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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Shape Evolution of C75 Large-Grain Niobium Half-Cells During Cavity Fabrication

The largely anisotropic deformation of large-grain Nb discs during deep drawing into half-cells poses a challenge for achieving a desired shape accuracy. Two 5-cell cavities for the C75 CEBAF cryomodule rework program have been fabricated at Jefferson Lab from large-grain Nb discs directly sliced from an ingot. The shape of the inner surface of eight half-cells has been inspected using a FARO Edge laser scanner during the fabrication process and compared to the reference shape. On average, approximately 63% of the half-cell inner surface was found to be within 0.1 mm of the reference shape and ~90% to be within 0.2 mm, after the final equator machining. Several 5-cell C75 cavities have also been fabricated at Research Instruments, Germany, and measurements of the shape accuracy using a Zeiss 3D coordinate measuring machine gave similar results. One half-cell was measured both at Research Instruments and Jefferson Lab for comparison.

Ciovati, G.↗
NASA NTRS1991

On the accuracy of shape sensitivity

The calculation of sensitivity of the response of a structure modeled by finite elements to shape variation is known to be subject to numerical difficulties. The accuracy of a given method is typically measured against the yard stick of finite-difference sensitivity calculation. The present paper demonstrates with a simple example that this approach may be flawed because of discretization errors associated with the finite element mesh. Seven methods for calculating sensitivity derivatives are compared for a two-material beam problem with a moving interface. It is found that as the mesh is refined, displacement sensitivity derivatives converge more slowly than the displacements. Six of the methods agree fairly well, but the adjoint variational surface method provides substantially different results. However, the difference is found to reflect convergence from another direction to the same answer rather than reduced accuracy. Additionally, it is observed that small derivatives are particularly prone to accuracy problems.

Haftka, R. T.↗
DOE OSTI2025

Toolpath Optimization of Polymer Composite Additive Manufacturing AM Printed Mold to Improve Performance for Compression Molding Applications

This study explores the optimization of toolpaths for short fiber polymer composite additive manufacturing (AM) printed molds in compression molding applications, an emerging trend driven by advancements in 3D printing technology. AM printed molds offer reduced tooling costs and greater design flexibility, particularly for prototyping and low-volume production. The proposed optimization approach evaluates mold performance using two key metrics: deformation and shape accuracy. Multiple toolpaths are generated, and finite element (FE) simulations capture fiber orientation and material properties, which are then integrated into a mechanical performance model. Shape accuracy is assessed by comparing the deformed mold shape with the original using surface normals as a descriptor. The analysis identifies the toolpath that delivers the best overall performance, establishing it as the most suitable option for achieving optimal mold characteristics in compression molding applications.

Limaye, Madhura [ORNL]↗
NASA NTRS1993

Effects of window size and shape on accuracy of subpixel centroid estimation of target images

A new algorithm is presented for increasing the accuracy of subpixel centroid estimation of (nearly) point target images in cases where the signal-to-noise ratio is low and the signal amplitude and shape vary from frame to frame. In the algorithm, the centroid is calculated over a data window that is matched in width to the image distribution. Fourier analysis is used to explain the dependency of the centroid estimate on the size of the data window, and simulation and experimental results are presented which demonstrate the effects of window size for two different noise models. The effects of window shape were also investigated for uniform and Gaussian-shaped windows. The new algorithm was developed to improve the dynamic range of a close-range photogrammetric tracking system that provides feedback for control of a large gap magnetic suspension system (LGMSS).

Welch, Sharon S.↗
NASA NTRS1989

On the accuracy of shape sensitivity derivatives

Six methods for calculating shape sensitivity derivatives are compared for a two-material beam problem with a moving interface. It is found that as the finite-element mesh is refined, displacement sensitivity derivatives converge more slowly than the displacement themselves. Five of the methods agree fairly well, but the adjoint variational surface method provides substantially different results. However, the difference is found to reflect convergence from another direction to the same answer, rather than reduced accuracy.

