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At least 217 records · Page 12

All sources NASA NTRS DOE OSTI

DOE OSTI2025

Lightweight Metal Stamping Optimization Enabled by Artificial Intelligence

Successfully manufacturing an automotive body structure made via the sheet metal stamping process depends upon simultaneous consideration of component design, tooling design, stamping process control, and material properties. In many cases, introducing lightweight sheet materials (e.g., aluminum alloys, magnesium alloys, advanced high strength steels) holds the potential to significantly reduce vehicle weight, but challenges the stamping process by introducing materials with inherently less ductility. Successful and repeatable applications require co-developing the stamping process controls with the varying material properties, including formability. During the stamping process, as soon as the forming limit of the sheet is exceeded, the material shows localized necking which quickly leads to splits. Controlling process variability to avoid these material splits will enable deployment of less formable, lighter, and stronger materials for stamped automotive components. A typical optimization procedure for manufacturing requires an iterative process involving parameter setting, execution of computational simulations, and modifying the parameters. The entire process demands substantial computational time, making it impractical for real-time feedback towards rapid corrective actions required for in-line control for running production processes. To overcome this challenge, artificial intelligence (AI) can be leveraged to determine optimal manufacturing parameters within a single manufacturing cycle time. This research proposes an in-line optimization framework incorporating a trained AI model to predict kidney-shaped die forming. Preliminary results indicate that the AI framework can accurately predict draw-in values based on a given parameter set, a process referred to as forward prediction. Furthermore, the AI framework can also predict the optimal parameter set that leads to the desired draw-in values, referred to as inverse optimization (or backward prediction). This research has been performed in collaborations with USCAR (US Council for Automotive Research) and AutoForm. The members of USCAR are Ford, GM, and Stellantis.

36 MATERIALS SCIENCE↗

NASA NTRS2011

External Tank - The Structure Backbone

The External Tank forms the structural backbone of the Space Shuttle in the launch configuration. Because the tank flies to orbital velocity with the Space Shuttle Orbiter, minimization of weight is mandatory, to maximize payload performance. Choice of lightweight materials both for structure and thermal conditioning was necessary. The tank is large, and unique manufacturing facilities, tooling, handling, and transportation operations were required. Weld processes and tooling evolved with the design as it matured through several block changes, to reduce weight. Non Destructive Evaluation methods were used to assure integrity of welds and thermal protection system materials. The aluminum-lithium alloy was used near the end of the program and weld processes and weld repair techniques had to be refined. Development and implementation of friction stir welding was a substantial technology development incorporated during the Program. Automated thermal protection system application processes were developed for the majority of the tank surface. Material obsolescence was an issue throughout the 40 year program. The final configuration and tank weight enabled international space station assembly in a high inclination orbit allowing international cooperation with the Russian Federal Space Agency. Numerous process controls were implemented to assure product quality, and innovative proof testing was accomplished prior to delivery. Process controls were implemented to assure cleanliness in the production environment, to control contaminants, and to preclude corrosion. Each tank was accepted via rigorous inspections, including non-destructive evaluation techniques, proof testing, and all systems testing. In the post STS-107 era, the project focused on ascent debris risk reduction. This was accomplished via stringent process controls, post flight assessment using substantially improved imagery, and selective redesigns. These efforts were supported with a number of test programs to simulate combined environments. Processing improvements included development and use of low spray guns for foam application, additional human factors considerations for production, use of high fidelity mockups during hardware processing with video review, improved tank access, extensive use of non destructive evaluation, and producibility enhancements. Design improvements included redesigned bipod fittings, a bellows heater, a feedline camera active during ascent flight, removal of the protuberance airload ramps, redesigned ice frost ramps, and titanium brackets replaced aluminum brackets on the liquid oxygen feedline. Post flight assessment improved due to significant addition of imagery assets, greatly improving situational awareness. The debris risk was reduced by two orders of magnitude. During this time a major natural disaster was overcome when Katrina damaged the manufacturing facility. Numerous lessons from these efforts are documented within the paper.

