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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
NASA NTRS1980

Completion of evaluation of manufacturing processes for B/Al composites containing 0.2mm diameter boron fibers

Four fabricators produced a total of 54 B/1100 Al, B/6061 Al, and B/2024 Al panels for evaluation. The 8 ply unidirectional, 45 to 50 volume percent, panels were made using 0.20 mm diameter boron fibers which were obtained from a single supplier. Hot press consolidation was carried out in vacuum except for one set of dry woven tape panels which were hot pressed in air. A single testing contractor conducted nondestructive inspection, metallography, fractography and mechanical property tests. The mechanical property tests included 21 and 260 C tensile tests and 21 C shear tests. Panel quality, as measured by nondestructive evaluation, was generally good as were the 21 C tensile properties. The panels hot pressed in air delaminated in the shear tests. Shear strength values were lower in these panels. But tensile strengths were not affected by the delaminations because of the relation between the tensile loading direction and the delaminations. Composite tensile strength was found to be proportional to the volume percent boron and the aluminum matrix rather than to the tape used or fabrication technique. Suitability of these composites for 260 C service was confirmed by tensile tests.

Moore, T. J.↗
NASA NTRSDate not supplied

Machine Learning Explainability and Transferability for Path Navigation

Deep neural networks are powerful tools for machine perception. Unfortunately their decisions are difficult to explain due to the complexity and size of the networks. Previously we have alleviated this issue by using the representational portion of a deep neural network and combining it with a k-nearest neighbor (KNN) classifier. Through inspection of the decisions made by the KNN, we can directly see the training data responsible for the decisions, allowing us to determine the quality of the overall decision and the quality of the representational layer of the deep NN. While the technique worked well, it requires tens of thousands of latent vectors to be stored for classification. In addition, it lacks the ability to show how parts of an image influence the classification decision. Here we address these issues by 1) Using a radial basis function network (RBFN) in place of the KNN allowing far fewer images to be used in deployment and 2) Using an auto encoder network for explainability. In addition to these techniques, we examine the effects of transfer learning to determine that results are robust. All results are tested on a domain where an unmanned aerial vehicle (UAV) navigates a forest trail through a single camera.

explainable machine learning↗
NASA NTRSDate not supplied

In-Situ Process Monitoring, Synchronization, and Mapping Laser Powder Bed Fusion Builds of Ti6Al4V

The use of in-situ process monitoring is of interest to lower the cost of inspection for the qualification of laser powder bed fusion (LPBF) parts. Precise monitoring of the LPBF-AM build process constitutes a multi-scale and multi-discipline task. There are several significant challenges to the in-situ approach: the synchronization of sensor signals to process steps, the physical interpretation and classification of sensor signals, managing very large datasets, and comparing the inputs with the observed monitoring signals. At NASA Langley Research Center, a configurable architecture additive testbed has been developed to monitor the build process with synchronized sensors. The philosophy and method adopted for the synchronization of the cameras with laser power & position Ti-6Al-4V LPBF are described. The synchronized in-situ monitoring signals are compared with ex-situ nondestructive inspection and optical microscopy observations. Such comparisons permit a better understanding of how the sequential process actions of LPBF-AM can affect build quality.

Laser Powder Bed Fusion↗
DOE OSTI2021

Search for Infrasound Signals in InSight Data Using Coupled Pressure/Ground Deformation Methods

The unprecedented quality and sampling rate of seismometer and pressure sensors of the InSight Mars mission allow us to investigate infrasound through its pressure and ground deformation signals. This study focuses on compliance effects induced by acoustic waves propagating almost horizontally close to the surface. The compliance of acoustic waves is first estimated using the compliance estimates from pressure perturbations moving at wind speed. Then, a marker of compliance events is used to detect events of ground deformation induced by pressure variations, in three frequency bands from 0.4 to 3.2 Hz, from InSight sol 180 to 690. Additional selection criteria are imposed on the detected events to focus on acoustic waves and to remove various noise sources (e.g., wind effects or seismometer artifacts). After an automated selection, the visual inspection of the records allows us to validate two infrasound candidates that cannot be related to pressure perturbations moving at wind speed nor to known noise sources. For our highest quality infrasound candidate, the relation between this event and a convective vortex occuring 10 s later is tested. The azimuth of the vortex position at the time of infrasound detection is not consistent with the arrival azimuth of the suspected infrasound inferred from the polarization of seismometer records, thus the link between these two phenomena cannot be demonstrated. Further investigations would require a better understanding of wind-related noise impacting InSight sensors and of the effects of lateral variations of subsurface mechanical properties on the ground deformations induced by atmospheric pressure variations.

