Towards a circular economy for PET bottle resin using a system dynamics inspired material flow model
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Ghosh, Tapajyoti (ORCID:0000000205220235)↗
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Results for “manufacturing process planning”
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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Space Station design integration
This paper discusses the top Program level design integration process which involves the integration of a US Space Station manned base that consists of both US and international Elements. It explains the form and function of the Program Requirements Review (PRR), which certifies that the program is ready for preliminary design, the Program Design Review (PDR), which certifies the program is ready to start the detail design, and the Critical Design Review (CDR), which certifies that the program is completing a design that meets the Program objectives. The paper also discusses experience, status to date, and plans for continued system integration through manufacturing, testing and final verification of the Space Station system performance.
Carlisle, Richard F.↗
Materials processing in space tasks. WBS task 5.4: Generic tasks
This task encompassed a wide range of activities related to materials processing in space. For example, all aspects of the space station's flight and ground based systems design were assessed for the Office of Advanced Concepts and Technology (OACT) Space Processing Division Office. Activities for that organization also included the consolidation of space processing payload requirements for the space station and the development of an OACT payload operations plan. Similar duties were performed for the MSFC Payload Project Office. The SPACECOM database was used to conduct preliminary design studies for microgravity payload carriers and to conduct assessments of materials processing technology. Concepts for the Advanced Protein Crystal Growth Facility (APCGF) were developed. Materials processing vent products were analyzed and a furnace facility filter concept was developed using those studies. A preliminary design for a space station aluminum payload rack was developed. Analysis was conducted to characterize the acceleration environment onboard the space shuttle. Equipment for two fluid experiment apparatus was designed and manufactured for the Space Science Laboratory. The Fluids and Materials Experiments (FAME) data base was expanded. Also, Mir payload integration, technology transfer, and spacelab-to-space station transition studies were conducted.
Crull, Robert↗
JUSTIFI: Software for Improving Performance Objectives via Energy Efficiency
With growing energy supply concerns and rising costs, energy efficiency is a critical component of industrial energy resilience and competitiveness by directly reducing energy operating costs. Energy efficiency projects in manufacturing also yield valuable benefits to other key metrics, such as improved quality, reduced maintenance costs, improved safety, decreased pollution, and enhanced productivity. However, it is difficult to receive approval for energy efficiency projects, so implementation rates are low, even when meeting capital project payback period criteria. The inclusion and quantification of non-energy benefits (NEBs) in the decision-making process for energy efficiency projects can improve the overall financial payback period while demonstrating a positive impact on the firm's key performance metrics and business strategy. Despite their significant financial and strategic value, NEBs are rarely factored into decision-making due to lack of tools to effectively identify and quantify them. Therefore, a comprehensive and integrative approach is needed for the rapidly evolving energy landscape. To address these challenges, through funding from U.S. Department of Energy, our new assessment methodology integrates common continuous improvement six sigma concepts, such as the DMAIC process, and a protocol of guiding questions, into energy efficiency assessments to identify NEBs. We have also developed open-source software, JUSTIFI, to guide users through this process, data collection, and quantification. It is designed to be used concurrently with DOE energy system analysis software suite, MEASUR. Our methodology and tools inform energy assessors, firm engineering, decision makers, and workforce seeking to increase energy resilience and to maximize benefits aligned with performance metrics.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
One NASA PEM qualification standard : comparison of JPL and GSFC standards
Although use of Plastic Encapsulated Microelectronics (PEMs) in space applications is discouraged, their use is mandatory for selected applications involving the need for advanced technology and small packages. Various space systems designers and manufacturers have developed methods to qualify and screen PEMs. In general, each procedure is different. The purpose of this fiscal year’s investigation is to initiate a process to coordinate the efforts at various NASA centers to eventually develop a One NASA method. Part of this activity includes sharing of test data and PEM qualification methodologies. Various experts in the NASA community were identified and contacted to support this effort. We were successful in finding such experts at GSFC, APL and the Constellation office (Orion and Ares). All these experts provided typical qualification program plans. Since funding was severely restricted, it was decided to concentrate on coordination activity with GSFC. GSFC is planning a new version of IEEE-INST-002 section applying to PEMs. The GSFC expert (Dr. Alexander Teverovsky) provided a detailed assessment of the differences between the planned new version of IEEE-INST-002 and the JPL-D-19426 (JPL guideline) as well as a summary rationale for the decisions within the IEEE-INST-002. It should be noted that GSFC’s assessment of IEEE-INST-002 in the area of PEMs is not finalized. JPL is also considering changes in PEM qualification methodologies based on test data from recent qualification testing for their newer Projects (MSL, Grail, Juno). A spreadsheet delineating the differences between the JPL standard and the GSFC standard is presented.
