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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Validating Thermal Compensated Deposition using Computed Aided Manufacturing Software

DP Technology Corporation’s flagship product, ESPRIT, is a highly adaptable computer-aided manufacturing system that’s used across industries and continents to create nearly anything. ESPRIT is used to generate toolpath trajectories for traditional subtractive and additive manufacturing (AM) cycles. DP Technology and Oak Ridge National Laboratory have partnered together to improve the generated additive toolpath by means of API simulation. The potential impact of this research is the enhancement of toolpath planning for additive and hybrid manufacturing. Being able to simulate and compensate for various effects such as overheating, and distortion are critical components for the industrial adoption of hybrid manufacturing processes. Industrial applications include the mold & die, automotive, and aerospace industries.

42 ENGINEERING↗
NASA NTRS1992

Army (MANTECH) Thrust Area Concept: Optics Thrust Area

With the shrinking of the U.S. Army's material needs and the compression of defense requirements, the Army Manufacturing Technology (MANTECH) Program has the opportunity to advance the manufacturing state-of-the-art and solve near term production problems of the U.S. industrial base. To exploit this opportunity, the Army restructured its MANTECH efforts in FY 90 based on a thrust area concept. Each of the ten current thrusts, directed by a thrust area manager, has a broad technical objective selected to improve specific manufacturing processes. The manager is charged with setting objectives, selecting tasks, monitoring execution, leveraging external resources, and establishing microfactories to promote technology transfer. The Optics Manufacturing Thrust is an example of the concept. It is currently directed at revitalizing the domestic precision optics manufacturing base, now characterized by high labor costs and 1940's technology, through introduction of revolutionary machines, new processes, and Computer Integrated Manufacturing (CIM) principles. Leveraging of MANTECH dollars with those of industry, academia, and state governments led to the establishment of the center for Optics Manufacturing and plans for regional centers. Recognition of the U.S. as a world leader in precision optics manufacturing and a dramatic reduction of both manufacturing time and cost should accrue from thrust area efforts.

Kopacz, Stanley P.↗
NASA NTRS2001

Manufacturing Challenges Implementing Material Changes for the Super Light Weight External Tank: A Welding Process Perspective

A viewgraph presentation gives an overview of the manufacturing challenges in implementing welding material changes for the super lightweight external tank. Details are given on the external tank configuration, the weld purging equipment used, planning the selection of weld filler wire alloy, the initial weld microstructure, the wide panel tensile testing, and the dome cap welding.

Lawless, K.↗
NASA NTRS2010

Design for Safety - The Ares Launch Vehicles Paradigm Change

The lessons learned from the S&MA early involvement in the Ares I launch vehicle design phases proved that performing an in-line function jointly with engineering is critical for S&MA to have an effective role in supporting the system, element, and component design. These lessons learned were used to effectively support the Ares V conceptual design phase and planning for post conceptual design phases. The Top level Conceptual LOM assessment for Ares V performed by the S&MA community jointly with the engineering Advanced Concept Office (ACO) was influential in the final selection of the Ares V system configuration. Post conceptual phase, extensive reliability effort should be planned to support future Heavy Lift Launch Vehicles (HLLV) design. In-depth reliability analysis involving the design, manufacturing, and system engineering communities is critical to understand design and process uncertainties and system integrated failures.

