syntactic core. Syntectic is an epoxy containing glass microballoons. Two cover specimens were successfully tested. The first specimen (H27) was designed to verify the stability and compression strength of the cover when it is hot and wet. Failure occurred at 120 percent of design ultimate load. As the failure appeared to be fixture induced and was limited to one end of the panel, the remainder of the panel will be tested. The second specimen (H28) was designed to verify the failsafe aspects of the design. The test verified the design. Preparation of the PRVT test facility is nearing completion and all ten spar durability specimens were installed in the test chambers.

Source record↗

NASA NTRS1990

Seamless metal-clad fiber-reinforced organic matrix composite structures and process for their manufacture

A metallic outer sleeve is provided which is capable of enveloping a hollow metallic inner member having continuous reinforcing fibers attached to the distal end thereof. The inner member is then introduced into outer sleeve until inner member is completely enveloped by outer sleeve. A liquid matrix member is then injected into space between inner member and outer sleeve. A pressurized heat transfer medium is flowed through the inside of inner member, thereby forming a fiber reinforced matrix composite material. The wall thicknesses of both inner member and outer sleeve are then reduced to the appropriate size by chemical etching, to adjust the thermal expansion coefficient of the metal-clad composite structure to the desired value. thereby forming a fiber reinforced matrix composite material. The wall thicknesses of both inner member and outer sleeve are then reduced to the appropriate size by chemical etching, to adjust the thermal expansion coefficient of the metal-clad composite structure to the desired value. The novelty of this invention resides in the development of a efficient method of producing seamless metal clad fiber reinforced organic matrix composite structures.

Bluck, Raymond M.↗

NASA NTRS1997

Rotordynamic Instability Problems in High-Performance Turbomachinery 1996

The first rotordynamics workshop proceedings emphasized a feeling of uncertainty in predicting the stability of characteristics of high-performance turbomachinery. In the second workshop proceedings these uncertainties were reduced through programs established to systematically resolve problems, with emphasis on experimental validation of the forces that influence rotordynamics. In the third proceedings many programs for predicting or measuring forces and force coefficients in high-performance turbomachinery produced results. Data became available for designing new machines with enhanced stability characteristics or for upgrading existing machines. In the fourth proceedings there emerged trends towards a more unified view of rotordynamic instability problems and several encouraging new analytical developments. The fifth workshop supported the continuing trend toward a unified view with several new developments in the design and manufacture of new turbomachineries with enhanced stability characteristics along with new data and associated numerical/theoretical results. The sixth workshop report provided field experience and experimental results, and expanded the use of computational and control techniques with integration of damper, bearing, and eccentric seal operation results. The seventh workshop report provided field experiences, numerical, theoretical, and experimental results and control methods for seals, bearings, and dampers with some attention given to variable thermophysical properties and turbulence measurements, and introduction of two-phase flow results. In the present workshop, active magnetic bearings (AMB's) evolve into a new method of measuring rotordynamic coefficients with discussions on honeycomb seals, drop of magnetically supported rotors, seals, bearings and dampers with new data being reported. The intent of the workshop and this proceedings is to provide a continuing impetus for an understanding and resolution of these problems.

Source record↗

NASA NTRS2013

Next Generation Lightweight Mirror Modeling Software

The advances in manufacturing techniques for lightweight mirrors, such as EXELSIS deep core low temperature fusion, Corning's continued improvements in the Frit bonding process and the ability to cast large complex designs, combined with water-jet and conventional diamond machining of glasses and ceramics has created the need for more efficient means of generating finite element models of these structures. Traditional methods of assembling 400,000 + element models can take weeks of effort, severely limiting the range of possible optimization variables. This paper will introduce model generation software developed under NASA sponsorship for the design of both terrestrial and space based mirrors. The software deals with any current mirror manufacturing technique, single substrates, multiple arrays of substrates, as well as the ability to merge submodels into a single large model. The modeler generates both mirror and suspension system elements, suspensions can be created either for each individual petal or the whole mirror. A typical model generation of 250,000 nodes and 450,000 elements only takes 5-10 minutes, much of that time being variable input time. The program can create input decks for ANSYS, ABAQUS and NASTRAN. An archive/retrieval system permits creation of complete trade studies, varying cell size, depth, and petal size, suspension geometry with the ability to recall a particular set of parameters and make small or large changes with ease. The input decks created by the modeler are text files which can be modified by any editor, all the key shell thickness parameters are accessible and comments in deck identify which groups of elements are associated with these parameters. This again makes optimization easier. With ANSYS decks, the nodes representing support attachments are grouped into components; in ABAQUS these are SETS and in NASTRAN as GRIDPOINT SETS, this make integration of these models into large telescope or satellite models possible.

