Manufacturing and quality control requirements for space systems electrical harnesses
Manufacturing and quality control requirements for space vehicle electrical harnesses
QUALITY CONTROL↗
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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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The Value Added by Manufacturing Quality Requirements
A methodology for assessing the value of manufacturing quality requirements to the final product, QVAL, is presented. The prime objective of this project was to reduce the Manufacturing Quality Requirements (MQR) that the Jet Propulsion Laboratory (JPL) imposes on internal and contracted electronics assembly organizations to the minimum number of requirements of significant value to the product.
manufacturing quality quality control quality requ↗
Materials for advanced turbine engines. Volume 1: Advanced blade tip seal system
Project 3, the subject of this technical report, was structured toward the successful engine demonstration of an improved-efficiency, long-life, tip-seal system for turbine blades. The advanced tip-seal system was designed to maintain close operating clearances between turbine blade tips and turbine shrouds and, at the same time, be resistant to environmental effects including high-temperature oxidation, hot corrosion, and thermal cycling. The turbine blade tip comprised an environmentally resistant, activated-diffussion-bonded, monocrystal superalloy combined with a thin layer of aluminium oxide abrasive particles entrapped in an electroplated NiCr matrix. The project established the tip design and joint location, characterized the single-crystal tip alloy and abrasive tip treatment, and established the manufacturing and quality-control plans required to fully process the blades. A total of 171 blades were fully manufactured, and 100 were endurance and performance engine-tested.
Zelahy, J. W.↗
Ablator manufacturing
Studies are being conducted to determine how manufacturing-induced defects affect the performance of ablative heat shields. If commonly occurring defects do not affect material performance, simpler manufacturing techniques can be used, quality control requirements can be relaxed, repair and rework operations can be held to a minimum, and thus the total manufacturing cost can be reduced.
Pittman, C. M.↗
Impact of electrode thick spot irregularities on polymer electrolyte membrane fuel cell initial performance
Polymer electrolyte membrane fuel cells have great potential for power generation in many applications, but to implement them on a larger scale, understanding of quality requirements, tolerances, and controls during manufacturing must improve. As part of this broad challenge, irregularities resulting from the membrane electrode assembly production process must be studied to determine if they impact the performance of the cell. One potential irregularity is a locally increased thickness of the coated or deposited electrode. In order to understand and provide insight into the impact of such irregularities, we intentionally created thick spots in the center of cathode electrodes. The thick spots fabricated by two different approaches were carefully characterized by optical microscopy, X-ray fluorescence spectroscopy and scanning electron microscopy (SEM). We found that the impact of the thick spots on the electrochemically active catalyst area and mass activity was minimal. However, specific electrode thick spot irregularities significantly impacted the mass transport properties of the cells. Based on SEM analysis, the likely cause of the performance drop is morphological changes associated with the creation of the thick spot irregularity. Spatial performance results obtained with a segmented cell system further indicated that the area of the performance impact exceeded that of the intentionally created thick spot.
25 ENERGY STORAGE↗
Advanced turbine blade tip seal system
An advanced blade/shroud system designed to maintain close clearance between blade tips and turbine shrouds and at the same time, be resistant to environmental effects including high temperature oxidation, hot corrosion, and thermal cycling is described. Increased efficiency and increased blade life are attained by using the advanced blade tip seal system. Features of the system include improved clearance control when blade tips preferentially wear the shrouds and a superior single crystal superalloy tip. The tip design, joint location, characterization of the single crystal tip alloy, the abrasive tip treatment, and the component and engine test are among the factors addressed. Results of wear testing, quality control plans, and the total manufacturing cycle required to fully process the blades are also discussed.
Zelahy, J. W.↗
Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields
Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and require extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk.
Nathaniel Olson↗
Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields
Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and require extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk.
Nathaniel Olson↗
Manufacture and quality control of interconnecting wire hardnesses, Volume 1
A standard is presented for manufacture, installation, and quality control of eight types of interconnecting wire harnesses. The processes, process controls, and inspection and test requirements reflected are based on acknowledgment of harness design requirements, acknowledgment of harness installation requirements, identification of the various parts, materials, etc., utilized in harness manufacture, and formulation of a typical manufacturing flow diagram for identification of each manufacturing and quality control process, operation, inspection, and test. The document covers interconnecting wire harnesses defined in the design standard, including type 1, enclosed in fluorocarbon elastomer convolute, tubing; type 2, enclosed in TFE convolute tubing lines with fiberglass braid; type 3, enclosed in TFE convolute tubing; and type 5, combination of types 3 and 4. Knowledge gained through experience on the Saturn 5 program coupled with recent advances in techniques, materials, and processes was incorporated.