Welzyn, Kenneth↗

NASA NTRS2005

An Assessment of the International Space Station's Trace Contaminant Control Subassembly Process Economics

The International Space Station (ISS) Environmental Control and Life Support System includes equipment speci.cally designed to actively remove trace chemical contamination from the cabin atmosphere. In the U.S. on-orbit segment, this function is provided by the trace contaminant control subassembly (TCCS) located in the atmosphere revitalization subsystem rack housed in the laboratory module, Destiny. The TCCS employs expendable adsorbent beds to accomplish its function leading to a potentially signi.cant life cycle cost over the life of the ISS. Because maintaining the TCCSs proper can be logistically intensive, its performance in .ight has been studied in detail to determine where savings may be achieved. Details of these studies and recommendations for improving the TCCS s process economics without compromising its performance or crew health and safety are presented and discussed.

Perry J. L.↗

NASA NTRS1998

Process for controlling morphology and improving thermal mechanical performance of high performance interpenetrating and semiinterpenetrating polymer networks

In the process of the present invention, a non-polar, aprotic solvent is removed from an oligomer/polymer solution by freeze-drying in order to produce IPNs and semi-IPNs. By thermally quenching the solution to a solid in a short length of time, the size of the minor constituent-rich regions is greatly reduced as they are excluded along with the major constituent from the regions of crystallizing solvent. The use of this process sequence of controlling phase morphology provides IPNs and semi-IPNs with improved fracture toughness, microcracking resistance, and other physical-mechanical properties as compared to IPNs and semi-IPNs formed when the solvent is evaporated rather than sublimed.

Pater, Ruth H.↗

NASA NTRS2002

Adopting Industry Standards for Control Systems Within Advanced Life Support

This paper gives a description of OPC (Object Linking and Embedding for Process Control) standards for process control and outlines the experiences at JSC with using these standards to interface with I/O hardware from three independent vendors. The I/O hardware was integrated with a commercially available SCADA/HMI software package to make up the control and monitoring system for the Environmental Systems Test Stand (ESTS). OPC standards were utilized for communicating with I/O hardware and the software was used for implementing monitoring, PC-based distributed control, and redundant data storage over an Ethernet physical layer using an embedded din-rail mounted PC.

Young, James Scott↗

NASA NTRS2005

Using SPC and Trending to Reduce FOD

This paper presents viewgraphs showing the trends and Statistical Process Control (SPC) used by ATK-Thiokol to reduce Foreign Object Debris (FOD). Some of the topics include: 1) Amazing Little Known and Less Used Facts; 2) Critical Nature of Rocket Manufacturing; 3) ATK-Thiokol Foreign Object Debris (FOD) Philosophy; 4) FOD Trending and SPC at ATK-Thiokol Philosophy; 5) Trending and Statistical Process Control (SPC) Basic Philosophy; 6) Trending and Statistical Process Control (SPC); 7) FOD Trending and SPC at ATK-Thiokol Trending; 8) FOD Trending and SPC at ATK-Thiokol Specific Instances; 9) FOD Trending and SPC at ATK-Thiokol Contamination in Air; and 10) FOD Trending and SPC at ATK-Thiokol Nitrogen Dewpoint.

Wallentine, Mark↗

NASA NTRS1991

The process of control design for the NASA Langley Minimast structure

The design process used to select sensors for feedback and performance weights on the Minimast facility is discussed. Initially, a series of controllers are synthesized using H2 optimal control techniques for the given structural model, a variety of sensor locations and performance criteria to determine the best displacement sensor and/or accelerometers to be used for feedback. Upon selection of the sensors, controllers are formulated to determine the affect of using a reduced-order model of the Minimast structure instead of the higher-order structural analysis model for control design and the relationship between the actuator torque level and the closed-loop performance. Based on this information, controllers are designed using micro-synthesis techniques and implemented on the Minimast structure. Results of the implementation of these controllers on the Minimast experimental facility are presented.