Safie, Fayssal M.↗
NASA NTRSDate not supplied

MAB Phase Ceramics for Lunar Applications

During the ten-week internship my work focused on designing characterization protocol for 3D printed MAB phase ceramics on steel and Tiplates. I was mentored by Dr. Samuel Hocker of NASA and advised by Dr. Gupta from University of North Dakota. I also collaborated with Mackenzie Short from the University of North Dakota. The characterization protocol was divided into following steps; initially, we performed visual inspection of the plates. During this process, the coatings which spalled or delaminated were discarded for further evaluation. During the next step, we performed optical microscopy to discern and document surface features and porosities of the samples. We also noted some decomposition under the optical microscope as well. Thereafter, profilometry analysis was performed to understand the effect of power density on the surface roughness. Due to the deposited powder over the samples, the profilometry was inconclusive. We then cleaned the samples on the steel plate using ethanol and cotton swabs to wipe up the loose powder covering the samples. Detailed SEM analysis was then performed on the cleaned specimens. In parallel, the 3D printed samples on the Tiplate were cleaned by using an ultrasonic bath for 1h. Optical imaging showed that this cleaning process was more effective for cleaning except that small cracks propagated through the layered ceramics. The profilometry data gathered on the titanium plate after cleaning was more conclusive. The SEM data on the steel plate showed that there is decomposition at all wattages although at 100 W the extent of decomposition was lower. We are planning to characterize the steel samples after cleaning in ultrasonic bath for 5-10 min to minimize cracking during the cleaning process. In addition, we are also planning to study the fractured surface by SEM analysis.

Additive Manufacturing, Laser Powder Bed Fusion, S↗
NASA NTRS1999

Testing of the International Space Station and X-38 Crew Return Vehicle GPS Receiver

This paper discusses the process and results of the performance testing of the GPS receiver planned for use on the International Space Station (ISS) and the X-38 Crew Return Vehicle (CRV). The receiver is a Force-19 unit manufactured by Trimble Navigation and modified in software by the NASA Goddard Space Flight Center (GSFC) to perform navigation and attitude determination in space. The receiver is the primary source of navigation and attitude information for ISS and CRV. Engineers at GSFC have developed and tested the new receiver with a Global Simulation Systems Ltd (GSS) GPS Signal Generator (GPSSG). This paper documents the unique aspects of ground testing a GPS receiver that is designed for use in space. A discussion of the design of tests using the GPSSG, documentation, data capture, data analysis, and lessons learned will precede an overview of the performance of the new receiver. A description of the challenges that were overcome during this testing exercise will be presented. Results from testing show that the receiver will be within or near the specifications for ISS attitude and navigation performance. The process for verifying other requirements such as Time to First Fix, Time to First Attitude, selection/deselection of a specific GPS satellite vehicles (SV), minimum signal strength while still obtaining attitude and navigation, navigation and attitude output coverage, GPS week rollover, and Y2K requirements are also given in this paper.

Simpson, James↗
NASA NTRS1999

Testing of the International Space Station and X-38 Crew Return Vehicle GPS Receiver

This paper discusses the process and results of the performance testing of the GPS receiver planned for use on the International Space Station (ISS) and the X-38 Crew Return Vehicle (CRV). The receiver is a Force-19 unit manufactured by Trimble Navigation and Modified in software by the NASA Goddard Space Flight Center (GSFC) to perform navigation and attitude determination in space. The receiver is the primary source of navigation and attitude information for ISS and CRV. Engineers at GSFC have developed and tested the new receiver with a Global Simulation Systems Ltd (GSS) GPS Signal Generator (GPSSG). This paper documents the unique aspects of ground testing a GPS receiver that is designed for use in space. A discussion of the design and tests using the GPSSG, documentation, data capture, data analysis, and lessons learned will precede an overview of the performance of the new receiver. A description of the challenges of that were overcome during this testing exercise will be presented. Results from testing show that the receiver will be within or near the specifications for ISS attitude and navigation performance. The process for verifying other requirements such as Time to First Fix, Time to First Attitude, selection/deselection of a specific GPS satellite vehicles (SV), minimum signal strength while still obtaining attitude and navigation, navigation and attitude output coverage, GPS week rollover, and Y2K requirements are also given in this paper.