Source record↗
Modeling batch melting: Roles of heat transfer and reaction kinetics
Development of mathematical models of heat and mass transfer in glass-melting furnaces began in the 1970s and progressed rapidly with advances in sophisticated experimental/numerical techniques and increasing computational power. Today, practically all newly built or rebuilt furnaces are optimized with these models to meet stringent quality requirements, reduce the unit costs of manufacturing, or control emissions. One remaining hurdle is to model the batch-to-glass conversion accurately enough to reliably assess the glass production rate. This article summarizes two key aspects of the batch-conversion modeling—the heat transfer and the kinetics of conversion—and reviews the current state-of-the-art approaches to simulating them. We critically examine the advantages of the commonly used heat transfer approach, but also explain that its predictive capabilities are significantly restricted by the dependence of batch thermal properties on the time-temperature history. We argue that kinetic approaches to the batch-conversion modeling would offer a significant improvement when coupled with the heat transfer approach. Finally, we summarize key areas requiring further research on the way toward a realistic model of the batch blanket.
Pokorny, Richard↗
Reliability history of the Apollo guidance computer
The Apollo guidance computer was designed to provide the computation necessary for guidance, navigation and control of the command module and the lunar landing module of the Apollo spacecraft. The computer was designed using the technology of the early 1960's and the production was completed by 1969. During the development, production, and operational phase of the program, the computer has accumulated a very interesting history which is valuable for evaluating the technology, production methods, system integration, and the reliability of the hardware. The operational experience in the Apollo guidance systems includes 17 computers which flew missions and another 26 flight type computers which are still in various phases of prelaunch activity including storage, system checkout, prelaunch spacecraft checkout, etc. These computers were manufactured and maintained under very strict quality control procedures with requirements for reporting and analyzing all indications of failure. Probably no other computer or electronic equipment with equivalent complexity has been as well documented and monitored. Since it has demonstrated a unique reliability history, it is important to evaluate the techniques and methods which have contributed to the high reliability of this computer.
Hall, E. C.↗
Space vehicle production and attendant requirements
Management techniques to maintain quality, cost control, and production schedules in manufacture of space vehicle end products
COST ESTIMATE↗
Visual and x-ray inspection characteristics of eutectic and lead free assemblies
For high reliability applications, visual inspection has been the key technique for most conventional electronic package assemblies. Now, the use of x-ray technique has become an additional inspection requirement for quality control and detection of unique defects due to manufacturing of advanced electronic array packages such as ball grid array (BGAs) and chip scale packages (CSPs).
x-ray↗
Optimization of key energy and performance metrics for drug product manufacturing
During the development of pharmaceutical manufacturing processes, detailed systems-based analysis and optimization are required to control and regulate critical quality attributes within specific ranges, to maintain product performance. As discussions on carbon footprint, sustainability, and energy efficiency are gaining prominence, the development and utilization of these concepts in pharmaceutical manufacturing are seldom reported, which limits the potential of pharmaceutical industry in maximizing key energy and performance metrics. Based on an integrated modeling and techno-economic analysis framework previously developed by the authors, this study presents the development of a combined sensitivity analysis and optimization approach to minimize energy consumption while maintaining product quality and meeting operational constraints in a pharmaceutical process. The optimal input process conditions identified were validated against experiments and good agreement resulted between simulated and experimental data. Here, the results also allowed for a comparison of the capital and operational costs for batch and continuous manufacturing schemes under nominal and optimized conditions. Using the nominal batch operations as a basis, the optimized batch operation results in a 71.7% reduction of energy consumption, whereas the optimized continuous case results in an energy saving of 83.3%.