Cooper, Mark↗
PIP-II Linac Cryogenic Distribution System Design Challenges
The PIP-II linac Cryogenic Distribution System (CDS) is characterized by extremely small heat inflows and robust mechanical design. It consists of a Distribution Valve Box (DVB), Intermediate Transfer Line, Tunnel Transfer Line, comprising 25 Bayonet Cans, and ends with a Turnaround Can. Multiple helium streams, each characterized by distinct helium parameters, flow through each of these elements. The CDS geometry allows maintaining an acceptable pressure drop for each helium stream, considering the planned flows and helium parameters in different operation modes. This is particularly crucial for the return line of helium vapors, which return from cryomodules to the cold compressors and thus have very restrictive pressure drop requirements. On both sides of the DVB there are fixed supports for process pipes. One of the DVB design challenges was to route the process pipes in such a way that their shape provided sufficient compensation for thermal shrinkage. This ensures th at the forces resulting from thermal shrinkage acting on the cryogenic valves remain at a level acceptable to the manufacturer. The required thermal budget of the CDS was achieved by thermo-mechanical optimization of its components, like process pipes fixed supports in Bayonet Cans.
43 PARTICLE ACCELERATORS↗
Manufacturing Challenges and Benefits when Scaling the HIAD Stacked-Torus Aeroshell to a 15m-Class System
Over a decade of work has been conducted in the development of NASAs Hypersonic Inflatable Aerodynamic Decelerator (HIAD) deployable aeroshell technology. This effort has included multiple ground test campaigns and flight tests culminating in the HIAD projects second generation (Gen-2) aeroshell system. The HIAD project team has developed, fabricated, and tested stacked-torus inflatable structures (IS) with flexible thermal protection systems (F-TPS) ranging in diameters from 3-6m, with cone angles of 60 and 70 deg. To meet NASA and commercial near term objectives, the HIAD team must scale the current technology up to 12-15m in diameter. Therefore, the HIAD projects experience in scaling the technology has reached a critical juncture. Growing from a 6m to a 15m-class system will introduce many new structural and logistical challenges to an already complicated manufacturing process.Although the general architecture and key aspects of the HIAD design scale well to larger vehicles, details of the technology will need to be reevaluated and possibly redesigned for use in a 15m-class HIAD system. These include: layout and size of the structural webbing that transfers load throughout the IS, inflatable gas barrier design, torus diameter and braid construction, internal pressure and inflation line routing, adhesives used for coating and bonding, and F-TPS gore design and seam fabrication. The logistics of fabricating and testing the IS and the F-TPS also become more challenging with increased scale. Compared to the 6m aeroshell (the largest HIAD built to date), a 12m aeroshell has four times the cross-sectional area, and a 15m one has over six times the area. This means that fabrication and test procedures will need to be reexamined to ac-count for the sheer size and weight of the aeroshell components. This will affect a variety of steps in the manufacturing process, such as: stacking the tori during assembly, stitching the structural webbing, initial inflation of tori, and stitching of F-TPS gores. Additionally, new approaches and hardware will be required for handling and ground testing of both individual tori and the fully assembled HIADs.There are also noteworthy benefits of scaling up the HIAD aeroshell to a 15m-class system. Two complications in working with handmade textile structures are the non-linearity of the material components and the role of human accuracy during fabrication. Larger, more capable, HIAD structures should see much larger operational loads, potentially bringing the structural response of the material components out of the non-linear regime and into the preferred linear response range. Also, making the reasonable assumption that the magnitude of fabrication accuracy remains constant as the structures grow, the relative effect of fabrication errors should decrease as a percentage of the textile component size. Combined, these two effects improve the predictive capability and the uniformity of the structural response for a 12-15m HIAD.In this presentation, a handful of the challenges and associated mitigation plans will be discussed, as well as an update on current 12m aeroshell manufacturing and testing that is addressing these challenges