Balas, Gary J.↗

NASA NTRS1997

Process for controlling morphology and improving thermal-mechanical performance of high performance interpenetrating and semi-interpenetrating polymer networks

Pater, Ruth H.↗

NASA NTRS1991

Development of a portable multispectral thermal infrared camera

The purpose of this research and development effort was to design and build a prototype instrument designated the 'Thermal Infrared Multispectral Camera' (TIRC). The Phase 2 effort was a continuation of the Phase 1 feasibility study and preliminary design for such an instrument. The completed instrument designated AA465 has application in the field of geologic remote sensing and exploration. The AA465 Thermal Infrared Camera (TIRC) System is a field-portable multispectral thermal infrared camera operating over the 8.0 - 13.0 micron wavelength range. Its primary function is to acquire two-dimensional thermal infrared images of user-selected scenes. Thermal infrared energy emitted by the scene is collected, dispersed into ten 0.5 micron wide channels, and then measured and recorded by the AA465 System. This multispectral information is presented in real time on a color display to be used by the operator to identify spectral and spatial variations in the scenes emissivity and/or irradiance. This fundamental instrument capability has a wide variety of commercial and research applications. While ideally suited for two-man operation in the field, the AA465 System can be transported and operated effectively by a single user. Functionally, the instrument operates as if it were a single exposure camera. System measurement sensitivity requirements dictate relatively long (several minutes) instrument exposure times. As such, the instrument is not suited for recording time-variant information. The AA465 was fabricated, assembled, tested, and documented during this Phase 2 work period. The detailed design and fabrication of the instrument was performed during the period of June 1989 to July 1990. The software development effort and instrument integration/test extended from July 1990 to February 1991. Software development included an operator interface/menu structure, instrument internal control functions, DSP image processing code, and a display algorithm coding program. The instrument was delivered to NASA in March 1991. Potential commercial and research uses for this instrument are in its primary application as a field geologists exploration tool. Other applications have been suggested but not investigated in depth. These are measurements of process control in commercial materials processing and quality control functions which require information on surface heterogeneity.

Osterwisch, Frederick G.↗

NASA NTRS1994

Computer Control For Gas/Tungsten-Arc Welding

Prototype computer-based feedback control system developed for use in gas/tungsten arc welding. Beyond improving welding technician's moment-to-moment general control of welding process, control system designed to assist technician in selecting appropriate welding-process parameters, and provide better automatic voltage control. Modular for ease of reconfiguration and upgrading. Modularity also reflected in software. Includes rack-mounted computer, based on VME bus, containing Intel 80286 and 80386 processors.

Andersen, Kristinn↗

DOE OSTI2025

Beam Shaping and Oscillation for Metals Additive Manufacturing

Additive Manufacturing (AM) is pivotal for next-generation industrial manufacturing but is hampered by process control challenges leading to unwanted defects and sub-optimal material properties. Our research builds on prior work that utilized beam oscillation techniques to mitigate these issues (Wu et al., 2023). We focus on investigating the influence of beam oscillation frequency on melt pool dynamics, utilizing in-situ synchrotron material characterization from the ESRF (Chen et al., 2026). Preliminary findings indicated that beam oscillation results in unique fluid flow patterns and enhanced melting stability. These findings suggested the possibility of optimized AM process control, including minimized defects and tailored thermal histories. We proposed further research to explore the effects of beam oscillation frequencies comprehensively, using the in-situ characterization capabilities at the ESRF. The goal was to quantify this relationship, offering a pathway to more precise AM process control and optimization. Our research is expected to offer new scientific insights into the fluid mechanics and thermal behaviour in AM, contributing to its broader applicability and commercial viability.