Arnold, William↗

NASA NTRS2013

Next-Generation Lightweight Mirror Modeling Software

The advances in manufacturing techniques for lightweight mirrors, such as EXELSIS deep core low temperature fusion, Corning's continued improvements in the Frit bonding process and the ability to cast large complex designs, combined with water-jet and conventional diamond machining of glasses and ceramics has created the need for more efficient means of generating finite element models of these structures. Traditional methods of assembling 400,000 + element models can take weeks of effort, severely limiting the range of possible optimization variables. This paper will introduce model generation software developed under NASA sponsorship for the design of both terrestrial and space based mirrors. The software deals with any current mirror manufacturing technique, single substrates, multiple arrays of substrates, as well as the ability to merge submodels into a single large model. The modeler generates both mirror and suspension system elements, suspensions can be created either for each individual petal or the whole mirror. A typical model generation of 250,000 nodes and 450,000 elements only takes 5-10 minutes, much of that time being variable input time. The program can create input decks for ANSYS, ABAQUS and NASTRAN. An archive/retrieval system permits creation of complete trade studies, varying cell size, depth, and petal size, suspension geometry with the ability to recall a particular set of parameters and make small or large changes with ease. The input decks created by the modeler are text files which can be modified by any editor, all the key shell thickness parameters are accessible and comments in deck identify which groups of elements are associated with these parameters. This again makes optimization easier. With ANSYS decks, the nodes representing support attachments are grouped into components; in ABAQUS these are SETS and in NASTRAN as GRIDPOINT SETS, this make integration of these models into large telescope or satellite models possible

Arnold, William R., Sr.↗

NASA NTRS2013

Next Generation Lightweight Mirror Modeling Software

The advances in manufacturing techniques for lightweight mirrors, such as EXELSIS deep core low temperature fusion, Corning's continued improvements in the Frit bonding process and the ability to cast large complex designs, combined with water-jet and conventional diamond machining of glasses and ceramics has created the need for more efficient means of generating finite element models of these structures. Traditional methods of assembling 400,000 + element models can take weeks of effort, severely limiting the range of possible optimization variables. This paper will introduce model generation software developed under NASA sponsorship for the design of both terrestrial and space based mirrors. The software deals with any current mirror manufacturing technique, single substrates, multiple arrays of substrates, as well as the ability to merge submodels into a single large model. The modeler generates both mirror and suspension system elements, suspensions can be created either for each individual petal or the whole mirror. A typical model generation of 250,000 nodes and 450,000 elements only takes 5-10 minutes, much of that time being variable input time. The program can create input decks for ANSYS, ABAQUS and NASTRAN. An archive/retrieval system permits creation of complete trade studies, varying cell size, depth, and petal size, suspension geometry with the ability to recall a particular set of parameters and make small or large changes with ease. The input decks created by the modeler are text files which can be modified by any editor, all the key shell thickness parameters are accessible and comments in deck identify which groups of elements are associated with these parameters. This again makes optimization easier. With ANSYS decks, the nodes representing support attachments are grouped into components; in ABAQUS these are SETS and in NASTRAN as GRIDPOINT SETS, this make integration of these models into large telescope or satellite models easier.

Arnold, William R., Sr.↗

NASA NTRS1978

Water system microbial check valve development

A residual iodine microbial check valve (RIMCV) assembly was developed and tested. The assembly is designed to be used in the space shuttle potable water system. The RIMCV is based on an anion exchange resin that is supersaturated with an iodine solution. This system causes a residual to be present in the effluent water which provides continuing bactericidal action. A flight prototype design was finalized and five units were manufactured and delivered.

Colombo, G. V.↗

NASA NTRS1980

Space Shuttle Orbiter status - April 1980

The Orbiter is in the final stages of preparation, proceeding toward mating with the other Shuttle flight hardware elements, preparatory to its maiden voyage. The first orbital vehicle, Columbia, has been undergoing manufacturing, modifications, and testing at KSC, and integrated vehicle processing is planned to continue prior to the planned STS-1 launch. In order to establish a national fleet of operational Orbiters, Space Shuttle production includes fabrication of two additional Orbiters, refurbishment of the Columbia after its use in the orbital flight test program and early operations, and conversion of the Orbiter structural test article to a flight operational Orbiter.