Simpson, James↗
DOE OSTI2023

Irradiation and corrosion testing of laser powder bed fusion-manufactured materials in the AMMT program

The Advanced Materials and Manufacturing Technologies (AMMT) program operating under the Department of Energy Office of Nuclear Energy is accelerating the qualification and deployment of additively manufactured materials in advanced reactor environments. Laser powder bed fusion (LPBF) has emerged as a promising additive manufacturing technique to fabricate complex components with the potential of tailored material properties. In the nuclear industry, metal additive manufacturing can offer numerous advantages, such as reduced lead times, streamlined quality assurance, and cost-effective low-volume production of new and replacement components with conventional or novel materials and geometries. The rapid and effective qualification of the effect of processing variability on the performance and degradation of additively manufactured materials is essential for the deployment of these components into advanced reactor environments. As part of this effort, AMMT is performing irradiation and corrosion testing of several materials built by LPBF, including 316L and 316H stainless steels. Our efforts encompass neutron irradiation testing, ion irradiation testing, and advanced modeling to provide a robust technical basis for understanding the effect of process variability on materials degradation and developing a sound methodology for accelerated ion irradiation testing. We develop focused irradiation test plans that align well with risk-informed and technologically inclusive approaches to licensing. We will also discuss our plans and specific concerns for corrosion testing additively manufactured material, with a primary focus on molten salt and liquid sodium environments.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2018

Automated Fiber Placement Defect Identity Cards: Cause, Anticipation, Existence, Significance, and Progression

Automated Fiber Placement (AFP), a major composite manufacturing process, can result in many defects during the layup process that often require manual corrective action to produce a part with acceptable quality. These defects are the main limitation of the technology and can be hard to categorize or define in many situations. This paper provides a thorough definition and classification of all AFP defects. This effort constitutes a comprehensive and extensive library relevant to AFP defects. The defects selected and defined in this work are based on understanding and experience from the manufacture and research of advanced composite structure. Proper classification of these defects required an in-depth literature review and consideration of various viewpoints ranging from designers, manufacturers, analysts, and inspection professionals. Collectively, these sources were utilized to develop the most accurate view of each of the individual defect types. The results are presented as identity cards for each defect type, intended to provide researchers and the manufacturing industry a clear understanding of the (1) cause, (2) anticipation, (3) existence, (4) significance, and (5) progression of the defined AFP defects. The link between AFP defects and process planning, layup strategies, and machining was also investigated. Categorization of all important automated fiber placement defects is presented.

Harik, Ramy↗
NASA NTRS2013

Visit from JAXA to NASA MSFC: The Engines Element & Ideas for Collaboration

System Design, Development, and Fabrication: Design, develop, and fabricate or procure MB-60 component hardware compliant with the imposed technical requirements and in sufficient quantities to fulfill the overall MB-60 development effort. System Development, Assembly, and Test: Manage the scope of the development, assembly, and test-related activities for MB-60 development. This scope includes engine-level development planning, engine assembly and disassembly, test planning, engine testing, inspection, anomaly resolution, and development of necessary ground support equipment and special test equipment. System Integration: Provide coordinated integration in the realms of engineering, safety, quality, and manufacturing disciplines across the scope of the MB-60 design and associated products development Safety and Mission Assurance, structural design, fracture control, materials and processes, thermal analysis. Systems Engineering and Analysis: Manage and perform Systems Engineering and Analysis to provide rigor and structure to the overall design and development effort for the MB-60. Milestone reviews, requirements management, system analysis, program management support Program Management: Manage, plan, and coordinate the activities across all portions of the MB-60 work scope by providing direction for program administration, business management, and supplier management.