Infatables↗
In situ high-energy X-ray study of deformation mechanisms in additively manufactured 316L stainless steel
A key structural material planned to be used in the core of the Transformational Challenge Reactor is the additively manufactured 316L stainless steel (AM 316L SS). While the deformation of conventionally-manufactured 316 SS have been extensively studied, the deformation mechanism of AM 316L SS is less known. Here the room-temperature tensile behavior of AM 316L SS was studied in situ using high-energy X-ray diffraction and X-ray tomography. Diffraction yielded the lattice strains and the dislocation densi-ties of the AM 316L SS, which were compared to those of a conventionally processed 316H SS. It was found that while the conventional 316H SS had three distinct deformation stages, namely stage II ather-mal hardening, stage III dynamic recovery, and stage IV, the AM 316L experienced only the stages III and IV after an initial transitional period. The plastic instability stresses (PIS), i.e. the true ultimate tensile strength, were nearly the same in both materials. The AM 316L had very low dislocation barrier strength throughout the plastic deformation, which, in combination with the invariant PIS, explained its high dis-location storage capability and the attractive combination of strength and ductility. Tomography revealed morphological changes of the built-in pores in the AM 316L during deformation and fracture, and it was concluded that large pores close to the surface might have significant roles in the necking stage.
316 stainless steel↗
Materials Characterization: A Primer for Solid Phase Processing Applications
The Pacific Northwest National Laboratory (PNNL) undertook the Materials Characterization, Prediction, and Control (MCPC) Laboratory Directed Research and Development (LDRD) Project to advance understanding of nuclear material processing and enable multifold acceleration in the development and qualification of new material systems produced via advanced manufacturing methods, such as solid phase processing, for use in national security and advanced energy applications (Smith 2021). As a two-year LDRD investment requiring focused research, the MCPC project applied only a subset of the wide range of available destructive and nondestructive characterization methods to provide data to the predictive modeling and data analytics tasks. The purpose of this report is to review a wide range of destructive and nondestructive characterization methods that are relevant in solid-phase processing (SPP) applications, but not necessarily applied in the MCPC Project as a guide to the planning of characterization activities in future research. Particular attention is given to measured characteristics that can correlate to other material characteristics, with a particular interest in nondestructive evaluation (NDE) that can be applied to samples obtained in the MCPC Project. Destructive examinations include tensile tests, optical and electron microscopy, micro-hardness, and residual stress tests. NDE tests include surface visual inspection, eddy current examination for cracks, 4-point potential drop, ultrasound, x-ray, and computed tomography.
36 MATERIALS SCIENCE↗
Development of the COMmerical Experiment Transporter (COMET)
In order to commercialize space, this nation must develop a well defined path through which the Centers for the Commercial Development of Space (CCDS's) and their industrial partners and counterparts can exploit the advantages of space manufacturing and processing. Such a capability requires systems, a supporting infrastructure, and funding to become a viable component of this nation's economic strength. This paper follows the development of the COMmercial Experiment Program (COMET) from inception to its current position as the country's first space program dedicated to satisfying the needs of industry: an industry which must investigate the feasibility of space based processes, materials, and prototypes. With proposals now being evaluated, much of the COMET story is yet to be written, however concepts and events which led to it's current status and the plans for implementation may be presented.