Jones, S. C., Jr.↗

NASA NTRS2013

Magnetostrictive Alternator

This innovation replaces the linear alternator presently used in Stirling engines with a continuous-gradient, impedance-matched, oscillating magnetostrictive transducer that eliminates all moving parts via compression, maintains high efficiency, costs less to manufacture, reduces mass, and eliminates the need for a bearing system. The key components of this new technology are the use of stacked magnetostrictive materials, such as Terfenol-D, under a biased magnetic and stress-induced compression, continuous-gradient impedance-matching material, coils, force-focusing metallic structure, and supports. The acoustic energy from the engine travels through an impedancematching layer that is physically connected to the magnetostrictive mass. Compression bolts keep the structure under compressive strain, allowing for the micron-scale compression of the magnetostrictive material and eliminating the need for bearings. The relatively large millimeter displacement of the pressure side of the impedance-matching material is reduced to micron motion, and undergoes stress amplification at the magnetostrictive interface. The alternating compression and expansion of the magnetostrictive material creates an alternating magnetic field that then induces an electric current in a coil that is wound around the stack. This produces electrical power from the acoustic pressure wave and, if the resonant frequency is tuned to match the engine, can replace the linear alternator that is commonly used.

Dyson, Rodger↗

NASA NTRS2002

Microgravity Manufacturing

Manufacturing capability in outer space remains one of the critical milestones to surpass to allow humans to conduct long-duration manned space exploration. The high cost-to-orbit for leaving the Earth's gravitational field continues to be the limiting factor in carrying sufficient hardware to maintain extended life support in microgravity or on other planets. Additive manufacturing techniques, or 'chipless' fabrication, like RP are being considered as the most promising technologies for achieving in situ or remote processing of hardware components, as well as for the repair of existing hardware. At least three RP technologies are currently being explored for use in microgravity and extraterrestrial fabrication.

Cooper, Ken↗

NASA NTRS1999

The Second Joint NASA/FAA/DoD Conference on Aging Aircraft

The purpose of the Conference was to bring together world leaders in aviation safety research, aircraft design and manufacturing, fleet operation and aviation maintenance to disseminate information on current practices and advanced technologies that will assure the continued airworthiness of the aging aircraft in the military and commercial fleets. The Conference included reviews of current industry practices, assessments of future technology requirements, and status of aviation safety research. The Conference provided an opportunity for interactions among the key personnel in the research and technology development community, the original equipment manufacturers, commercial airline operators, military fleet operators, aviation maintenance, and aircraft certification and regulatory authorities. Conference participation was unrestricted and open to the international aviation community. Appendix B contains the name and addresses of the 623 participants in the Conference.

Harris, Charles E.↗

NASA NTRS1999

The Second Joint NASA/FAA/DOD Conference on Aging Aircraft

The purpose of the Conference was to bring together world leaders in aviation safety research, aircraft design and manufacturing, fleet operation and aviation maintenance to disseminate information on current practices and advanced technologies that will assure the continued airworthiness of the aging aircraft in the military and commercial fleets. The Conference included reviews of current industry practices, assessments of future technology requirements, and status of aviation safety research. The Conference provided an opportunity for interactions among the key personnel in the research and technology development community, the original equipment manufacturers, commercial airline operators, military fleet operators, aviation maintenance, and aircraft certification and regulatory authorities. Conference participation was unrestricted and open to the international aviation community.

