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At least 433 records · Page 24

Scientific Foundations and Approaches for Qualification of Additively Manufactured Structural Components

Additive manufacturing (AM) maintains a wide process window that enables complex designs otherwise unattainable via conventional production technologies. However, the lack of confidence in qualifying AM parts that leverage AM process–structure–property–performance (PSPP) relationships stymies design optimization and adoption of AM. While continuing efforts to map fundamental PSPP relationships that cover the potential design space, we first need pragmatic and then long-term solutions that overcome challenges associated with qualifying AM-designed parts. Two pragmatic solutions include: (1) AM material specifications to substantiate process reproducibility, and (2) component risk categorization to associate system risk relative to part performance and required part quality. A novel qualification paradigm under development involves efficient prediction of part performance over wide-ranging PSPP relationships through targeted testing and computational simulation. Here this paper describes projects at Sandia National Laboratories on PSPP relationship discovery, these pragmatic approaches, and the novel qualification approach.

36 MATERIALS SCIENCE↗

Lyndon B. Johnson Space Center (JSC) proposed dual-use technology investment program in intelligent robots

This paper presents an overview of the proposed Lyndon B. Johnson Space Center (JSC) precompetitive, dual-use technology investment project in robotics. New robotic technology in advanced robots, which can recognize and respond to their environments and to spoken human supervision so as to perform a variety of combined mobility and manipulation tasks in various sectors, is an obejective of this work. In the U.S. economy, such robots offer the benefits of improved global competitiveness in a critical industrial sector; improved productivity by the end users of these robots; a growing robotics industry that produces jobs and profits; lower cost health care delivery with quality improvements; and, as these 'intelligent' robots become acceptable throughout society, an increase in the standard of living for everyone. In space, such robots will provide improved safety, reliability, and productivity as Space Station evolves, and will enable human space exploration (by human/robot teams). The proposed effort consists of partnerships between manufacturers, universities, and JSC to develop working production prototypes of these robots by leveraging current development by both sides. Currently targeted applications are in the manufacturing, health care, services, and construction sectors of the U.S. economy and in the inspection, servicing, maintenance, and repair aspects of space exploration. But the focus is on the generic software architecture and standardized interfaces for custom modules tailored for the various applications allowing end users to customize a robot as PC users customize PC's. Production prototypes would be completed in 5 years under this proposal.

Erikson, Jon D.↗

Lyndon B. Johnson Space Center (JSC) proposed dual-use technology investment program in intelligent robotics

This paper presents an overview of the proposed Lyndon B. Johnson Space Center (JSC) precompetitive, dual-use technology investment project in robotics. New robotic technology in advanced robots, which can recognize and respond to their environments and to spoken human supervision so as to perform a variety of combined mobility and manipulation tasks in various sectors, is an objective of this work. In the U.S. economy, such robots offer the benefits of improved global competitiveness in a critical industrial sector; improved productivity by the end users of these robots; a growing robotics industry that produces jobs and profits; lower cost health care delivery with quality improvements; and, as these 'intelligent' robots become acceptable throughout society, an increase in the standard of living for everyone. In space, such robots will provide improved safety, reliability, and productivity as Space Station evolves, and will enable human space exploration (by human/robot teams). The proposed effort consists of partnerships between manufacturers, universities, and JSC to develop working production prototypes of these robots by leveraging current development by both sides. Currently targeted applications are in the manufacturing, health care, services, and construction sectors of the U.S. economy and in the inspection, servicing, maintenance, and repair aspects of space exploration. But the focus is on the generic software architecture and standardized interfaces for custom modules tailored for the various applications allowing end users to customize a robot as PC users customize PC's. Production prototypes would be completed in 5 years under this proposal.

Erickson, Jon D.↗

Deploying Automation Technology Supporting Packaging and Transportation Operations

Various United States Department of Energy (DOE) sites are investigating the deployment of robotics to provide safer, effective, and more efficient operations. By implementing robotics in packaging and transportation operations, improvements toward production efficiency, worker ergonomics, radiological dose reduction, and security assurance can be realized. Robotic Systems must be designed and implemented in concert with a facility’s safety basis, classification, and security constraints, while improving overall operational effectiveness. The desired robotic implementation should provide a path to potential long-term cost savings, reduce/eliminate hazardous conditions and radiological exposure, while improving quality and reliability of an operation process. The Savannah River Site (SRS), a DOE Site located in Aiken South Carolina, has initiated several large scale projects supporting future nuclear material disposition activities. Incorporation of automation and robotic equipment in system designs will support effective and efficient material handling operations, including container movements and packaging activities. Robotic systems will execute tasks that are precise, procedural and integrated with control systems to verify and record data for material inventory and historical archiving. An overview of the current robotic system development to perform receipt inspection, packaging, storage and shipment preparation activities of designated Type A and B shipping packages will be presented.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Enhancements to the GRIDGEN structured grid generation system for internal and external flow applications

