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At least 181 records · Page 10

All sources NASA NTRS DOE OSTI

NASA NTRS1977

Quiet Clean Short-haul Experimental Engine (QCSEE) under-the-wing engine composite fan blade design report

A total of 38 quiet clean short haul experimental engine under the wing composite fan blades were manufactured for various component tests, process and tooling, checkout, and use in the QCSEE UTW engine. The component tests included frequency characterization, strain distribution, bench fatigue, platform static load, whirligig high cycle fatigue, whirligig low cycle fatigue, whirligig strain distribution, and whirligig over-speed. All tests were successfully completed. All blades planned for use in the engine were subjected to and passed a whirligig proof spin test.

Ravenhall, R.↗

NASA NTRS1991

Hyperswitch communication network

The Hyperswitch Communication Network (HCN) is a large scale parallel computer prototype being developed at JPL. Commercial versions of the HCN computer are planned. The HCN computer being designed is a message passing multiple instruction multiple data (MIMD) computer, and offers many advantages in price-performance ratio, reliability and availability, and manufacturing over traditional uniprocessors and bus based multiprocessors. The design of the HCN operating system is a uniquely flexible environment that combines both parallel processing and distributed processing. This programming paradigm can achieve a balance among the following competing factors: performance in processing and communications, user friendliness, and fault tolerance. The prototype is being designed to accommodate a maximum of 64 state of the art microprocessors. The HCN is classified as a distributed supercomputer. The HCN system is described, and the performance/cost analysis and other competing factors within the system design are reviewed.

Peterson, J.↗

NASA NTRS1999

Effect of High Temperature on the Tensile Behavior of CFRP and Cementitious Composites

Concrete and other composite manufacturing processes are continuing to evolve and become more and more suited for use in non-Earth settings such as the Moon and Mars. The fact that structures built in lunar environments would experience a range of effects from temperature extremes to bombardment by micrometeorites and that all the materials for concrete production exist on the Moon means that concrete appears to be the most feasible building material. it can provide adequate shelter from the harshness of the lunar environment and at the same time be a cost effective building material. With a return to the Moon planned by NASA to occur after the turn of the century, it will be necessary to include concrete manufacturing as one of the experiments to be conducted in one of the coming missions. Concrete's many possible uses and possibilities for manufacturing make it ideal for lunar construction. The objectives of this research are summarized as follows: i) study the possibility of concrete production on the Moon or other planets, ii) study the effect of high temperature on the tensile behavior of concrete, and iii) study the effect of high temperature on the tensile behavior of carbon fiber reinforced with inorganic polymer composites. Literature review indicates that production of concrete on the Moon or other planets is feasible using the indigenous materials. Results of this study has shown that both the tensile strength and static elastic modulus of concrete decreased with a rise in temperature from 200 to 500 C. The addition of silica fume to concrete showed higher resistance to high temperatures. Carbon fiber reinforced inorganic polymer (CFRIP) composites seemed to perform well up to 300 C. However, a significant reduction in strength was observed of about 40% at 400 C and up to 80% when the specimens were exposed to 700 C.

Toutanji, Houssam A.↗

NASA NTRS2013

Friction Stir Weld Application and Tooling Design for the Multi-purpose Crew Vehicle Stage Adapter