Pawlick, Joseph F., Jr.↗
Manufacturing Challenges and Benefits When Scaling the HIAD Stacked-Torus Aeroshell to a 15 Meter Class System
Over a decade of work has been conducted in the development of NASA's Hypersonic Inflatable Aerodynamic Decelerator (HIAD) deployable aeroshell technology. This effort has included multiple ground test campaigns and flight tests culminating in the HIAD project's second generation (Gen-2) aeroshell system. The HIAD project team has developed, fabricated, and tested stacked-torus inflatable structures (IS) with flexible thermal protection systems (F-TPS) ranging in diameters from 3-6 meters, with cone angles of 60 and 70 degrees. To meet NASA and commercial near-term objectives, the HIAD team must scale the current technology up to 12-15 meters in diameter. Therefore, the HIAD project's experience in scaling the technology has reached a critical juncture. Growing from a 6-meter to a 15-meter class system will introduce many new structural and logistical challenges to an already complicated manufacturing process. Although the general architecture and key aspects of the HIAD design scale well to larger vehicles, details of the technology will need to be reevaluated and possibly redesigned for use in a 15-meter-class HIAD system. These include: layout and size of the structural webbing that transfers load throughout the IS, inflatable gas barrier design, torus diameter and braid construction, internal pressure and inflation line routing, adhesives used for coating and bonding, and F-TPS gore design and seam fabrication. The logistics of fabricating and testing the IS and the F-TPS also become more challenging with increased scale. Compared to the 6-meter aeroshell (the largest HIAD built to date), a 12-meter aeroshell has four times the cross-sectional area, and a 15-meter one has over six times the area. This means that fabrication and test procedures will need to be reexamined to account for the sheer size and weight of the aeroshell components. This will affect a variety of steps in the manufacturing process, such as: stacking the tori during assembly, stitching the structural webbing, initial inflation of tori, and stitching of F-TPS gores. Additionally, new approaches and hardware will be required for handling and ground testing of both individual tori and the fully assembled HIADs. There are also noteworthy benefits of scaling up the HIAD aeroshell to a 15m-class system. Two complications in working with handmade textile structures are the non-linearity of the material components and the role of human accuracy during fabrication. Larger, more capable, HIAD structures should see much larger operational loads, potentially bringing the structural response of the material components out of the non-linear regime and into the preferred linear response range. Also, making the reasonable assumption that the magnitude of fabrication accuracy remains constant as the structures grow, the relative effect of fabrication errors should decrease as a percentage of the textile component size. Combined, these two effects improve the predictive capability and the uniformity of the structural response for a 12-15-meter HIAD. In this presentation, a handful of the challenges and associated mitigation plans will be discussed, as well as an update on current manufacturing and testing that addressing these challenges.
Infatables↗
Opportunities and challenges for the expansion of LFP battery supply chains
Global markets for energy storage are growing rapidly, with some applications transitioning from traditional LiNi x Mn y Co 1−x−y O 2 (NMC) toward LiFePO 4 (LFP) due to cost, safety, and performance advantages. Battery growth has seeded interest in critical material supplies such as high-purity lithium precursors. In contrast, challenges in securing high-purity iron and phosphorus, historically not considered critical materials, are often overlooked. Precursors must remain inexpensive to maintain LFP's current cost advantage, which leverages the low-cost (∼$\$100$ per t) FeSO 4 byproduct from titanium dioxide manufacturing and will not be available as LFP manufacturing expands. As an alternative, iron is mined primarily for steel manufacturing, for which the existing supply chain and beneficiation process is optimized. LFP batteries require small iron volumes compared to steel (0.11%), but profit margins associated with existing low-cost iron ores and high costs (∼$27 000 per t) associated with low volume high-purity iron oxides may limit interest in manufacturing small volumes of high-purity, specialized iron battery precursors. The complementary LFP precursor, phosphoric acid (H 3 PO 4 ), is primarily utilized in fertilizers. Of the current phosphate ore demand for fertilizers, 4–22.8% would be required to meet projected 2045 LFP H 3 PO 4 demand, suggesting significant supply chain planning is needed to achieve projected demand. If only higher-grade material is considered, demand jumps to 15–77% of current world production. While lithium precursor purity requirements have been evaluated (Li 2 CO 3 is commonly defined as ≥99.5%), “battery grade” iron and phosphorus precursors remain poorly defined, with no internationally accessible and widely adopted standard, further challenging expanding industry by creating manufacturing uncertainty and increasing potential costs.
