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Results for “low-cost manufacturing”

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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1975

Development of a monolithic GaAs integrated optical transmitter

The paper discusses a program designed for the development of a GaAs IOC transmitter consisting of a monolithic surface laser whose output is coupled into patterned channel waveguides. Modulation and switching of the radiation occur in the waveguide circuit and are controlled separately. These structures are to be fabricated monolithically on a single semiconductor chip with each device amenable to integrated low-cost manufacture. The waveguide outputs of the IOC transmitter will be coupled to single mode optical fibers which form a transmission cable. The properties of the semiconductors (Ga,Al)As and (Ga,In)As permit performance of each of the basic functions included in the device considered. The concept of monolithic nondiscrete GaAs diode lasers is examined along with optical stripline channel waveguides and electro-optic channel waveguide modulators and switches.

Blum, F. A.↗
NASA NTRS1976

Experiments to evaluate high-temperature rolling as a low-cost process for silicon solar cells

Mechanical rolling (a process used in industry for producing large quantities of metallic sheet and strip) has been suggested for the rapid low-cost manufacture of silicon sheet to be used for photovoltaic power generation equipment, such as solar arrays. The advantages of rolling include: high rates of production, wide sheets as products, good control of dimension, and (in the case of solar grade silicon) minimal development of impurities. Experiments have been performed using high-temperature, high-speed compression of polycrystalline silicon cylinders. Metallography and X-ray diffraction techniques have been used to examine the samples both before and after compression, and a model process has been designed to evaluate the technical practicality and economic feasibility of the method.

Noel, G. T.↗
NASA NTRS2026

NASA Weather Balloon Demonstration of an Additively Manufactured Antenna

Additive manufacturing (AM) enables low-cost, lightweight, and geometrically flexible antennas for rapid deployment missions. This work reports a left-hand circularly polarized magneto-electric dipole printed on a Radix dielectric with inkjet silver metallization and demonstrated as a process replacement for NASA weather-balloon RF hardware. By combining substrate fabrication and metallization, AM provides value for unrecoverable or field-replaceable systems. A physics based verification workflow links AM-specific material behavior to electromagnetic performance and yields bounded total, radiation, and mismatch efficiencies. Standard surface-impedance and roughness models failed to reproduce the frequency-dependent radiation loss observed in printed inks, underscoring the need for AM-specific conductor parameterization. Mission testing confirmed TDRSS link closure from NASA’s Columbia Scientific Balloon Facility and validated a repeatable print–measure–fly workflow for bounding RF performance and qualifying AM antennas for field use.

Peter Moschetti↗
NASA NTRSDate not supplied

NASA Weather Balloon Demonstration of an Additively Manufactured Antenna

Additive manufacturing (AM) enables low-cost, lightweight, and geometrically flexible antennas for rapid deployment missions. This work reports a left-hand circularly polarized magneto-electric dipole printed on a Radix dielectric with inkjet silver metallization and demonstrated as a process replacement for NASA weather-balloon RF hardware. By combining substrate fabrication and metallization, AM provides value for unrecoverable or field-replaceable systems. A physics based verification workflow links AM-specific material behavior to electromagnetic performance and yields bounded total, radiation, and mismatch efficiencies. Standard surface-impedance and roughness models failed to reproduce the frequency-dependent radiation loss observed in printed inks, underscoring the need for AM-specific conductor parameterization. Mission testing confirmed TDRSS link closure from NASA’s Columbia Scientific Balloon Facility and validated a repeatable print–measure–fly workflow for bounding RF performance and qualifying AM antennas for field use.

Peter Moschetti↗
NASA NTRS1972

Investigation of low-cost ablative heat shield fabrication for space shuttles

Improvements in the processes and design to reduce the manufacturing costs for low density ablative panels for the space shuttle are discussed. The areas that were studied included methods of loading honeycomb core, alternative reinforcement concepts, and the use of reusable subpanels. A review of previous studies on the fabrication of low-cost ablative panels and on permissible defects that do not affect thermal performance was conducted. Considerable differences in the quoted prices for ablative panels, even though the various contractors had reported similar fabrication times were discovered. How these cost differences arise from different estimating criteria and which estimating assumptions and other costs must be included in order to arrive at a realistic price are discussed.