Harris, Charles E.↗

NASA NTRS2020

AERoBOND Project Summary

Under NASA’s Convergent Aeronautics Solutions (CAS) project, the Adhesive-Free Bonding of Complex Composites (AERoBOND) project investigated off-stoichiometric epoxy polymers for fast, reliable assembly of epoxy matrix composite structures. The project goal was to demonstrate feasibility of the AERoBOND joining method by demonstrating mechanical properties greater than 80% of conventional co-cured materials while reducing structure weight by 1%. The project consisted of three convergent research areas: material and process development, systems analysis, and material and process modeling. Material and process development was the largest component of AERoBOND with approximately 6 FTE and 1WYE of support to formulate and characterize new resins, prepare carbon fiber prepregs, fabricate laminates, measure mechanical properties, analyze failure results, and select material and process improvements. The systems analysis activity estimated the potential reduction in part count and aircraft weight by comparing models of composite wing boxes with no fasteners (co-cured structure), fasteners in major joints (co-cured stringers), and fasteners in all joints. The materials and process modeling activity included a molecular model of the AERoBOND materials system to predict mechanical properties of resins with offset stoichiometry and a process model to predict the effect of resin formulation and processing conditions on the extent of mixing and degree of cure in a finished joint. As the number of airline passenger trips doubles in the next 20 years (IATA/Tourism Economics Air Passenger Forecasts, April 2019), the increased demand for new commercial aircraft is now the single greatest technical challenge to the airframe manufacturing industry. To meet efficiency requirements, new aircraft must be fabricated primarily from high performance structural composites, but manufacturing processes are inherently slow with the largest bottleneck attributed to assembly and installation of fasteners (NASA/TM–2019-220428). Manufactures of commercial transport aircraft are compelled to install more than 100,000 redundant fasteners into bonded joints to prevent failures due to unpredictable weak bonds. In structural adhesive bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination, which can cause weak bonds. Currently, bond strength assessment is only possible through destructive testing (i.e., breaking the joint). For these reasons, regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to alleviate concerns with bond performance. The AERoBOND process enables reflow of matrix resin during assembly to eliminate the material discontinuity at the interface, thereby eliminating the dependence of mechanical performance on interfacial adhesion. The AERoBOND joint is equivalent to the interlaminar region obtained during a co-cure process, so joint performance depends on the cohesive properties of the matrix resin. Conventional co-cured structures, although too costly and complex for large-scale manufacturing, are trusted by manufacturers and regulators, and are certified for flight with few or no redundant fasteners.Systems analysis performed on a composite wing model at the scale of a single-aisle commercial transport aircraft indicated that >20,000 redundant fasteners per wing could be eliminated by implementing the AERoBOND joining method. A total weight reduction of 15% was predicted in a wing box by eliminating fasteners and thinning components that must no longer support localized fastener loads and accommodate fastener dimensions. Interlaminar shear fracture toughness measured by the end-notched flexure test was greater than 1 kJ/m2 (nearly 140% of the co-cured benchmark property), which is greatly in excess of the project goals for mechanical properties. Testing was planned to measure interlaminar tensile fracture toughness as well as interlaminar tensile and shear strengths using the same AERoBOND configuration, but was delayed due to closure of LaRC facilities during the COVID-19 pandemic. The AERoBOND process model is partially validated and available for experimental use. It allows the user to input AERoBOND process parameters such as material composition, laminate configuration, and cure cycle to predict the final cure state of the AERoBOND joint. A preliminary, multi-scale material model was developed to predict AERoBOND joint mechanical properties (stiffness and strength) based on the cure state of the joint provided by the process model. The timing for transition of this technology within NASA is excellent as NASA initiates new enduring projects to address composites manufacturing rate challenges. AERoBOND technology is well suited to AAVP/AATT objectives for rapid manufacturing of a composite wing. A minimal effort (1 FTE/$15k procurement/0 WYE) is proposed in FY21 to continue a minor mechanical testing effort and maintain a SAA with ASX composites to develop commercial quality prepreg material. An RFI with the composites industry is suggested to quantify the technology gap between the current TRL and the TRL needed for transition to industry. A moderate effort [3-4 FTE/$150k/1 WYE (~$115k)] is proposed in FY22 for the “high rate composites manufacturing” project currently in planning. The partnership with ASX Composites will be expanded to produce material for sub-element/element-scale “panel-off” activities. Industry partnerships with airframe manufacturers is an expected component to explore damage tolerance and environmental stability. Further development of multi-scale modeling tools (process model, meso-scale model, and molecular model) is planned to enhance and deliver tools for rapid manufacturing infusion.

