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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
NASA NTRS1994

Inspection planning development: An evolutionary approach using reliability engineering as a tool

This paper proposes an evolutionary approach for inspection planning which introduces various reliability engineering tools into the process and assess system trade-offs among reliability, engineering requirement, manufacturing capability and inspection cost to establish an optimal inspection plan. The examples presented in the paper illustrate some advantages and benefits of the new approach. Through the analysis, reliability and engineering impacts due to manufacturing process capability and inspection uncertainty are clearly understood; the most cost effective and efficient inspection plan can be established and associated risks are well controlled; some inspection reductions and relaxations are well justified; and design feedbacks and changes may be initiated from the analysis conclusion to further enhance reliability and reduce cost. The approach is particularly promising as global competitions and customer quality improvement expectations are rapidly increasing.

Graf, David A.↗
NASA NTRS2004

Process for testing a xenon gas feed system of a hollow cathode assembly

The design and manufacturing processes for Hollow Cathode Assemblies (HCA's) that operate over a broad range of emission currents up to 30 Amperes, at low potentials, with lifetimes in excess of 17,500 hours. The processes include contamination control procedures which cover hollow cathode component cleaning procedures, gas feed system designs and specifications, and hollow cathode activation and operating procedures to thereby produce cathode assemblies that have demonstrated stable and repeatable operating conditions, for both the discharge current and voltage. The HCA of this invention provides lifetimes of greater than 10,000 hours, and expected lifetimes of greater than 17,500 hours, whereas the present state-of-the-art is less than 500 hours at emission currents in excess of 1 Ampere. Stable operation is provided over a large range of operating emission currents, up to a 6:1 ratio, and this HCA can emit electron currents of up to 30 Amperes in magnitude to an external anode that simulates the current drawn to a space plasma, at voltages of less than 20 Volts.

Patterson, Michael J.↗
NASA NTRS2000

Process for Ignition of Gaseous Electrical Discharge Between Electrodes of a Hollow Cathode Assembly

The design and manufacturing processes for Hollow Cathode Assemblies (HCA's) that operate over a broad range of emission currents up to 30 Amperes, at low potentials, with lifetimes in excess of 17,500 hours. The processes include contamination control procedures which cover hollow cathode component cleaning procedures, gas feed system designs and specifications, and hollow cathode activation and operating procedures to thereby produce cathode assemblies that have demonstrated stable and repeatable operating conditions, for both the discharge current and voltage. The HCA of this invention provides lifetimes of greater than 10,000 hours, and expected lifetimes of greater than 17,500 hours, whereas the present state-of-the-art is less than 500 hours at emission currents in excess of 1 Ampere. Stable operation is provided over a large range of operating emission currents, up to a 6:1 ratio, and this HCA can emit electron currents of up to 30 Amperes in magnitude to an external anode that simulates the current drawn to a space plasma, at voltages of less than 20 Volts.

Patterson, Michael J.↗
NASA NTRS1993

Fuzzy sets predict flexural strength and density of silicon nitride ceramics

In this work, we utilize fuzzy sets theory to evaluate and make predictions of flexural strength and density of NASA 6Y silicon nitride ceramic. Processing variables of milling time, sintering time, and sintering nitrogen pressure are used as an input to the fuzzy system. Flexural strength and density are the output parameters of the system. Data from 273 Si3N4 modulus of rupture bars tested at room temperature and 135 bars tested at 1370 C are used in this study. Generalized mean operator and Hamming distance are utilized to build the fuzzy predictive model. The maximum test error for density does not exceed 3.3 percent, and for flexural strength 7.1 percent, as compared with the errors of 1.72 percent and 11.34 percent obtained by using neural networks, respectively. These results demonstrate that fuzzy sets theory can be incorporated into the process of designing materials, such as ceramics, especially for assessing more complex relationships between the processing variables and parameters, like strength, which are governed by randomness of manufacturing processes.