Greene, William D.↗
NASA NTRS2011

Low Cost Nuclear Thermal Rocket Cermet Fuel Element Environment Testing

Deep space missions with large payloads require high specific impulse and relatively high thrust to achieve mission goals in reasonable time frames.1,2 Conventional storable propellants produce average specific impulse. Nuclear thermal rockets capable of producing high specific impulse are proposed. Nuclear thermal rockets employ heat produced by fission reaction to heat and therefore accelerate hydrogen, which is then forced through a rocket nozzle providing thrust. Fuel element temperatures are very high (up to 3000 K), and hydrogen is highly reactive with most materials at high temperatures. Data covering the effects of high-temperature hydrogen exposure on fuel elements are limited.3 The primary concern is the mechanical failure of fuel elements that employ high-melting-point metals, ceramics, or a combination (cermet) as a structural matrix into which the nuclear fuel is distributed. The purpose of the testing is to obtain data to assess the properties of the non-nuclear support materials, as-fabricated, and determine their ability to survive and maintain thermal performance in a prototypical NTR reactor environment of exposure to hydrogen at very high temperatures. The fission process of the planned fissile material and the resulting heating performance is well known and does not therefore require that active fissile material be integrated in this testing. A small-scale test bed designed to heat fuel element samples via non-contact radio frequency heating and expose samples to hydrogen is being developed to assist in optimal material and manufacturing process selection without employing fissile material. This paper details the test bed design and results of testing conducted to date.

Bradley, D. E.↗
NASA NTRSDate not supplied

NASA Technology Maturation Plan for In-space Manufacturing of Metals

As the International Space Station’s (ISS) life approaches its end, NASA intends to travel back to the Moon and establish a sustainable presence, paving a pathway towards Mars. A fundamental shift in the current logistics strategy is required to support extended missions. On-demand manufacturing enables reduced operational cost and increased long term sustainability providing a pathway towards reducing NASA’s logistics burden. The In-Space Manufacturing (ISM) portfolio at Marshall Space Flight Center is developing additive polymers, metals, and electronics manufacturing technologies to enable a sustainable presence on the Moon and enable long-duration transit missions. Manufacturing systems for in-space applications must meet a unique set of constraints requiring a maturation path independent from processes targeted for terrestrial use. In May 2023, the On Demand Manufacturing of Metals (ODMM) project, part of the ISM portfolio funded through the Game Changing Development (GCD) program office, was canceled; however, prior to cancelation, the engineering team developed a technology maturation plan for in-space manufacturing of metallic components. The status of ODMM at closeout and an overview of the technology maturation plan for ODMM are discussed.

In Space Manufacturing↗
NASA NTRS1978

Automated Array Assembly, Phase 2

The purpose of the overall program is to establish technological readiness and provide verification for the elements of a manufacturing sequence which would ultimately be suitable for the large-scale production of silicon solar-array modules at a selling price of less than $500/kW. A program and process plan for accomplishing this objective was developed and put into operation. Three junction-formation processes are shown; since cost analysis shows that they do not differ greatly in cost, each should be considered for technical merits and possible future cost reduction. The progress made in the various process steps of the plan is described, and conclusions are presented.

Daiello, R. V.↗
NASA NTRS1980

IPAD: Integrated Programs for Aerospace-Vehicle Design

The conference was organized to promote wider awareness of the IPAD program and its coming impact on American industry. The program focuses on technology issues that are critical to computer aided design manufacturing. Included is a description of a representative aerospace design process and its interface with manufacturing, the design of a future IPAD integrated computer aided design system, results to date in developing IPAD products and associated technology, and industry experiences and plans to exploit these products.

Source record↗
DOE OSTI2025

AdditiveFOAM: A Continuum Multiphysics Code for Additive Manufacturing

AdditiveFOAM is a computational framework that simulates transport phenomena in Additive Manufacturing (AM) processes. It is built on OpenFOAM (Weller et al., 1998), the leading free, open-source software package for computational fluid dynamics (CFD). OpenFOAM offers an extensible platform for solving complex multiphysics problems using state-of-the-art finite volume methods. AdditiveFOAM leverages these capabilities to develop specialized tools aimed at addressing challenges in AM processing. Metal additive manufacturing, also known as metal 3D printing, is an advanced manufacturing technique that creates physical parts from a three-dimensional (3D) digital model by melting metal powder or wire feedstock. A significant area of research in metal AM focuses on process planning to mitigate anomalous features during printing that are deleterious to part performance (e.g., porosity and cracking), as well as controlling localized microstructure and material properties. Given the high costs and substantial time requirements associated with experimental methods for qualifying new materials and processes, there is a compelling incentive for researchers to utilize advanced computational simulations. In this context, AdditiveFOAM offers a simulation framework to better understand undesirable features in printing, thereby enhancing process planning and reducing the reliance on labor-intensive experimental campaigns.