59 BASIC BIOLOGICAL SCIENCES↗
Characterization and manufacture of braided composites for large commercial aircraft structures
Braided composite materials, one of the advanced material forms which is under investigation in Boeing's ATCAS program, have been recognized as a potential cost-effective material form for fuselage structural elements. Consequently, there is a strong need for more knowledge in the design, manufacture, test, and analysis of textile structural composites. The overall objective of this work is to advance braided composite technology towards applications to a large commercial transport fuselage. This paper summarizes the mechanics of materials and manufacturing demonstration results which have been obtained in order to acquire an understanding of how braided composites can be applied to a commercial fuselage. Textile composites consisting of 1D, 2D triaxial, and 3D braid patterns with thermoplastic and two RTM resin systems were investigated. The structural performance of braided composites was evaluated through an extensive mechanical test program. Analytical methods were also developed and applied to predict the following: internal fiber architectures, stiffnesses, fiber stresses, failure mechanisms, notch effects, and the entire history of failure of the braided composites specimens. The applicability of braided composites to a commercial transport fuselage was further assessed through a manufacturing demonstration. Three foot fuselage circumferential hoop frames were manufactured to demonstrate the feasibility of consistently producing high quality braided/RTM composite primary structures. The manufacturing issues (tooling requirements, processing requirements, and process/quality control) addressed during the demonstration are summarized. The manufacturing demonstration in conjunction with the mechanical test results and developed analytical methods increased the confidence in the ATCAS approach to the design, manufacture, test, and analysis of braided composites.
Fedro, Mark J.↗
Eco-Friendly High-Performance Carbon Building Material Development from Coal
The development of eco-friendly high-performance building materials based on coal-derived materials is greatly beneficial for promoting environmental sustainability and the coal industry. This project focused on advancing technology to create innovative and scalable construction materials from two domestic sources: (1) coal-derived pyrolyzed char (PC), and (2) solvent-extracted coal deposit, extracts, and residue (CDER). It aimed to simultaneously develop and produce two types of coal-derived building products: (1) char-based concrete bricks (CCB) for wall construction in buildings, and (2) carbon-based structural units (CSU) intended as alternatives to traditional wood, concrete, or steel framing structures. The project team has successfully developed methods for manufacturing CCB samples. Extensive experiments were conducted to assess various manufacturing techniques for these samples. This included measuring their physical properties such as thermal conductivity (ranging from 0.26 to 0.38 W/mK) and bulk density (ranging from 0.85 to 1.15 g/cm 3 ), along with their mechanical properties (e.g., compressive strength ranging from 14 to 16 MPa at 28 days) for samples with a PC composition of 70%. Quality assurance and quality control tests, focusing on density and compressive strength, were also performed on samples selected randomly from pilot-scale production, and cured for a long term (over three months). The average long-term compressive strength of two randomly selected CCB samples was measured as 15.1 MPa, which was higher than the required target strength of 14 MPa. This indicates that the manufactured CCB samples from the preliminary pilot scale production run have good quality control and long-term strength performance.
01 COAL, LIGNITE, AND PEAT↗
Development of Quality Control Methods for Robust and Reliable Sensor Design
The successful adoption of additive manufacturing for the rapid prototyping of printed sensors requires the establishment of quantifiable metrics that can interrogate device performance. One measure of performance is the adhesion strength between the substrate and sensor interface, which is critical since the strength of this interface can dictate the accuracy and reliability of the printed sensor. In this work, a non-contact laser-induced spallation technique was used to quantify the adhesion of silver prints on an aluminum alloy substrate. The laser-based method was compared to a standardized pull-off adhesion test, which provided baseline measurements of adhesion strength. The sintering conditions were shown to play an important role in the film-substrate adhesion strength, as well as the cohesion and ductility of the film itself. The methods and results described in this work supports the establishment of process control steps that are necessary for verifying the reliability of printed devices prior to its deployment in critical experiments.
36 MATERIALS SCIENCE↗
Manual control models of industrial management
The industrial engineer is often required to design and implement control systems and organization for manufacturing and service facilities, to optimize quality, delivery, and yield, and minimize cost. Despite progress in computer science most such systems still employ human operators and managers as real-time control elements. Manual control theory should therefore be applicable to at least some aspects of industrial system design and operations. Formulation of adequate model structures is an essential prerequisite to progress in this area; since real-world production systems invariably include multilevel and multiloop control, and are implemented by timeshared human effort. A modular structure incorporating certain new types of functional element, has been developed. This forms the basis for analysis of an industrial process operation. In this case it appears that managerial controllers operate in a discrete predictive mode based on fast time modelling, with sampling interval related to plant dynamics. Successive aggregation causes reduced response bandwidth and hence increased sampling interval as a function of level.
Crossman, E. R. F. W.↗