36 MATERIALS SCIENCE↗

NASA NTRS1994

Integration for navigation on the UMASS mobile perception lab

Integration of real-time visual procedures for use on the Mobile Perception Lab (MPL) was presented. The MPL is an autonomous vehicle designed for testing visually guided behavior. Two critical areas of focus in the system design were data storage/exchange and process control. The Intermediate Symbolic Representation (ISR3) supported data storage and exchange, and the MPL script monitor provided process control. Resource allocation, inter-process communication, and real-time control are difficult problems which must be solved in order to construct strong autonomous systems.

Draper, Bruce↗

NASA NTRS1987

Knowledge acquisition for a simple expert controller

A method is presented for process control which has the properties of being incremental, cyclic and top-down. It is described on the basis of the development of an expert controller for a simple, but nonlinear control route. A quality comparison between expert controller and process operator shows the ability of the method for knowledge acquisition.

Bieker, B.↗

NASA NTRS1991

Tuning maps for setpoint changes and load disturbance upsets in a three capacity process under multivariable control

Tuning maps are an aid in the controller tuning process because they provide a convenient way for the plant operator to determine the consequences of adjusting different controller parameters. In this application the maps provide a graphical representation of the effect of varying the gains in the state feedback matrix on startup and load disturbance transients for a three capacity process. Nominally, the three tank system, represented in diagonal form, has a Proportional-Integral control on each loop. Cross coupling is then introduced between the loops by using non-zero off-diagonal proportional parameters. Changes in transient behavior due to setpoint and load changes are examined by varying the gains of the cross coupling terms.

Litt, Jonathan S.↗

NASA NTRS1972

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↗

NASA NTRS2002

Workload-Matched Adaptive Automation Support of Air Traffic Controller Information Processing Stages

Adaptive automation (AA) has been explored as a solution to the problems associated with human-automation interaction in supervisory control environments. However, research has focused on the performance effects of dynamic control allocations of early stage sensory and information acquisition functions. The present research compares the effects of AA to the entire range of information processing stages of human operators, such as air traffic controllers. The results provide evidence that the effectiveness of AA is dependent on the stage of task performance (human-machine system information processing) that is flexibly automated. The results suggest that humans are better able to adapt to AA when applied to lower-level sensory and psychomotor functions, such as information acquisition and action implementation, as compared to AA applied to cognitive (analysis and decision-making) tasks. The results also provide support for the use of AA, as compared to completely manual control. These results are discussed in terms of implications for AA design for aviation.

Kaber, David B.↗

NASA NTRS1991

CRN5EXP: Expert system for statistical quality control

The purpose of the Expert System CRN5EXP is to assist in checking the quality of the coils at two very important mills: Hot Rolling and Cold Rolling in a steel plant. The system interprets the statistical quality control charts, diagnoses and predicts the quality of the steel. Measurements of process control variables are recorded in a database and sample statistics such as the mean and the range are computed and plotted on a control chart. The chart is analyzed through patterns using the C Language Integrated Production System (CLIPS) and a forward chaining technique to reach a conclusion about the causes of defects and to take management measures for the improvement of the quality control techniques. The Expert System combines the certainty factors associated with the process control variables to predict the quality of the steel. The paper presents the approach to extract data from the database, the reason to combine certainty factors, the architecture and the use of the Expert System. However, the interpretation of control charts patterns requires the human expert's knowledge and lends to Expert Systems rules.

Hentea, Mariana↗

NASA NTRS1972

Progress in electrochemical storage for battery systems

Efforts to improve electrochemical systems for space use relate to: (1) improvement of conventional systems; (2) development of fuel cells to practical power systems; and (3) a search for new systems that provide gains in energy density but offer comparable life and performance as conventional systems. Improvements in sealed conventional systems resulted in the areas of materials, charge control methods, cell operations and battery control, and specific process controls required during cell manufacture. Fuel-cell systems have been developed for spacecraft but the use of these power plants is limited. For present and planned flights, nickel-cadmium, silver-zinc, and silver-cadmium systems will be used. Improvements in nickel-cadmium batteries have been applied in medical and commercial areas.

Ford, F. E.↗