GRIDGEN is a government domain software package for interactive generation of multiple block grids around general configurations. Though it has been freely available since 1989, it has not been widely embraced by the internal flow community due to a misconception that it was designed for external flow use only. In reality GRIDGEN has always worked for internal flow applications, and GRIDGEN ongoing enhancements are increasing the quality of and efficiency with which grids for external and internal flow problems may be constructed. The software consists of four codes used to perform the four steps of the grid generation process. GRIDBLOCK is first used to decompose the flow domain into a collection of component blocks and then to establish interblock connections and flow solver boundary conditions. GRIDGEN2D is then used to generate surface grids on the outer shell of each component block. GRIDGEN3D generates grid points on the interior of each block, and finally GRIDVUE3D is used to inspect the resulting multiple block grid. Three of these codes (GRIDBLOCK, GRIDGEN2D, and GRIDVUE3D) are highly interactive and graphical in nature, and currently run on Silicon Graphics, Inc., and IBM RS/6000 workstations. The lone batch code (GRIDGEN3D) may be run on any of several Unix based platforms. Surface grid generation in GRIDGEN2D is being improved with the addition of higher order surface definitions (NURBS and parametric surfaces input in IGES format and bicubic surfaces input in PATRAN Neutral File format) and double precision mathematics. In addition, two types of automation have been added to GRIDGEN2D that reduce the learning curve slope for new users and eliminate work for experienced users. Volume grid generation using GRIDGEN3D has been improved via the addition of an advanced hybrid control function formulation that provides both orthogonality and clustering control at the block faces and clustering control on the block interior.

Steinbrenner, John P.↗

Land Surface Temperature Measurements from EOD MODIS Data

We made more tests of the version 2.0 daily Level 2 and Level 3 Land-Surface Temperature (LST) code (PGE 16) jointly with the MODIS Science Data Support Team (SDST). After making minor changes a few times, the PGE16 code has been successfully integrated and tested by MODIS SDST, and recently has passed the inspection at the Goddard Distributed Active Archive Center (DAAC). We conducted a field campaign in the area of Mono Lake, California on March 10, 1998, in order to validate the MODIS LST algorithm in cold and dry conditions. Two MODIS Airborne Simulator (MAS) flights were completed during the field campaign, one before noon, and another around 10 pm PST. The weather condition for the daytime flight was perfect: clear sky, the column water vapor measured by radiosonde around 0.3 cm, and wind speed less than a half meter per second. The quality of MAS data is good for both day and night flights. We analyzed the noise equivalent temperature difference (NE(delta)T) and the calibration accuracy of the seven MAS thermal infrared (TIR) bands, that are used in the MODIS day/night LST algorithm, with daytime MAS data over four flat homogeneous study areas: two on Grant Lake (covered with ice and snow, respectively), one on Mono Lake, and another on the snow field site where we made field measurements. NE(delta)T ranges from 0.2 to 0.6 k for bands 42, 45, 46, and 48. It ranges from 0.8 to 1.1 K for bands 30-32. The day and night MAS data have been used to retrieve surface temperature and emissivities in these bands. A simple method to correct the effect of night thin cirrus has been incorporated into the day/night LST algorithm in dry atmospheric conditions. We compared the retrieved surface temperatures with those measured with TIR spectrometer, radiometers and thermistors in the snow test site, and the retrieved emissivity images with topographic map. The daytime LST values match well within 1 K. The night LST retrieved from MAS data is 3.3 K colder than those from field measurements most likely because of the effect of haze at night. The good agreement among the regional averaged surface temperatures obtained from LST values retrieved at different resolutions increased our confidence in the MODIS day/night LST algorithm.

Wan, Zheng-Ming↗

Automated Fiber Placement Defect Identity Cards: Cause, Anticipation, Existence, Significance, and Progression

Automated Fiber Placement (AFP), a major composite manufacturing process, can result in many defects during the layup process that often require manual corrective action to produce a part with acceptable quality. These defects are the main limitation of the technology and can be hard to categorize or define in many situations. This paper provides a thorough definition and classification of all AFP defects. This effort constitutes a comprehensive and extensive library relevant to AFP defects. The defects selected and defined in this work are based on understanding and experience from the manufacture and research of advanced composite structure. Proper classification of these defects required an in-depth literature review and consideration of various viewpoints ranging from designers, manufacturers, analysts, and inspection professionals. Collectively, these sources were utilized to develop the most accurate view of each of the individual defect types. The results are presented as identity cards for each defect type, intended to provide researchers and the manufacturing industry a clear understanding of the (1) cause, (2) anticipation, (3) existence, (4) significance, and (5) progression of the defined AFP defects. The link between AFP defects and process planning, layup strategies, and machining was also investigated. Categorization of all important automated fiber placement defects is presented.