25 ENERGY STORAGE↗
Ames Engineering Directorate
The Ames Engineering Directorate is the principal engineering organization supporting aerospace systems and spaceflight projects at NASA's Ames Research Center in California's Silicon Valley. The Directorate supports all phases of engineering and project management for flight and mission projects-from R&D to Close-out-by leveraging the capabilities of multiple divisions and facilities.The Mission Design Center (MDC) has full end-to-end mission design capability with sophisticated analysis and simulation tools in a collaborative concurrent design environment. Services include concept maturity level (CML) maturation, spacecraft design and trades, scientific instruments selection, feasibility assessments, and proposal support and partnerships. The Engineering Systems Division provides robust project management support as well as systems engineering, mechanical and electrical analysis and design, technical authority and project integration support to a variety of programs and projects across NASA centers. The Applied Manufacturing Division turns abstract ideas into tangible hardware for aeronautics, spaceflight and science applications, specializing in fabrication methods and management of complex fabrication projects. The Engineering Evaluation Lab (EEL) provides full satellite or payload environmental testing services including vibration, temperature, humidity, immersion, pressure/altitude, vacuum, high G centrifuge, shock impact testing and the Flight Processing Center (FPC), which includes cleanrooms, bonded stores and flight preparation resources. The Multi-Mission Operations Center (MMOC) is composed of the facilities, networks, IT equipment, software and support services needed by flight projects to effectively and efficiently perform all mission functions, including planning, scheduling, command, telemetry processing and science analysis.
Small Satellites↗
ISyCL technical report
The Air Force Integrated Information Systems Evolution Environment (IISEE) is a program focused on the development of technology for enabling the planning definition development and maintenance of evolutionary integrated information systems. This program has studied the representational needs of this knowledge base from the point of view of the needs of engineering, manufacturing, and logistics Evolutionary Information Systems (EIS). The definition of the concepts for a suite of automated tools and environments to support the pursuit of such engineering, manufacturing, and logistics EIS's has also required examination of languages and representation schemes for the knowledge base of these integrated systems. To accomplish this purpose, the language must be very rich, and must support object orientation, relational orientation, persistent storage, process transaction specification, and first order logic. The task of designing a unified language which supports these paradigms is a challenge. The Information Systems Constraint Language (ISyCL) is described. It was designed to meet the definitional and knowledge representation needs of three perspectives. It supports users from the area expert to the data base designer.
Decker, Louis P.↗
Developments on Low Cost Manufacturing Methods for Cylindrical Launch Vehicle Structures
Due to the increasing international competition and growing pressure to lower the cost of launch vehicles, enhanced technologies and competences for efficient, low cost manufacturing have to be developed. In this paper, an innovative manufacturing technology for launch vehicle applications is presented that was developed over the last few years at MT Aerospace AG (MTA) in collaboration with NASA Langley Research Center, the European Space Agency (ESA), Lockheed Martin Corporation (LMCO), Leifeld Metal Spinning and Scot Forge. The Integrally Stiffened Cylinder (ISC) manufacturing method was first investigated in 2010. Early results indicated a high mass saving potential for cylindrical structures for launch vehicle systems, such as cryogenic tank barrels and intertanks, produced using the ISC method. Cost-benefit studies conducted at NASA and MTA estimated up to 50% reduction in manufacturing costs is possible compared to conventional multi-piece, welded fabrication methods. Associated reductions in manufacturing lead times have shown that a 40% faster production rate is possible by the ISC process. Following proof of concept and process development efforts, a cylindrical structure manufactured using the ISC method had its maiden flight in 2015 on a Black Brant sounding rocket at NASA Wallops Flight Facility. Further collaboration between ESA, NASA, MTA, LMCO, and Scot Forge led to manufacturing test campaigns at MT Aerospace in 2017 and 2018 that successfully demonstrated ISC fabrication at a scale representative of commercial launch vehicles. This paper summarizes the status and relevant results of the development sequence of the ISC cylinder manufacturing method. Results of cost / benefit and structural performance analyses are also summarized. Moreover, an outlook will be given on further planned activities and development steps.