Haftka, Raphael T.↗
NASA NTRS2016

NIAC Phase I Study Final Report on Large Ultra-Lightweight Photonic Muscle Space Structures

The research goal is to develop new tools support NASA's mission of understanding of the Cosmos by developing cost effective solutions that yield a leap in performance and science data. 'Maikalani' in Hawaiian translates to, "knowledge we gain from the cosmos." Missions like Hubble have fundamentally changed humanity's view of the cosmos. Last year's Nobel prize in physics was a result of astronomical discoveries. $9B class JWST size (6.5 meter diameter) space telescopes, when launched are anticipated to rewrite our knowledge of physics. Here we report on a neoteric meta-material telescope mirror technology designed to enable a factor of 100 or more reduction in areal density, a factor of 100 reduction in telescope production and launch costs as well as other advantages; a leap to enable missions to image the cosmos in unprecedented detail, with the associated gain in knowledge. Whether terahertz, visible or X-ray, reflectors used for high quality electromagnetic imaging require shape accuracy (surface figure) to far better than 1 wavelength (lambda) of the incident photons, more typically lambda/10 or better. Imaging visible light therefore requires mirror surfaces that approximate a desired curve (e.g. a sphere or paraboloid) with smooth shape deviation of th less than approximately 1/1000 the diameter of a human hair. This requires either thick high modulus material like glass or metal, or actuators to control mirror shape. During Phase I our team studied a novel solution to this systems level design mass/shape tradespace requirement both to advance the innovative space technology concept and also to help NASA and other agencies meet current operational and future mission requirements. Extreme and revolutionary NASA imaging missions such as Terrestrial Planet Imager (TPI) require lightweight mirrors with minimum diameters of 20 to 40 meters. For reference, NASA's great achievement; the Hubble space telescope, is only 2.4 meters in diameter. What is required is a way to make large inexpensive deployable mirrors where the cost is measured in millions, not billions like current efforts. For example we seek an interim goal within 10 years of a Hubble size (2.4m) primary mirror weighing 1 pound at a cost of 10K in materials. Described here is a technology using thin ultra lightweight materials where shape can be controlled simply with a beam of light, allowing imaging with incredibly low mass yet precisely shaped mirrors. These " Photonic Muscle" substrates will eventually make precision control of giant s p a c e apertures (mirrors) possible. OCCAM substrates make precision control of giant ultra light-weight mirror apertures possible. This technology is posed to create a revolution in remote sensing by making large ultra lightweight space telescopes a fiscal and material reality over the next decade.

Cosmos↗
NASA NTRS2012

Membrane Shell Reflector Segment Antenna

The mesh reflector is the only type of large, in-space deployable antenna that has successfully flown in space. However, state-of-the-art large deployable mesh antenna systems are RF-frequency-limited by both global shape accuracy and local surface quality. The limitations of mesh reflectors stem from two factors. First, at higher frequencies, the porosity and surface roughness of the mesh results in loss and scattering of the signal. Second, the mesh material does not have any bending stiffness and thus cannot be formed into true parabolic (or other desired) shapes. To advance the deployable reflector technology at high RF frequencies from the current state-of-the-art, significant improvements need to be made in three major aspects: a high-stability and highprecision deployable truss; a continuously curved RF reflecting surface (the function of the surface as well as its first derivative are both continuous); and the RF reflecting surface should be made of a continuous material. To meet these three requirements, the Membrane Shell Reflector Segment (MSRS) antenna was developed.