Cios, Krzysztof J.↗
NASA NTRS2016

Evaluation of the Effect of Surface Finish on High-Cycle Fatigue of SLM-IN718

The surface finish of parts produced by additive manufacturing processes is much rougher than the surface finish generated by machining processes, and a rougher surface can reduce the fatigue strength of a part. This paper discusses an effort to quantify that reduction of strength in high-cycle fatigue for selective laser melt (SLM) coupons. A high-cycle fatigue (HCF) knockdown factor was estimated for Inconel 718, manufactured with the SLM process. This factor is the percentage reduction from the maximum stress in fatigue for low-stress ground (LSG) specimens to the maximum stress of those left with the original surface condition at the same fatigue life. Specimens were provided by a number of vendors, free to use their "best practice"; only one heat treat condition was considered; and several test temperatures were characterized, including room temperature, 800F, 1000F, and 1200F. The 1000F data had a large variance, and was omitted from consideration in this document. A first method used linear approximations extracted from the graphs, and only where data was available for both. A recommended knockdown factor of the as-built surface condition (average roughness of approximately 245 micro-inches/inch) versus low-stress ground condition (roughness no more than 4 micro-inches/inch) was established at approximately 1/3 or 33%. This is to say that for the as-built surface condition, a maximum stress of 2/3 of the stress for LSG can be expected to produce a similar life in the as-built surface condition. In this first evaluation, the knockdown factor did not appear to be a function of temperature. A second approach, the "KP method", incorporated the surface finish measure into a new parameter termed the pseudo-stress intensity factor, Kp, which was formulated to be similar to the fracture mechanics stress intensity factor. Using Kp, the variance seemed to be reduced across all sources, and knockdown factors were estimated using Kp over the range where data occurred. A plot of the results suggests that the knockdown factor is a function of temperature, and that for low lives the knockdown might be lower than the knockdown observed above about one million cycles, where it tended to stabilize. This was not universal for all temperatures tested. The higher temperature tests are thought to be influenced by the test temperature, which perhaps continued the aging process. Further evaluation of the method is suggested.

Lambert, D. M.↗
NASA NTRS2003

VARTM Process Modeling of Aerospace Composite Structures

A three-dimensional model was developed to simulate the VARTM composite manufacturing process. The model considers the two important mechanisms that occur during the process: resin flow, and compaction and relaxation of the preform. The model was used to simulate infiltration of a carbon preform with an epoxy resin by the VARTM process. The model predicted flow patterns and preform thickness changes agreed qualitatively with the measured values. However, the predicted total infiltration times were much longer than measured most likely due to the inaccurate preform permeability values used in the simulation.

Song, Xiao-Lan↗
NASA NTRS1971

Advanced thrust chamber designs

A regeneratively cooled thrust chamber has been designed and fabricated, consisting of an inner TD nickel liner which was spin formed, welded, and machined and an outer shell of electroformed nickel. Coolant channels were produced in the outer surface of the inner liner by the electric discharge machining process before electroforming the shell. Accessory manifolds and piping were attached by welding. Manufacturing processes employed are described.

Dietrich, F. J.↗
NASA NTRS1988

Reasoning with case histories of process knowledge for efficient process development

The significance of compiling case histories of empirical process knowledge and the role of such histories in improving the efficiency of manufacturing process development is discussed in this paper. Methods of representing important investigations as cases and using the information from such cases to eliminate redundancy of empirical investigations in analogous process development situations are also discussed. A system is proposed that uses such methods to capture the problem-solving framework of the application domain. A conceptual design of the system is presented and discussed.

Bharwani, Seraj S.↗
NASA NTRS1993

Motorcycle Parts

An article in NASA Tech Briefs describing a vacuum bagging process for forming composite parts helped a small Oklahoma Company to improve its manufacturing process. President of Performance Extremes, Larry Ortega, and his partners make motorcycle parts from carbon/epoxy to reduce weight. Using vacuum bags, parts have a better surface and fewer voids inside. When heat used in the vacuum bag process caused deformation upon cooling, a solution found in another tech brief solved the problem. A metal plate inside the vacuum bag made for more even heat transfer. A third article described a simple procedure for repairing loose connector pins, which the company has also utilized.