The Multi-Purpose Crew Vehicle (MPCV), commonly known as the Orion capsule, is planned to be the United States' next manned spacecraft for missions beyond low earth orbit. Following the cancellation of the Constellation program and creation of SLS (Space Launch System), the need arose for the MPCV to utilize the Delta IV Heavy rocket for a test launch scheduled for 2014 instead of the previously planned Ares I rocket. As a result, an adapter (MSA) must be used in conjunction with the MPCV to account for the variation in diameter of the launch vehicles; 5.5 meters down to 5.0 meters. Prior to ight article fabrication, a path nder (test article) will be fabricated to ne tune the associated manufacturing processes. The adapter will be comprised of an aluminum frustum (partial cone) that employs isogrid technology and circumferential rings on each end. The frustum will be fabricated by friction stir welding (FSW) three individual panels together on a Vertical Weld Tool (VWT) at NASA Marshall Space Flight Center. Subsequently, each circumferential ring will be friction stir welded to the frustum using a Robotic Weld Tool (RWT). The irregular geometry and large mass of the MSA require that extensive tooling preparation be put into support structures for the friction stir weld. The tooling on the VWT will be comprised of a set of conveyors mounted on pre-existing stanchions so that the MSA will have the ability to be rotated after each of the three friction stir welds. The tooling requirements to friction stir weld the rings with the RWT are somewhat more demanding. To support the mass of the MSA and resist the load of the weld tool, a system of mandrels will be mounted to stanchions and assembled in a circle. The goal of the paper will be to explain the design, fabrication, and assembly of the tooling, to explain the use of friction stir welding on the MSA path nder, and also to discuss the lessons learned and modi cations made in preparation for ight article fabrication in support of the 2014 launch of the Orion MPCV.

Alcorn, John↗

NASA NTRS1994

Assembly flow simulation of a radar

A discrete event simulation model has been developed to predict the assembly flow time of a new radar product. The simulation was the key tool employed to identify flow constraints. The radar, production facility, and equipment complement were designed, arranged, and selected to provide the most manufacturable assembly possible. A goal was to reduce the assembly and testing cycle time from twenty-six weeks. A computer software simulation package (SLAM 2) was utilized as the foundation for simulating the assembly flow time. FORTRAN subroutines were incorporated into the software to deal with unique flow circumstances that were not accommodated by the software. Detailed information relating to the assembly operations was provided by a team selected from the engineering, manufacturing management, inspection, and production assembly staff. The simulation verified that it would be possible to achieve the cycle time goal of six weeks. Equipment and manpower constraints were identified during the simulation process and adjusted as required to achieve the flow with a given monthly production requirement. The simulation is being maintained as a planning tool to be used to identify constraints in the event that monthly output is increased. 'What-if' studies have been conducted to identify the cost of reducing constraints caused by increases in output requirement.

Rutherford, W. C.↗

NASA NTRS1985

Fabrication process of a high temperature polymer matrix engine duct

The process that was used in the molding of an advanced composite outer by-pass duct planned for the F404 engine is discussed. This duct was developed as a potential replacement for the existing titanium duct in order to reduce both the weight and cost of the duct. The composite duct is now going into the manufacturing technology portion of the program. The duct is fabricated using graphite cloth impregnated with the PMR-15 matrix system.

Pratt, R. D.↗

NASA NTRS1989

Transportation cost - Impacts on commercial users

The potential impact of transportation price on the financial performance of space business ventures is analyzed. Business plans for generic space facilities (both STS based and free-flying), space processing, and communications satellite businesses were developed. Impacts were established parametrically for return on investment and customer product/service price as a function of transportation price. The following businesses were considered: communications satellite; shuttle based and free-flying space facilities; and space pharmaceuticals manufacturing and minilab leasing.

Greenberg, Joel S.↗

NASA NTRS1976

The NASA Space Processing Program

The program is intended to initiate utilization of spaceflight for economically beneficial activities in all branches of materials science and technology. In view of the prospect they offer for reducing the costs of space operations, the Spacelab and Space Shuttle are expected to become widely used for work on materials early in the 1980's. At first they will be employed for space experiments and for services, such as sample preparation, that support research and development activities on the ground. Orbital manufacturing operations are expected to develop as well when research has prepared an adequate basis for them. During the past year, NASA has initiated a series of rocket flights on which prospective participants in the Shuttle/Spacelab program can perform preliminary experiments. Participation in these flights is open to investigators from all countries, and experiments are being solicited from private sponsors also. NASA is performing concurrent definition studies of Shuttle/Spacelab payloads, and design work on equipment for the first two years of operations is planned to begin early in 1977. The Office of Applications currently plans to fly two space processing payloads on Orbital Flight Test missions in 1980 and two on operational Spacelab missions in 1981.