58 GEOSCIENCES↗
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.↗
DOE OSTI2023

Real-time process monitoring for direct ink write additive manufacturing

Direct ink write (DIW) printing of reactive resins presents a unique challenge due to the time-dependent nature of the rheological and chemical properties of the ink. As a result, careful print optimization or process control is important to obtain consistent, high quality prints. The present invention uses a flow-through characterization cell for in situ chemical monitoring of a resin ink during DIW printing. Additionally, in-line extrusion force monitoring can be combined with off-line post inspection using machine vision. By combining in-line spectroscopy and force monitoring, it is possible to follow reaction kinetics (for example, curing of a reactive resin) and viscosity changes during printing, which can be used for a closed-loop process control. Additionally, the capability of machine vision to automatically identify and quantify print artifacts can be incorporated on the printing line to enable real-time, AI-assisted quality control of the printed products. Together, these techniques can form the building blocks of an optimized process control strategy when complex reactive ink must be used to produce printed hardware.

Cook, Adam W.↗
NASA NTRS1984

Requirements for Printed Wiring Boards

In order to maintain the high standards of the NASA printed wiring programs, this publication: prescribes NASA's requirements for assuring reliable rigid printed wiring boards; describes and incorporates basic considerations necessary to assure reliable rigid printed wiring boards; establishes the supplier's responsibility to train and certify personnel; provides for supplier documentation of the fabrication and inspection procedures to be used for NASA work, including supplier innovations and changes in technology; and provides visual workmanship standards to aid those responsible for determining quality conformance to the established requirements.

Source record↗
NASA NTRS1985

Requirements for Conformal Coating and Staking of Printed Wiring Boards and Electronic Assemblies

In order to maintain the high standards of the NASA conformal coating and staking program, this publication: prescribes NASA's requirements for assuring reliable conformal coating and staking for printed wiring boards and electronic assemblies; describes and incorporates basic considerations necessary to assure reliable conformal coating and staking; establishes the supplier's responsibility to train and certify personnel; provides for supplier documentation of the fabrication and inspection procedures to be used for NASA work, including supplier innovations and changes in technology; and provides visual workmanship standards to aid those responsible for determining quality conformance to the established requirements.

Source record↗
NASA NTRS2000

NIRS in Space?

Proponents of near infrared reflectance spectroscopy (NIRS) have been exceptionally successful in applying NIRS techniques to many instances of organic material analyses. While this research and development began in the 1950s, in recent years, stimulation of advancements in instrumentation is allowing NIRS to begin to find its way into the food processing systems, into food quality and safety, textiles and much more. And, imaging high spectral resolution spectrometers are now being evaluated for the rapid scanning of foodstuffs, such as the inspection of whole chicken carcasses for fecal contamination. The imaging methods are also finding their way into medical applications, such as the non-intrusive monitoring of blood oxygenation in newborns. Can these scientific insights also be taken into space and successfully used to measure the Earth's condition? Is there an analog between the organic analyses in the laboratory and clinical settings and the study of Earth's living biosphere? How are the methods comparable and how do they differ?

Peterson, David L.↗
NASA NTRS2008

Metrology - Beyond the Calibration Lab

We rely on data from measurements every day; a gas-pump, a speedometer, and a supermarket weight scale are just three examples of measurements we use to make decisions. We generally accept the data from these measurements as "valid." One reason we can accept the data is the "legal metrology" requirements established and regulated by the government in matters of commerce. The measurement data used by NASA, other government agencies, and industry can be critical to decisions which affect everything from economic viability, to mission success, to the security of the nation. Measurement data can even affect life and death decisions. Metrology requirements must adequately provide for risks associated with these decisions. To do this, metrology must be integrated into all aspects of an industry including research, design, testing, and product acceptance. Metrology, the science of measurement, has traditionally focused on the calibration of instruments, and although instrument calibration is vital, it is only a part of the process that assures quality in measurement data. For example, measurements made in research can influence the fundamental premises that establish the design parameters, which then flow down to the manufacturing processes, and eventually impact the final product. Because a breakdown can occur anywhere within this cycle, measurement quality assurance has to be integrated into every part of the life-cycle process starting with the basic research and ending with the final product inspection process. The purpose of this paper is to discuss the role of metrology in the various phases of a product's life-cycle. For simplicity, the cycle will be divided in four broad phases, with discussions centering on metrology within NASA. .