Harik, Ramy↗

Gravitational Lenses in UNIONS and Euclid (GLUE). I. A Search for Strong Gravitational Lenses in UNIONS with Subaru, CFHT, and Pan-STARRS Data

We present the results of our pipeline for discovering strong gravitational lenses in the ongoing Ultraviolet Near-Infrared Optical Northern Survey (UNIONS). We successfully train a deep residual convolutional neural network based on CMU-Deeplens architecture, which is designed to detect strong lenses in ground-based imaging surveys. We train on images of real strong lenses and deploy on a sample of 8 million galaxies in areas with full coverage in the g, r, and i filters—the first multiband search for strong gravitational lenses in UNIONS. Following human inspection and grading, we report the discovery of a total of 1346 new strong-lens candidates, of which 146 are Grade A, 199 are Grade B, and 1001 are Grade C. Of these candidates, 283 have lens galaxy spectroscopic redshifts from the Sloan Digital Sky Survey, and an additional 297 have them from the Dark Energy Spectroscopic Instrument Data Release 1. We find 15 of these systems display evidence of both lens and source galaxy redshifts in spectral superposition. We also report the spectroscopic confirmation of seven lensed sources in high-quality systems, all with z > 2.1, using the Keck Near Infrared Echellette Spectrograph and the Gemini Near-Infrared Spectrograph.

Storfer, Christopher J. [University of Hawaii, Hon↗

Ultrasonic nondestructive evaluation of additively manufactured wear coatings

Here, this work pertains to the nondestructive evaluation of additively deposited coatings using ultrasound measurements. The specific objective was to evaluate using ultrasound surface wave measurements the quality of Stellite 21 coatings deposited on Inconel 718 substrates by the directed energy deposition (DED) additive manufacturing (AM) process. The surface wave speed and diffuse backscatter amplitude of the ultrasound waves were correlated with both cracking and warpage of the coating. This research is important, because, the integrity of DED-processed coatings currently requires a combination of destructive metallographic studies and X-ray computed tomography analysis, which are both expensive and time consuming. Instead of using a normal incidence configuration for the ultrasound measurements, the surface-wave approach allows the inspection of the near surface coating integrity. Three different frequencies were used to excite surface waves because each frequency has a different penetration depth. The signals obtained were used to quantify and compare the surface wave speed and surface wave-diffuse ultrasonic backscatter amplitude from five different DED-processed Stellite coated samples. Considering destructive metallurgical characterization as a reference, surface wave measurements were found to be effective for examining coating integrity. Further, the backscatter amplitude of the surface waves was correlated with the crack density and warpage. These flaws also change the stress state of the Stellite coating and consequently the surface wave propagation speed and its scattering behavior.

36 MATERIALS SCIENCE↗

Study Methods to Standardize Thermography NDE

The purpose of this work is to develop thermographic inspection methods and standards for use in evaluating structural composites and aerospace hardware. Qualification techniques and calibration methods are investigated to standardize the thermographic method for use in the field. Along with the inspections of test standards structural hardware, support hardware is designed and fabricated to aid in the thermographic process. Also, a standard operating procedure is developed for performing inspections with the Bales Thermal Image Processor (TIP). Inspections are performed on a broad range of structural composites. These materials include graphite/epoxies, graphite/cyanide-ester, graphite/silicon-carbide, graphite phenolic and Kevlar/epoxy. Also metal honeycomb (titanium and aluminum faceplates over an aluminum honeycomb core) structures are investigated. Various structural shapes are investigated and the thickness of the structures vary from as few as 3 plies to as many as 80 plies. Special emphasis is placed on characterizing defects in attachment holes and bondlines, in addition to those resulting from impact damage and the inclusion of foreign matter. Image processing through statistical analysis and digital filtering is investigated to enhance the quality and quantify the NDE thermal images when necessary.

Walker, James L.↗

Development of Critical Profilometers to Meet Current and Future NASA Composite Overwrapped Pressure Vessel (COPV) Inspection Needs

This project is part of a multi-center effort to develop and validate critical NDE techniques which can be implemented into current and future NASA spacecraft COPV manufacturing processes. After decades of COPV development, manufacturing variance is still high and has necessitated higher safety factors and additional mass to be flown on spacecraft (reducing overall performance). Additionally, the NASA Engineering and Safety Center (NESC) indicated that nondestructive evaluation (NDE) was not adequately implemented during Shuttle and International Space Station (ISS) COPV manufacturing and provisions were not made for on-going structural integrity and health checks during the various spacecraft programs. This project helps to provide additional data needed to help address these issues. This project seeks to develop and install internal and external laser profilometers at COPV manufacturing facilities to provide data needed to improve COPV quality and consistency. This project also investigates other scanning techniques that will enhance the system to more completely meet manufacturing needs, thus transforming the profilometer into what has been termed the "Universal Manufacturing COPV Scanner".