Chandler, H. H.↗
NASA NTRS1976

LSSA (Low-cost Silicon Solar Array) project

Methods are explored for economically generating electrical power to meet future requirements. The Low-Cost Silicon Solar Array Project (LSSA) was established to reduce the price of solar arrays by improving manufacturing technology, adapting mass production techniques, and promoting user acceptance. The new manufacturing technology includes the consideration of new silicon refinement processes, silicon sheet growth techniques, encapsulants, and automated assembly production being developed under contract by industries and universities.

Source record↗
NASA NTRS1972

Study of low-cost fabrication of ablative heat shields

The major objectives were accomplished in three tasks: (1) modification of the ablative material composition for ease of fabrication as well as thermal and mechanical performance; (2) scaled-up, simplified, manufacturing techniques which resulted in cost reductions; and (3) the identification of a significant design problem caused by the differential pressure buildup imposed on mechanically attached ablative heat shield panels during launch.

Norwood, L. B.↗
NASA NTRSDate not supplied

Carbon Fiber Composite Processing Using Isothermal Resins

To meet future demand for single-aisle composite aircraft production, manufacturing rates are expected to increase by up to six times current production rates. Resin infusion is a manufacturing method that has potential to enable fabrication of structures at the desired rates. However, production cycle times with currently available commercial infusion resins cannot support the rates needed for an estimated 80 aircraft per month. Recently, rapid-curing isothermal resins were developed that can reduce the overall processing time. These resins can be infused, cured, and demolded at a single temperature below 100 °C, thereby eliminating the need for time consuming temperature ramps and shortening the overall cure time. In addition, the low temperatures enable use of low-cost tooling during production. This presentation will discuss the use of resin transfer molding to produce composites with rapid-curing isothermal resins, manufacturing considerations, and performance characteristics of the composites.

John M Gardner↗
NASA NTRS1973

Active tuning circuit

Low-cost, inductorless, high Q active-tuning circuit can be made by coupling pair of transistors and their supporting circuitry to take advantage of frequency dependent energy storage effects. Circuit may be manufactured by standard micro-electronic techniques; has very low noise factor; and input-output matching networks are not necessary.

Kleinberg, L. L.↗
NASA NTRS1972

Aerodynamic study of a turbine designed for a small low-cost turbofan engine

An eight inch mean diameter two-stage turbine was experimentally investigated over a range of speeds from 0 to 110 percent of equivalent design speed and over a range of pressure ratios from 2.2 to 4.2. The principal results indicated that the performance level was substantially higher than that assumed in the design. As part of the program to reduce manufacturing costs, the first stage blading was reduced in thickness for ease in coining. Tests of the modified blades indicated that the aerodynamic performance of a stator or rotor blade with a large amount of reaction was effected very little by a significant change of the pressure surface.

Kofskey, M. G.↗
NASA NTRS1973

Low-cost fabrication and installation of ablative heat shields for the space shuttle orbiter.

Description of the formulation and evaluation of low-density elastomeric ablative compounds and low-cost techniques for fabricating and installing ablative panels being considered for the Space Shuttle orbiter's thermal protection system. Sixteen large panels, both flat and contoured, were successfully fabricated and time-studied to develop and refine tooling and manufacturing methods and to establish a realistic baseline for estimating costs. Six of the panels were bonded to a DC-3 airframe. The work included a detailed estimate of fabrication and installation costs.

Norwood, L. B.↗
NASA NTRS1980

Low cost composite materials for wind energy conversion systems

A winding process utilizing a low-cost E-glass fabric called transverse-filament tape for low-cost production of wind turbine generators (WTG) is described. The process can be carried out continuously at high speed to produce large one-piece parts with tapered wall thicknesses on a tapered mandrel. It is being used to manufacture blades for the NASA/DOE 200-ft-diameter MOD-1 WTG and Rockwell/DOE 40-kW small wind energy conversion system (SWECS).