Mimbs, Scott M.↗
NASA NTRSDate not supplied

Powder Bed Fusion Laser Beam Metals Additive Manufacturing: Process Monitoring Approaches for Qualification and Certification

The use of in-situ process monitoring is of interest to lower the cost of inspection for the qualification of powder bed fusion laser beam metal (PBF-LB/M) additively manufactured (AM) parts. Precise monitoring of the PBF-LB/M AM build process constitutes a multi-scale and multi-discipline task. There are several significant challenges to the in-situ approach: the synchronization of sensor signals to process steps; the physical interpretation and classification of sensor signals; managing very large datasets; and comparing the inputs with the observed monitoring signals. At NASA Langley Research Center, a configurable architecture additive testbed has been developed to monitor the build process with synchronized sensors. The philosophy and method adopted for the synchronization of the cameras with laser power and position throughout a complex PBF-LB/M AM build will be described. The synchronized in-situ monitoring signals are compared with ex-situ nondestructive inspection, x-ray computed tomography (XCT). Such comparisons permit a better understanding of how the sequential process actions of LPBF-AM can affect build quality. The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. This presentation will describe an additive manufacturing model-based process metric (AM-PM) computational method that is a fully parallel reduced order modeling approach developed to evaluate the evolution of AM processes. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology of the approach will be described and mapped to the porosity observed from XCT for a complex PBF-LB/M build. Such comparative results develop understanding of how the sequential process actions can affect the PBF-LB/M AM build quality and microstructure variability.

Laser Powder Bed Fusion↗
NASA NTRS1998

Single-Transducer, Ultrasonic Imaging Method for High-Temperature Structural Materials Eliminates the Effect of Thickness Variation in the Image

NASA Lewis Research Center's Life Prediction Branch, in partnership with Sonix, Inc., and Cleveland State University, recently advanced the development of, refined, and commercialized an advanced nondestructive evaluation (NDE) inspection method entitled the Single Transducer Thickness-Independent Ultrasonic Imaging Method. Selected by R&D Magazine as one of the 100 most technologically significant new products of 1996, the method uses a single transducer to eliminate the superimposing effects of thickness variation in the ultrasonic images of materials. As a result, any variation seen in the image is due solely to microstructural variation. This nondestructive method precisely and accurately characterizes material gradients (pore fraction, density, or chemical) that affect the uniformity of a material's physical performance (mechanical, thermal, or electrical). Advantages of the method over conventional ultrasonic imaging include (1) elimination of machining costs (for precision thickness control) during the quality control stages of material processing and development and (2) elimination of labor costs and subjectivity involved in further image processing and image interpretation. At NASA Lewis, the method has been used primarily for accurate inspections of high temperature structural materials including monolithic ceramics, metal matrix composites, and polymer matrix composites. Data were published this year for platelike samples, and current research is focusing on applying the method to tubular components. The initial publicity regarding the development of the method generated 150 requests for further information from a wide variety of institutions and individuals including the Federal Bureau of Investigation (FBI), Lockheed Martin Corporation, Rockwell International, Hewlett Packard Company, and Procter & Gamble Company. In addition, NASA has been solicited by the 3M Company and Allison Abrasives to use this method to inspect composite materials that are manufactured by these companies.

Roth, Don J.↗
NASA NTRS1981

Reliability and quality assurance on the MOD 2 wind system

The Safety, Reliability, and Quality Assurance (R&QA) approach developed for the largest wind turbine generator, the Mod 2, is described. The R&QA approach assures that the machine is not hazardous to the public or to the operating personnel, is operated unattended on a utility grid, demonstrates reliable operation, and helps establish the quality assurance and maintainability requirements for future wind turbine projects. The significant guideline consisted of a failure modes and effects analysis (FMEA) during the design phase, hardware inspections during parts fabrication, and three simple documents to control activities during machine construction and operation.