Bredt, J. H.↗

NASA NTRS1977

NASA's space processing program

The NASA Space Processing Program was initiated to develop uses of space flight that will support research efforts and manufacturing operations on the ground by processing materials in space. It is expected that the unique conditions that are available in space will provide a basis for a wide variety of economically beneficial services to science and industry in fields such as metallurgy, electronic materials, glass technology, fluid physics and chemistry, and in biological material preparation as well. Plans are described for developing payload equipment to implement materials processing experiments on the missions of the space transportation system (STS). This equipment is intended to support a diversified program of NASA-sponsored materials processing experiments by all classes of scientists, as well as pilot activities by non-NASA sponsors.

Bredt, J. H.↗

NASA NTRS1981

Design requirements for SRB production control system. Volume 3: Package evaluation, modification and hardware

The software package evaluation was designed to analyze commercially available, field-proven, production control or manufacturing resource planning management technology and software package. The analysis was conducted by comparing SRB production control software requirements and conceptual system design to software package capabilities. The methodology of evaluation and the findings at each stage of evaluation are described. Topics covered include: vendor listing; request for information (RFI) document; RFI response rate and quality; RFI evaluation process; and capabilities versus requirements.

Source record↗

NASA NTRS1984

Electric utility acid fuel cell stack technology advancement

The principal effort under this program was directed at the fuel cell stack technology required to accomplish the initial feasibility demonstrations of increased cell stack operating pressures and temperatures, increased cell active area, incorporation of the ribbed substrate cell configuration at the bove conditions, and the introduction of higher performance electrocatalysts. The program results were successful with the primary accomplishments being: (1) fabrication of 10 sq ft ribbed substrate, cell components including higher performing electrocatalysts; (2) assembly of a 10 sq ft, 30-cell short stack; and (3) initial test of this stack at 120 psia and 405 F. These accomplishments demonstrate the feasibility of fabricating and handling large area cells using materials and processes that are oriented to low cost manufacture. An additional accomplishment under the program was the testing of two 3.7 sq ft short stacks at 12 psia/405 F to 5400 and 4500 hours respectively. These tests demonstrate the durability of the components and the cell stack configuration to a nominal 5000 hours at the higher pressure and temperature condition planned for the next electric utility power plant.

Congdon, J. V.↗

NASA NTRS2012

Launch and Assembly Reliability Analysis for Human Space Exploration Missions

NASA's future human space exploration strategy includes single and multi-launch missions to various destinations including cis-lunar space, near Earth objects such as asteroids, and ultimately Mars. Each campaign is being defined by Design Reference Missions (DRMs). Many of these missions are complex, requiring multiple launches and assembly of vehicles in orbit. Certain missions also have constrained departure windows to the destination. These factors raise concerns regarding the reliability of launching and assembling all required elements in time to support planned departure. This paper describes an integrated methodology for analyzing launch and assembly reliability in any single DRM or set of DRMs starting with flight hardware manufacturing and ending with final departure to the destination. A discrete event simulation is built for each DRM that includes the pertinent risk factors including, but not limited to: manufacturing completion; ground transportation; ground processing; launch countdown; ascent; rendezvous and docking, assembly, and orbital operations leading up to trans-destination-injection. Each reliability factor can be selectively activated or deactivated so that the most critical risk factors can be identified. This enables NASA to prioritize mitigation actions so as to improve mission success.