Weingart, O.↗
NASA NTRS1976

An analytical and experimental evaluation of the plano-cylindrical Fresnel lens solar concentrator

Plastic Fresnel lenses for solar concentration are attractive because of potential for low-cost mass production. An analytical and experimental evaluation of line-focusing Fresnel lenses with application potential in the 200 to 370 C range is reported. Analytical techniques were formulated to assess the solar transmission and imaging properties of a grooves-down lens. Experimentation was based primarily on a 56 cm-wide lens with f-number 1.0. A sun-tracking heliostat provided a non-moving solar source. Measured data indicated more spreading at the profile base than analytically predicted. The measured and computed transmittances were 85 and 87% respectively. Preliminary testing with a second lens (1.85 m) indicated that modified manufacturing techniques corrected the profile spreading problem.

Hastings, L. J.↗
NASA NTRSDate not supplied

Multidisciplinary Design Optimization and Analysis of an Open Rotor Stage: Part 1

Successful design of open rotor propulsors requires effective analysis across multiple disciplines, including aerodynamics, acoustics, and structures. A viable design must not only be efficient but must also produce an acceptable level of noise and meet all static and dynamic structural requirements. For design and optimization, this is especially challenging because running high fidelity analyses is resource-intensive, and optimizing a design may require many thousands of cases to be analyzed. For this reason, the NASA team has applied design methodology that utilizes low-cost aerodynamic methods, machine learning models, and high-fidelity analyses when necessary. This includes standard two-dimensional methods such as throughflow analysis and quasi-3D blade-to-blade CFD, as well as some newly developed methods. Optimization using 3D CFD is necessary to maximize performance, and this is considered as well. All optimizations are carried out subject to structural constraints evaluated using finite element analysis. Doing this accurately requires a robust trunnion design, capable of pitching the blade between cruise and takeoff conditions while maintaining acceptable factor of safety. Hot to cold analysis must also be applied in order to correctly determine the as-manufactured shape. For acoustics, the unsteady pressures on the blade surfaces must be predicted, and this can be done either through full-annulus unsteady CFD or through a nonlinear harmonic method (NLH). NLH can run much faster, allowing some acoustic considerations to be made earlier in the design process. The design process is ongoing, and this presentation will review the current status and planned next steps. This part of the talk will focus on aerodynamic performance and be followed by a talk on structures and acoustics.

Design↗
NASA NTRS1972

Development of low-cost welding procedures for thick sections of HY-150 steel

Low cost welding procedures were developed for welding 6-inch thick HY-150 steel to be used in the manufacture of large diameter motor case Y rings and nozzle attachment flanges. An extensive investigation was made of the mechanical and metallurgical properties and fracture toughness of HY-150 base plate and welds made with manual shielded metal arc process and semi-automatic gas metal arc process in the flat position. Transverse tensiles, all-weld metal tensiles, Charpy V-notch specimens and edge notched bend specimens were tested in the course of the program. In addition metallographic studies and hardness tests were performed on the weld, weld HAZ and base metal. The results of the work performed indicate that both the shielded metal arc and gas metal arc processes are capable of producing consistently sound welds as determined by radiographic and ultrasonic inspection. In addition, the weld metal, deposited by each process was found to exhibit a good combination of strength and toughness such that the selection of a rolled and welded procedure for fabricating rocket motor case components would appear to be technically feasible.

Schmidt, P. M.↗
NASA NTRS1973

Evaluation of forming and manufacturing characterisitics of boron/aluminum materials

Low cost techniques were evaluated for forming boron-reinforced aluminum structural shapes from diffusion-bonded flat sheet and plate. Successful forming was accomplished on fully consolidated material up to .46 cm (0.180) in thick. Five hot section 12 in long were formed from 0.100 thick flat plates 12 in long by 7 in wide. Three of the hat sections were tested in cyclic compression to demonstrate the performance capability of structures by this type of low-cost secondary fabrication. The structural efficiency of these hats was found to be equal or superior to similar structures fabricated by more costly techniques.

Dolowy, J. F., Jr.↗
NASA NTRS1971

Study of alternate space shuttle concepts

A study of alternate space shuttle concepts was conducted to examine the stage-and-one-half concept and its potential for later conversion and use in the two stage reusable shuttle system. A study of external hydrogen tank concepts was conducted to determine the issues involved in the design and production of a low-cost expendable tank system. The major objectives of the study were to determine: (1) realistic drop tank program cost estimates, (2) estimated drop tank program cost for selected specific designs, and (3) change in program cost due to variations in design and manufacturing concepts and changes in program assumptions.

Source record↗