Fang, Houfei↗
NASA NTRS1988

Development of a verification program for deployable truss advanced technology

Use of large deployable space structures to satisfy the growth demands of space systems is contingent upon reducing the associated risks that pervade many related technical disciplines. The overall objectives of this program was to develop a detailed plan to verify deployable truss advanced technology applicable to future large space structures and to develop a preliminary design of a deployable truss reflector/beam structure for use a a technology demonstration test article. The planning is based on a Shuttle flight experiment program using deployable 5 and 15 meter aperture tetrahedral truss reflections and a 20 m long deployable truss beam structure. The plan addresses validation of analytical methods, the degree to which ground testing adequately simulates flight and in-space testing requirements for large precision antenna designs. Based on an assessment of future NASA and DOD space system requirements, the program was developed to verify four critical technology areas: deployment, shape accuracy and control, pointing and alignment, and articulation and maneuvers. The flight experiment technology verification objectives can be met using two shuttle flights with the total experiment integrated on a single Shuttle Test Experiment Platform (STEP) and a Mission Peculiar Experiment Support Structure (MPESS). First flight of the experiment can be achieved 60 months after go-ahead with a total program duration of 90 months.

Dyer, Jack E.↗
NASA NTRSDate not supplied

Segmented, Pleat-Folded and Rib-Supported Thin-Shell Composite Antenna Reflector

A new architecture scalable to sizes greater than 10 m for a deployable solid surface reflector antenna is presented. The design makes use of radially and circumferentially segmented thin-shell composite gores interconnected on the back side by a series of flexible shape memory composite elements. The reflector surface stows like an umbrella by creating serpentine-shaped pleats in the thin shell while being supported by a simple-hinged metering rib structure. A parametric study assessed how design features affect the deployed stiffness of the reflector and are used to identify a test matrix for manufacturing, foldability, and shape accuracy assessments. Various manufacturing tooling designs and dedicated folding fixtures were built to increase the fidelity and confidence of the test articles produced. An overview of the development effort is provided.

Deployable antennas↗
NASA NTRSDate not supplied

Segmented, Pleat-Folded and Rib-Supported Thin-Shell Composite Antenna Reflector

A new architecture scalable to sizes greater than 10 m for a deployable solid surface reflector antenna is presented. The design makes use of radially and circumferentially segmented thin-shell composite gores interconnected on the back side by a series of flexible shape memory composite elements. The reflector surface stows like an umbrella by creating serpentine-shaped pleats in the thin shell while being supported by a simple-hinged metering rib structure. A parametric study assessed how design features affect the deployed stiffness of the reflector and are used to identify a test matrix for manufacturing, foldability, and shape accuracy assessments. Various manufacturing tooling designs and dedicated folding fixtures were built to increase the fidelity and confidence of the test articles produced. An overview of the development effort is provided.

Deployable antennas↗
NASA NTRS1991

The effect of the Earth's oblate spheroid shape on the accuracy of a time-of-arrival lightning ground strike locating system

The algorithm used in previous technology time-of-arrival lightning mapping systems was based on the assumption that the earth is a perfect spheroid. These systems yield highly-accurate lightning locations, which is their major strength. However, extensive analysis of tower strike data has revealed occasionally significant (one to two kilometer) systematic offset errors which are not explained by the usual error sources. It was determined that these systematic errors reduce dramatically (in some cases) when the oblate shape of the earth is taken into account. The oblate spheroid correction algorithm and a case example is presented.

Casper, Paul W.↗
NASA NTRS1992

SHAPES - Spatial, high-accuracy, position-encoding sensor

Future space systems will require control sensors capable of real-time measurements of position coordinates of many structural locations. Applications for such a sensor include figure and vibration control, rendezvous and docking, and structure assembly verification. The paper discusses an experimental study of SHAPES (spatial, high-accuracy, position-encoding sensor), a 3D position sensor that provides range and two angular positions of laser-illuminated retroreflector targets that mark the locations to be measured. Simultaneous range measurements to multiple targets by a time-of-flight corelation of short laser pulses are made with a CCD-equipped streak tube. Angular positions are measured with a CCD camera. Position measurements of 24 targets with sub-millimeter range accuracy at a 10 Hz update rate have been demonstrated.