Cates, Grant↗

NASA NTRS2026

Polymer Composite Material Testing for a Cryotank Application

Composite cryotanks will play a key role in enabling the next generation of efficient aircraft. Carbon fiber reinforced polymer (CFRP) composites have the benefits of reduced weight and potentially higher structural strength compared to traditional metallic fuel tanks. A material screening study was conducted to inform material selection for liquid hydrogen (LH2) fuel storage. Three composite materials were considered because of their aerospace grade toughness, strength, and existing data to compare against. These materials were a thermoplastic low-melt polyaryletherketone (LM-PAEK)/carbon fiber (CF), thermoset/CF, and hybrid thermoset/thermoplastic polyurethane (TPU) veil/CF composite. Mechanical screening tests included tension, compression, in-plane shear (IPS), and tensile-tensile fatigue (TTF). Each material was tested at both a baseline (no liquid nitrogen/LN2 cycling) and 100 LN2-cycled conditions to determine the knockdown factor, if any, of each material when exposed to environmental loading effects in a cryotank. Results show minimal effects of the LN2-cycling compared against baseline values. The three materials behaved similarly in tension; however, the thermoplastic/CF had the highest IPS toughness. The hybrid thermoset/TPU/CF composite had the lowest IPS strength, compressive strength, and toughness. LN2-cycling had minimal effects on tensile-tensile fatigue performance of the thermoplastic/CF material. Mechanical data was captured to guide material down selection for future commercially viable hydrogen aircraft design. In its current state, there does not exist a consolidated, publicly available database for CFRP composite material performance data at cryogenic temperatures. The next step in this work is to test the thermoplastic and thermoset CFRP composites, as well as the neat resins, at LH2 relevant temperature (20 K) to capture this crucial material property data. These results are essential to inform cryotank design and modeling efforts. The process to start this next round of testing has begun. Planned mechanical tests include toughness (single-edge notched beam), tension (unidirectional and quasi-isotropic), thermal expansion, and thermal conductivity. Some tests will also be conducted at an intermediate temperature of 111 K relevant to liquid natural gas (LNG), another attractive fuel choice. The ultimate goal is to manufacture a sub-scale cryotank part that can pass relevant burst, fatigue, permeation, and thermal cycling tests. This work is a part of NASA’s Commercially viable Hydrogen Aircraft for Robust Growth in Efficiency (CHARGE) Project under the larger NASA Subsonic Vehicle Technologies and Tools (SVTT) Project.

composites↗

NASA NTRS2000

Separation and Conditioning of Mars Atmospheric Gases via TSA

Space and planetary exploration almost always presents interesting and unusual engineering challenges. Separations engineering for chemical processes that are critical to humans working in space is no exception. The challenges are becoming clearer as we make the transition from concepts and planning to hardware development, and as we understand better the constraints and environments in which the processes must perform. The coming decade will see a robotic Mars exploration program that has recovered from recent setbacks and is building a knowledge and technology base for human exploration. One of the missions will carry a small chemical pilot plant for demonstrating the manufacture of rocket propellants and life support consumables from the low-pressure (0.01 atm) Martian atmosphere. By manufacturing and storing the fuel and consumables needed for human-return missions in situ, launch mass and landed mass are reduced by tons and missions become far less expensive. The front-end to the pilot plant is a solid-state atmosphere acquisition and separation unit based on temperature-swing adsorption (TSA). The unit produces purified and pressurized (to 1.0 atm) carbon dioxide to downstream reactors that will make methane and oxygen. The unit also produces a nitrogen-argon mixture as a valuable by-product for life support, inflatable structures, and propellant pressurization. With nighttime temperatures falling to -100 degrees C, power availability restricted to a few watts, and flawless operation critical to success, the dusty Martian surface is a difficult place to operate a remote plant. This talk will focus on how this TSA separation process is designed and implemented for this application, and how it might be used in the more distant future for human exploration.

Finn, John E.↗

NASA NTRS2007

Control of Space-Based Electron Beam Free Form Fabrication

Engineering a closed-loop control system for an electron beam welder for space-based additive manufacturing is challenging. For earth and space based applications, components must work in a vacuum and optical components become occluded with metal vapor deposition. For extraterrestrial applications added components increase launch weight, increase complexity, and increase space flight certification efforts. Here we present a software tool that closely couples path planning and E-beam parameter controls into the build process to increase flexibility. In an environment where data collection hinders real-time control, another approach is considered that will still yield a high quality build.