Mason, W. E. B.↗
NASA NTRS1982

Experience with modified aerospace reliability and quality assurance method for wind turbines

The SR&QA approach assures that the machine is not hazardous to the public or operating personnel, can operate unattended on a utility grid, demonstrates reliability operation, and helps establish the quality assurance and maintainability requirements for future wind turbine projects. The approach consisted of modified failure modes and effects analysis (FMEA) during the design phase, minimal hardware inspection during parts fabrication, and three simple documents to control activities during machine construction and operation. Five years experience shows that this low cost approach works well enough that it should be considered by others for similar projects.

Klein, W. E.↗
NASA NTRS2004

Sandwich Panels Evaluated With Ultrasonic Spectroscopy

Enhanced, lightweight material systems, such as 17-4PH stainless steel sandwich panels are being developed for use as fan blades and fan containment systems for next-generation engines. The bond strength between the core and face sheets is critical in maintaining the structural integrity of the sandwich structure. To improve the inspection and production of these systems, researchers at the NASA Glenn Research Center are using nondestructive evaluation (NDE) techniques, such as ultrasonic spectroscopy, to evaluate the brazing quality between the face plates and the metallic foam core. The capabilities and limitations of a swept-frequency approach to ultrasonic spectroscopy were evaluated with respect to these sandwich structures. This report discusses results from three regions of a sandwich panel representing different levels of brazing quality between the outer face plates and a metallic foam core. Each region was investigated with ultrasonic spectroscopy. Then, on the basis of the NDE results, three shear specimens sectioned from the sandwich panel to contain each of these regions were mechanically tested.

Cosgriff, Laura M.↗
DOE OSTI2020

Robotic Mapping and Monitoring of Nuclear Infrastructure

Routine inspection of nuclear infrastructure is currently expensive and slow. To remedy this the Applied Research Center (ARC) at Florida International University (FIU) is developing a field robot capable of gathering valuable data quickly, safely, and cheaply. Motivation: Nuclear infrastructure should be inspected routinely to ensure early detection of problems. This process is expensive, hazardous, and slow. Objective: Develop a platform capable of surveying nuclear infrastructure autonomously. Discussion: The quality of the captured data depends on the success of every component of the robot. Good sensors, hardware, localization, data collection, and autonomy are required. Conclusion: This is a promising approach for surveying nuclear infrastructure. The captured data is rich with information and can be evaluated by both people and algorithms.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Effect of Si Content in Electrode and SiO2 Additions to the Slag during Electroslag Remelting

Evolution of Si concentration in 316 stainless steel electrodes was observed during a melting campaign consisting of recycling electroslag remelted (ESR) ingots to make new electrodes using vacuum induction melting (VIM). This campaign consisted of iterations of VIM + ESR operations to optimize melting parameters. The effect of Si content on the melt parameters and ingot quality was further evaluated and additions of SiO2 to the slag chemistry were studied using research-scale experiments, x-ray diffraction (XRF), combustion analysis, visual inspections, and computational tools. The Si concentration was found to decrease by approximately 600 ppm following ESR of 150 lb. research-scale electrodes. Eventually, this led to failure of the slag skin and direct ingot/crucible contact. Additions of SiO2 to the slag at levels matching the original calculated Si concentration in the electrode did not eliminate the slag skin failure and the current during steady state increased to maintain a constant melt rate. In this investigation, we propose a mechanism of slag skin failure consisting of local concentration of current density due to absence, or breakage, of the SiO2 layer around the molten metal drop during ESR. This theory was reinforced by additional experiments in which Nb was added to the electrode to change the structure of the oxide layer around the drops.

Jablonski, Paul↗
NASA NTRS1995

Cleanliness inspection tool for RSRM bond surfaces

Using optically stimulated electron emission (OSEE), Thiokol has monitored bond surfaces in process for contamination on the Redesigned Solid Rocket Motor (RSRM). This technique provides process control information to help assure bond surface quality and repeatability prior to bonding. This paper will describe OSEE theory of operation and the instrumentation implemented at Thiokol Corporation since 1987. Data from process hardware will be presented.

Mattes, Robert A.↗