Coleman, John [Oak Ridge National Laboratory (ORNL↗
NASA NTRS1992

Planning for the semiconductor manufacturer of the future

Texas Instruments (TI) is currently contracted by the Air Force Wright Laboratory and the Defense Advanced Research Projects Agency (DARPA) to develop the next generation flexible semiconductor wafer fabrication system called Microelectronics Manufacturing Science & Technology (MMST). Several revolutionary concepts are being pioneered on MMST, including the following: new single-wafer rapid thermal processes, in-situ sensors, cluster equipment, and advanced Computer Integrated Manufacturing (CIM) software. The objective of the project is to develop a manufacturing system capable of achieving an order of magnitude improvement in almost all aspects of wafer fabrication. TI was awarded the contract in Oct., 1988, and will complete development with a fabrication facility demonstration in April, 1993. An important part of MMST is development of the CIM environment responsible for coordinating all parts of the system. The CIM architecture being developed is based on a distributed object oriented framework made of several cooperating subsystems. The software subsystems include the following: process control for dynamic control of factory processes; modular processing system for controlling the processing equipment; generic equipment model which provides an interface between processing equipment and the rest of the factory; specification system which maintains factory documents and product specifications; simulator for modelling the factory for analysis purposes; scheduler for scheduling work on the factory floor; and the planner for planning and monitoring of orders within the factory. This paper first outlines the division of responsibility between the planner, scheduler, and simulator subsystems. It then describes the approach to incremental planning and the way in which uncertainty is modelled within the plan representation. Finally, current status and initial results are described.

Fargher, Hugh E.↗
NASA NTRS1987

The mechanics of manufacturing in space

The history of the U.S. manned space-flight program is briefly reviewed, with an emphasis on the development of materials-processing technology, and space-manufacturing aspects of the Space Station and proposed lunar and Martian bases are discussed. Consideration is given to the Mercury, Gemini, Apollo, and Apollo-Soyuz missions; Space Shuttle materials-processing experiments; plans for processing electronics crystals, metals, glasses and ceramics, biological materials, and fluids and chemicals on the Space Station; extraction of O2, Fe, Ni, and H2 from lunar materials for use as propellants and in space construction (e.g., of solar power satellites); and the requirements for a permanent base on Mars.

Wade, D. C.↗
NASA NTRS1992

Loran-C performance assurance assessment program

The Federal Aviation Administration (FAA) has accepted the Loran-C navigation system as a supplemental navigation aid for enroute use. Extension of Loran-C utilization to instrument approaches requires establishment of a process by which the current level of performance of the system is always known by the pilot. This system 'integrity' translates into confidence that, if the system is made available to the pilot, the guidance will be correct. Early in the consideration of Loran-C for instrument approaches, the Loran-C Planning Work-Group (LPW) was formed with membership from the FAA, the US Coast Guard, various state governments, aviation users, equipment manufacturers and technical experts. The group was hosted and co-chaired by the National Association of State Aviation Officials (NASAO). This forum was ideal for identification of system integrity issues and for finding the correct process for their resolution. Additionally, the Wild Goose Association (WGA), which is the international Loran-C technical and user forum, regularly brings together members of the FAA, Coast Guard, and the scientific community. Papers and discussions from WGA meetings have been helpful. Given here is a collection of the issues in which Ohio University became involved. Issues definition and resolution are included along with the recommendations in those areas where resolution is not yet complete.

Lilley, Robert W.↗