Source record↗
NASA NTRS1995

Implementation of environmentally compliant cleaning and insulation bonding for MNASA

Historically, many subscale and full-scale rocket motors have employed environmentally and physiologically harmful chemicals during the manufacturing process. This program examines the synergy and interdependency between environmentally acceptable materials for solid rocket motor insulation applications, bonding, corrosion inhibiting, painting, priming, and cleaning, and then implements new materials and processes in subscale motors. Tests have been conducted to eliminate or minimize hazardous chemicals used in the manufacture of modified-NASA materials test motor (MNASA) components and identify alternate materials and/or processes following NASA Operational Environmental Team (NOET) priorities. This presentation describes implementation of high pressure water refurbishment cleaning, aqueous precision cleaning using both Brulin 815 GD and Jettacin, and insulation case bonding using ozone depleting chemical (ODC) compliant primers and adhesives.

Hutchens, Dale E.↗
NASA NTRS1980

Development of simplified process for environmentally resistant cells

This report describes a program to develop a simple, foolproof, all vacuum solar cell manufacturing process which can be completely automated and which results in medium efficiency cells which are inherently environmentally resistant. All components of the completed cells are integrated into a monolithic structure with no material interfaces. The exposed materials (SI, Al2O3, Al, Ni) are all resistant to atmospheric attack and the junction, per se, is passivated to prevent long term degradation. Such cells are intended to be incorporated into a simple module consisting basically of a press formed metallic superstructure with a separated glass cover for missile, etc., protection.

King, W. J.↗
NASA NTRS1993

Vision-aided Monitoring and Control of Thermal Spray, Spray Forming, and Welding Processes

Vision is one of the most powerful forms of non-contact sensing for monitoring and control of manufacturing processes. However, processes involving an arc plasma or flame such as welding or thermal spraying pose particularly challenging problems to conventional vision sensing and processing techniques. The arc or plasma is not typically limited to a single spectral region and thus cannot be easily filtered out optically. This paper presents an innovative vision sensing system that uses intense stroboscopic illumination to overpower the arc light and produce a video image that is free of arc light or glare and dedicated image processing and analysis schemes that can enhance the video images or extract features of interest and produce quantitative process measures which can be used for process monitoring and control. Results of two SBIR programs sponsored by NASA and DOE and focusing on the application of this innovative vision sensing and processing technology to thermal spraying and welding process monitoring and control are discussed.

Agapakis, John E.↗
NASA NTRS1993

Application of hardness testing in foundry processing operations: A university and industry partnership

The objectives are the following: (1) to plan a tour of local manufacturing facility to observe hardness testing methods used and how they support the manufacturing process today; (2) to learn the operation of Brinell Hardness Testing and equipment set up with samples of accessory equipment for testing of various materials; (3) to use a Brinell scope (hand magnifier) to measure the diameter of the test indentation (in millimeters); (4) to use the hardness equation to determine the spherical area of the indentation and the calculation of the Brinell Hardness Number; (5) to use standard charts for ASTM standard size indenters to find the hardness number; and (6) to learn a method of conversion of the Brinell number to other hardness scales, their common usage, and also to convert the hardness number to the approximate tensile strength.

Martin, Donald H.↗
NASA NTRS1995

Effect of Processing Route on Strain Controlled Low Cycle Fatigue Behavior of Polycrystalline NiAl

The present investigation examines the effects of manufacturing process on the total axial strain controlled low cycle fatigue behavior of polycrystalline NiAl at 1000 K, a temperature above the monotonic Brittle-to-Ductile Transition Temperature (BDTT). The nickel aluminide samples were produced by three different processing routes: hot isostatic pressing of pre- alloyed powders, extrusion of prealloyed powders, and extrusion of vacuum induction melted ingots. The LCF behavior of the cast plus extruded material was also determined at room temperature (below the BD77) for comparison to the high temperature data. The cyclic stress response, cyclic stress-strain behavior, and strain-life relationships were influenced by the alloy preparation technique and the testing temperature. Detailed characterization of the LCF tested samples was conducted by optical and electron microscopy to determine the variations in fracture and deformation modes and to determine any microstructural changes that occurred during LCF testing. The dependence of LCF properties on processing route was rationalized on the basis of starting microstructure, brittle-to-ductile transition temperature, deformation induced changes in the basic microstructure, deformation substructure, and synergistic interaction between the damage modes.