Martin Stachulla↗
Opportunities for iron and steel industrial wastewater treatment and reuse in the United States
Concerns around water security in the United States have heightened the interest in industrial water treatment and reuse to improve water efficiency and operational reliability. Alongside nationwide efforts to expand industrial capacity, primary manufacturing sectors are adopting more resource-efficient technologies. This transition is expected to shift industrial water consumption patterns, driving the need for improved treatment and reuse practices. This study investigates opportunities for water use, treatment, and reuse in the iron and steel sector through a review of academic and industry literature and interviews with industry representatives. It identifies key challenges in water and wastewater management and outlines the conditions under which innovative treatment technologies could be deployed. Based on these insights, the study presents a practical water management action plan. Furthermore, it assesses water quality targets across different process operations, evaluates existing treatment technologies, and highlights challenges and opportunities for improvement relative to future performance expectations. Although water is often perceived as a low-cost commodity, industry feedback suggests that improvements in water use and treatment efficiency are typically prioritized only when they also reduce energy use, carbon emissions, or costs. This study advocates for a direct two-way partnership between industry and research audiences to bring their attention toward sustainable industrial water use, treatment, and reuse.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Effects of Yarn Crimping on Braided Composite Design Allowables
Braided composite materials are currently being evaluated for wing skin stiffeners on commercial aircraft. These carbon-fiber/epoxy materials allow for low-cost manufacturing while maintaining high strength-to-weight and stiffness-to-weight ratios. The proposed braid architecture consists of axial carbon fiber yarns and braider carbon fiber yarns making 60 deg to 70 deg angles with respect to the axial yarns. These 2-D triaxial braids are produced as long, continuous tubes, which are flattened, cut, and stacked to produce the desired part thickness and shape. When infiltrated with epoxy resin and cured under a compaction pressure, the fiber yarns become crimped, allowing for higher fiber packing. Although high fiber packing is desirable, yarn crimping (especially in the axial fiberyarns) is undesirable. Significant axial yarn crimp angles (greater than 10 deg) have been measured in braided composites. Comparable levels of crimping have been found to produce significant compressive strength reductions in laminated composites consisting of planar fiber sheets. Thus, axial yarn crimping is suspected of producing significant reductions in compressive strength allowables for braided composites. The objective of this research is to quantify the reduction in compressive strength as a function of axial yarn crimp severity. Since crimp severity can be reduced by lowering the compaction pressure during curing, the resulting compressive strengths may be used to determine optimum processing conditions. A 'cure-on-the-loom' manufacturing process was developed to produce braided composites with controlled levels of crimping. This method allowed for controlled levels of tension to be placed on the axial yarns and maintained during the curing process. With increasing tension, the crimp severity in the axial yarns was reduced. Thus, varying crimp severities were produced ranging from conventional levels (greater than 10 deg) to virtually straight axial yarns. Test results indicate that a 30% increase in compressive strength is obtainable by eliminating axial yarn crimping. Further compression testing is underway to quantify the relationship between crimp severity and compressive strength. Additional testing is planned to investigate the effect of crimping on the open-hole compressive strength, often considered a more significant design allowable.
Adams, Dan↗
NETL Direct Air Capture Center
In 2022 Congress authorized the $25M National Energy Technology Laboratory Direct Air Capture Center. The facility will be specifically targeted at accelerating the commercialization of technologies beyond the conceptual stage which have not yet reached full pilot-scale (TRL 3 to 6). The ability to operate over a wide range of conditions will help the developers to understand how their technologies respond in different climates, from summer to winter and arid to tropical. NETL recognizes that DAC technology is still early in its evolution, and a wide variety of highly varied technologies are being explored. The Center will be designed with substantial flexibility to accommodate the rapidly evolving technological landscape. Testing systems at three scales will be included: lab-scale systems designed to examine the long-term stability of DAC materials, bench-scale module testing systems capable of probing flow dynamics, and small pilot-scale skid rooms able to test prototype DAC units under a wide variety of climate conditions. The NETL DAC Center will feature dedicated engineering, technician, scientific and logistical support for experimental system design, installation, operation of experiments, and interpretation of results for projects including but not limited to kinetics of absorption/desorption, thermal duty, and post-mortem elemental characterization to understand degradation. The NETL DAC Center projects will also have access to dedicated process modeling and analysis to evaluate the technoeconomic aspects of new technologies. NETL’s Systems Engineering and Analysis (SEA) team, the Carbon Capture Simulation Initiative (CCSI), and the Institute for the Design of Advanced Energy Systems (IDAES) are all potential collaborators with NETL’s testing partners from industry, academia, and other research institutions. NETL also has world class capabilities in device scale modeling (i.e., MFIX) that will be available to help design more efficient contactors and optimize unique internal configurations that can be realized by advanced manufacturing. The talk will cover the design and capabilities of the center, the planned availability, and feedback will be solicited from the audience on DAC testing needs.
Luebke, David↗