Nerheim, Noble M.↗
NASA NTRS2012

Improved Displacement Transfer Functions for Structure Deformed Shape Predictions Using Discretely Distributed Surface Strains

In the formulations of earlier Displacement Transfer Functions for structure shape predictions, the surface strain distributions, along a strain-sensing line, were represented with piecewise linear functions. To improve the shape-prediction accuracies, Improved Displacement Transfer Functions were formulated using piecewise nonlinear strain representations. Through discretization of an embedded beam (depth-wise cross section of a structure along a strain-sensing line) into multiple small domains, piecewise nonlinear functions were used to describe the surface strain distributions along the discretized embedded beam. Such piecewise approach enabled the piecewise integrations of the embedded beam curvature equations to yield slope and deflection equations in recursive forms. The resulting Improved Displacement Transfer Functions, written in summation forms, were expressed in terms of beam geometrical parameters and surface strains along the strain-sensing line. By feeding the surface strains into the Improved Displacement Transfer Functions, structural deflections could be calculated at multiple points for mapping out the overall structural deformed shapes for visual display. The shape-prediction accuracies of the Improved Displacement Transfer Functions were then examined in view of finite-element-calculated deflections using different tapered cantilever tubular beams. It was found that by using the piecewise nonlinear strain representations, the shape-prediction accuracies could be greatly improved, especially for highly-tapered cantilever tubular beams.

Ko, William L.↗
NASA NTRS1982

Spatial, High-Accuracy, Positioning-Encoding Sensor (SHAPES) for large space system control applications

The Spatial, High-Accuracy, Position-Encoding Sensor is a controls sensor suitable for the determination of the static shape and vibrational motion of large space structures and similar systems and for the determination of position and velocity in rendezvous and docking. It uses a combination of electro-optical techniques to measure the three-dimensional coordinates distributed over the structure at reading rates high compared to the rates at which the coordinates are changing. The technical approach is that of measuring the distance to and the direction of points on the structure from a single sensor head. Many points can be measured simultaneously from a single head without significantly increasing the complexity of the system.

Mclauchlan, J. M.↗
NASA NTRS1987

SHAPES - Spatial, High-Accuracy, Position-Encoding Sensor for multi-point, 3-D position measurement of large flexible structures

An electro-optical position sensor for precise simultaneous measurement of the 3-D positions of multiple points on large space structures is described. The sensor data rate is sufficient for most control purposes. Range is determined by time-of-flight correlation of short laser pulses returned from retroreflector targets using a streak tube/CCD detector. Angular position is determined from target image locations on a second CCD. Experimental verification of dynamic ranging to multiple targets is discussed.

Nerheim, N. M↗
NASA NTRS1987

Accuracy of the domain method for the material derivative approach to shape design sensitivities

Numerical accuracy for the boundary and domain methods of the material derivative approach to shape design sensitivities is investigated through the use of mesh refinement. The results show that the domain method is generally more accurate than the boundary method, using the finite element technique. It is also shown that the domain method is equivalent, under certain assumptions, to the implicit differentiation approach not only theoretically but also numerically.

Yang, R. J.↗
NASA NTRS2012

First-and Second-Order Displacement Transfer Functions for Structural Shape Calculations Using Analytically Predicted Surface Strains

New first- and second-order displacement transfer functions have been developed for deformed shape calculations of nonuniform cross-sectional beam structures such as aircraft wings. The displacement transfer functions are expressed explicitly in terms of beam geometrical parameters and surface strains (uniaxial bending strains) obtained at equally spaced strain stations along the surface of the beam structure. By inputting the measured or analytically calculated surface strains into the displacement transfer functions, one could calculate local slopes, deflections, and cross-sectional twist angles of the nonuniform beam structure for mapping the overall structural deformed shapes for visual display. The accuracy of deformed shape calculations by the first- and second-order displacement transfer functions are determined by comparing these values to the analytically predicted values obtained from finite element analyses. This comparison shows that the new displacement transfer functions could quite accurately calculate the deformed shapes of tapered cantilever tubular beams with different tapered angles. The accuracy of the present displacement transfer functions also are compared to those of the previously developed displacement transfer functions.

Ko, William L.↗