Seifzer. W. J.↗

NASA NTRSDate not supplied

Computational and Physics-Based Modeling for the Development of in-Space Welding Technology

Welding will be an enabling technology for in-space assembly and manufacturing (ISAM) and in-space repair operations in support of the growing Space Economy. Prospective use cases of welding include metal repair on long-duration lunar surface missions and assembly of large structures that exceed dimensions of the currently available launch vehicle envelopes such as space arrays, tall lunar transmission towers, or even large transit vehicles powered by nuclear propulsion. There is a brief history of beam welding for in-space use. Soviet and NASA astronauts performed electron beam welds (EBW) in space in the late-1960s through mid-1980s and several parabolic flights of laser beam welding (LBW) were undertaken in the USA and Canada in the early-1990s. Work has since stagnated until the recent boom of the in-space economy has demonstrated need for continued development of EBW and LBW processes, which are desirable for their compactness, low mass, low power consumption, and high wall plug efficiency. No space-based manufacturing laboratory capable of demonstrating, developing, and applying welding processes exists, and costs are high to develop and fly individual space-based trials. This drives the current approach to develop welding technology with computational and physics-based models in tandem with earth-based experiments. Several approaches are taken to complement and drive the selection of instrumentation for planned parabolic and suborbital flights. First, a thermal model of Skylab EBW experiments is established and compared to empirical data. Next, the model is used to show variation between Earth-based and in-space weld structure and properties through exploration of key variables that define the Low earth orbit and lunar surface space environments, namely temperature (40 – 400 K), pressure (10-10 to 104 Pa), and gravity (10-6 g to 1 g). Finally, physical processes associated with heat and mass transport during welding are evaluated through several case studies across the above variable ranges demonstrating need for further research.

in-space welding↗

NASA NTRS1977

Space industrialization studies - An overview

An overview of NASA's current planning for a space industrialization program is described as an introduction to the papers on Space Industrialization being presented by Rockwell International Corporation and Science Applications Incorporated. Background information is presented that outlines the integrated planning process which resulted in specific long range goals and objectives being formulated for NASA programs in technology, environment, resources, earth science, communications, space exploration, aeronautics, and an expanded application of space called space industrialization. Program objectives for NASA's Industrialization of Space and studies on potential near term supporting elements (Space Platform, Large Space Structures, Orbital Operations Capabilities Development, Space Manufacturing Module) are discussed.

Priest, C.↗

NASA NTRS1993

Characteristics of products generated by selective sintering and stereolithography rapid prototyping processes

The trend in the modern global economy towards free market policies has motivated companies to use rapid prototyping technologies to not only reduce product development cycle time but also to maintain their competitive edge. A rapid prototyping technology is one which combines computer aided design with computer controlled tracking of focussed high energy source (eg. lasers, heat) on modern ceramic powders, metallic powders, plastics or photosensitive liquid resins in order to produce prototypes or models. At present, except for the process of shape melting, most rapid prototyping processes generate products that are only dimensionally similar to those of the desired end product. There is an urgent need, therefore, to enhance the understanding of the characteristics of these processes in order to realize their potential for production. Currently, the commercial market is dominated by four rapid prototyping processes, namely selective laser sintering, stereolithography, fused deposition modelling and laminated object manufacturing. This phase of the research has focussed on the selective laser sintering and stereolithography rapid prototyping processes. A theoretical model for these processes is under development. Different rapid prototyping sites supplied test specimens (based on ASTM 638-84, Type I) that have been measured and tested to provide a data base on surface finish, dimensional variation and ultimate tensile strength. Further plans call for developing and verifying the theoretical models by carefully designed experiments. This will be a joint effort between NASA and other prototyping centers to generate a larger database, thus encouraging more widespread usage by product designers.

Cariapa, Vikram↗