Frank Louis Palmieri↗

NASA NTRS2006

Deep Space Network, Cryogenic HEMT LNAs

Exploration of the Solar System with automated spacecraft that are more than ten astronomical units (1 AU = 149,597,870.691 km) from earth requires very large antennae employing extremely sensitive receivers. A key figure of merit in the specification of the spacecraft-to-earth telecommunications link is the ratio of the antenna gain to operatio nal noise temperature (G/Top) of the system. The Deep Space Network (DSN) receivers are cryogenic, low-noise amplifiers (LNAs) which addres s the need to maintain Top as low as technology permits. Historicall y, the extra-ordinarily sensitive receive systems operated by the DSN have required ctyogenically cooled, ruby masers, operating at a physi cal temperature near the boiling point of helium, as the LNA. Althoug h masers continue to be used today, they are hand crafted at JPL and expensive to manufacture and maintain. Recent advances in the developm ent of indium phosphide (InP) based high electron mobility transistor s (HEMTs) combined with cryogenic cooling near the boiling point of h ydrogen have made this alternate technology comparable with and a fraction of the cost of maser technology. InP HEMT LNA modules are demons trating noise temperatures less than ten times the quantum noise limi t (10hf/k) from 1 to 100 GHz. To date, the lowest noise LNA modules developed for the DSN have demonstrated noise temperatures of 3.5 K and 8.5 K at 8.5 K at 32 GHz, respectively. Front-end receiver packages employing these modules have demonstrated operating system noise temperatures of 17 K at 8.4 GHz (on a 70m antenna at zenith) and 39 K at 3 2 GHz (on a 34m antenna at zenith). The development and demonstration of cryogenic, InP HEMT based front-end amplifiers for the DSN requir es accurate component and module characterization, and modeling from 1 to 100 GHz at physical temperatures down to 12 K. The characterizati on and modeling begins with the HEMT chip, proceeds to the multi-stag e HEMT LNA module, and culminates with the complete front-end cryogenic receiver package for the antenna. This presentation will provide a n overview of this development process. Examples will be shown for de vices, LNA modules, front-end receiver packages, antennae employing these packages and the improvements to the down-link capacity.

low-noise amplifiers (LNAs)↗

NASA NTRS2012

Oxygen-Methane Thruster

An oxygen-methane thruster was conceived with integrated igniter/injector capable of nominal operation on either gaseous or liquid propellants. The thruster was designed to develop 100 lbf (approximately 445 N) thrust at vacuum conditions and use oxygen and methane as propellants. This continued development included refining the design of the thruster to minimize part count and manufacturing difficulties/cost, refining the modeling tools and capabilities that support system design and analysis, demonstrating the performance of the igniter and full thruster assembly with both gaseous and liquid propellants, and acquiring data from this testing in order to verify the design and operational parameters of the thruster. Thruster testing was conducted with gaseous propellants used for the igniter and thruster. The thruster was demonstrated to work with all types of propellant conditions, and provided the desired performance. Both the thruster and igniter were tested, as well as gaseous propellants, and found to provide the desired performance using the various propellant conditions. The engine also served as an injector testbed for MSFC-designed refractory combustion chambers made of rhenium.

Pickens, Tim↗

NASA NTRSDate not supplied

Nonlinear Buckling Analysis of Tow-Steered Composite Cylinders with Cutouts

The buckling and postbuckling behavior of two composite tow-steered shells with cutouts of different sizes is assessed using nonlinear finite element (FE) analysis and compared to experimental measurements. The cylindrical shells are manufactured using an automated fiber placement system, where the shells’ fiber orientation angles vary continuously around the shell circumference from ±10 degrees on the crown and keel to ±45 degrees on the sides. One shell features thickness variations due to tow overlaps that result from application of all 24 tows during each pass of the fiber placement system. The second shell uses the system’s tow drop/add capability to achieve a more uniform wall thickness without overlaps. Unreinforced cutouts of two different sizes—the first smaller cutout representing a passenger door on a commercial aircraft and the second larger cutout a cargo door—were machined into each of the two cylinders resulting in a total of four test cases. These cylinders were tested in axial compression and buckled elastically in previous work and are now analyzed using nonlinear FE models to compare bifurcation buckling loads as well as the load-displacement response in the prebuckling and postbuckling regimes. For all four shells analyzed, the prebuckling stiffness, buckling load, and deformation mode sequence throughout the loading-unloading cycle is accurately reproduced by the models. In particular, the shells first buckle locally around the cutouts in a stable (super-critical) manner with only a slight decrease in axial stiffness, which occurs due to the favorable load redistribution facilitated by tow steering. The shells then buckle globally in an unstable (sub-critical) manner with diamond-shaped buckles forming to the left and right of the cutouts. The buckling load of all shells with cutouts is at least 82% of the buckling load of the pristine shells without cutouts. Overall, the ability to sustain local buckling phenomena, and the relatively small reductions in global buckling load compared to pristine shells without cutouts, demonstrates the great potential of using tow steering to mitigate the adverse effects of cutouts in axially-compressed shell structures.

composites↗