Rao, K. Bhanu Sankara↗
NASA NTRS1990

Filament winding cylinders. II - Validation of the process model

Analytical and experimental studies were performed to validate the model developed by Lee and Springer for simulating the manufacturing process of filament wound composite cylinders. First, results calculated by the Lee-Springer model were compared to results of the Calius-Springer thin cylinder model. Second, temperatures and strains calculated by the Lee-Springer model were compared to data. The data used in these comparisons were generated during the course of this investigation with cylinders made of Hercules IM-6G/HBRF-55 and Fiberite T-300/976 graphite-epoxy tows. Good agreement was found between the calculated and measured stresses and strains, indicating that the model is a useful representation of the winding and curing processes.

Calius, Emilio P.↗
NASA NTRS1992

Tension fracture of laminates for transport fuselage. Part 1: Material screening

Transport fuselage structures are designed to contain pressure following a large penetrating damage event. Application of composites to fuselage structures requires a data base and supporting analysis on tension damage tolerance. Tests with 430 fracture specimens were used to accomplish the following: (1) identify critical material and laminate variables affecting notch sensitivity, (2) evaluate composite failure criteria, and (3) recommend a screening test method. Variables studied included fiber type, matrix toughness, lamination manufacturing process, and intraply hybridization. The laminates found to have the lowest notch sensitivity were manufactured using automated tow placement. This suggests a possible relationship between the stress distribution and repeatable levels of material inhomogeneity that are larger than found in traditional tape laminates. Laminates with the highest notch sensitivity consisted of toughened matrix materials that were resistant to a splitting phenomena that reduces stress concentrations in load bearing plies. Parameters for conventional fracture criteria were found to increase with the crack length of the smallest notch sizes studied. Most materials and laminate combinations followed less than a square root singularity for the largest crack sizes studied. Specimen geometry, notch type, and notch size were evaluated in developing a screening test procedure. Results indicate that a range of notch sizes must be tested to determine notch sensitivity.

Walker, T. H.↗
NASA NTRS1992

Tension fracture of laminates for transport fuselage. Part 1: Material screening

Transport fuselage structures are designed to contain pressure following a large penetrating damage event. Applications of composites to fuselage structures require a database and supporting analysis on tension damage tolerance. Tests with 430 fracture specimens were used to accomplish the following: (1) identify critical material and laminate variables affecting notch sensitivity; (2) evaluate composite failure criteria; and (3) recommend a screening test method. Variables studied included fiber type, matrix toughness, lamination manufacturing process, and intraply hybridization. The laminates found to have the lowest notch sensitivity were manufactured using automated tow placement. This suggests a possible relationship between the stress distribution and repeatable levels of material inhomogeneity that are larger than found in traditional tape laminates. Laminates with the highest notch sensitivity consisted of toughened matrix materials that were resistant to a splitting phenomena that reduces stress concentrations in major load bearing plies. Parameters for conventional fracture criteria were found to increase with crack length for the smallest notch sizes studied. Most material and laminate combinations followed less than a square root singularity for the largest crack sizes studied. Specimen geometry, notch type, and notch size were evaluated in developing a screening test procedure. Traitional methods of correcting for specimen finite width were found to be lacking. Results indicate that a range of notch sizes must be tested to determine notch sensitivity. Data for a single small notch size (0.25 in. diameter) was found to give no indication of the sensitivity of a particular material and laminate layup to larger notch sizes.

Walker, T. H.↗
NASA NTRSDate not supplied

Metal Extraction Lunar Technology from Carbothermal Reduction (MELT-CR)

Large metallic infrastructure components on the Moon are currently cost prohibitive due to the expense of transporting mass to the lunar surface. Astrobotic has quoted upwards of $1.2 million dollars per kilogram of payload to the surface. Advantageously, however, aluminum is present in great quantities as aluminum silicates on the lunar surface. And because aluminum is ductile, highly conductive, and amendable for advanced manufacturing processes such as wire fed directed energy deposition (DED), if it can be refined from regolith, its utilization can enable cost-effective, on-surface manufacturing of metallic infrastructure. The goal of project is to develop the core processes and technologies to extract aluminum from Lunar regolith and refine it into wire feedstock from a carbothermic reduction process.

ISRU↗