Saulsberry, Regor↗

DETERMINATION OF STRUT QUALITY FACTORS IN ADDITIVELY MANUFACTURED LATTICES USING IN-SITU COMPRESSION TESTING µ-CT

In response to the need for an automated, commercial method to qualify additively manufactured (AM) lattice components, an experiment was conducted to evaluate the effects of defective lattice struts on the structural compression strength. Lattice samples with known defective or missing struts were compressed using a Deben CT5000RT and imaged using xray µ-CT. The compressive force and x-ray computed tomography results were compared to defect free standards to evaluate the impact of each defect type on the overall structure’s compressive strength. This analysis will allow for simplifications to Finite Element Analysis (FEA) on AM parts without sacrificing model fidelity. Understanding the contribution of each defect type and severity will also better inform non-destructive evaluation (NDE) personnel of the inspection parameters necessary to detect the smallest feature of importance.

Dinova, Vincent A.↗

Study Methods to Standardize Thermography NDE

The purpose of this work is to develop thermographic inspection methods and standards for use in evaluating structural composites and aerospace hardware. Qualification techniques and calibration methods are investigated to standardize the thermographic method for use in the field. Along with the inspections of test standards structural hardware, support hardware is designed and fabricated to aid in the thermographic process. Also, a standard operating procedure is developed for performing inspections with the Bales Thermal Image Processor (TIP). Inspections are performed on a broad range of structural composites. These materials include various graphite/epoxies, graphite/cyanide-ester, graphite/silicon-carbide, graphite phenolic and Keviar/epoxy. Also metal honeycomb (titanium and aluminum faceplates over an aluminum honeycomb core) structures are investigated. Various structural shapes are investigated and the thickness of the structures vary from as few as 3 plies to as many as 80 plies. Special emphasis is placed on characterizing defects in attachment holes and bondlines, in addition to those resulting from impact damage and the inclusion of foreign matter. Image processing through statistical analysis and digital filtering is investigated to enhance the quality and quantify the NDE thermal images when necessary.

Walker, James L.↗

A Study on the Development of Service Quality Index for Incheon International Airport

The main purpose of this study is located at developing Ominibus Monitors System(OMS) for internal management, which will enable to establish standards, finding out matters to be improved, and appreciation for its treatment in a systematic way. It is through developing subjective or objective estimation tool with use importance, perceived level, and complex index at international airport by each principal service items. The direction of this study came towards for the purpose of developing a metric analysis tool, utilizing the Quantitative Second Data, Analysing Perceived Data through airport user surveys, systemizing the data collection-input-analysis process, making data image according to graph of results, planning Service Encounter and endowing control attribution, and ensuring competitiveness at the minimal international standards. It is much important to set up a pre-investigation plan on the base of existent foreign literature and actual inspection to international airport. Two tasks have been executed together on the base of this pre-investigation; one is developing subjective estimation standards for departing party, entering party, and airport residence and the other is developing objective standards as complementary methods. The study has processed for the purpose of monitoring services at airports regularly and irregularly through developing software system for operating standards after ensuring credibility and feasibility of estimation standards with substantial and statistical way.

Lee, Kang Seok↗

Detecting defects that reduce breakdown voltage using machine learning and optical profilometry

Abstract Semiconductor wafer manufacturing relies on the precise control of various performance metrics to ensure the quality and reliability of integrated circuits. In particular, GaN has properties that are advantageous for high voltage and high frequency power devices; however, defects in the substrate growth and manufacturing are preventing vertical devices from performing optimally. This paper explores the application of machine learning techniques utilizing data obtained from optical profilometry as input variables to predict the probability of a wafer meeting performance metrics, specifically the breakdown voltage (V bk ). By incorporating machine learning techniques, it is possible to reliably predict performance metrics that cause devices to fail at low voltage. For diodes that fail at a higher (but still below theoretical) breakdown voltage, alternative inspection methods or a combination of several experimental techniques may be necessary.

42 ENGINEERING↗

Software for Analyzing Laminar-to-Turbulent Flow Transitions

Software assurance is the planned and systematic set of activities that ensures that software processes and products conform to requirements, standards, and procedures. Examples of such activities are the following: code inspections, unit tests, design reviews, performance analyses, construction of traceability matrices, etc. In practice, software development projects have only limited resources (e.g., schedule, budget, and availability of personnel) to cover the entire development effort, of which assurance is but a part. Projects must therefore select judiciously from among the possible assurance activities. At its heart, this can be viewed as an optimization problem; namely, to determine the allocation of limited resources (time, money, and personnel) to minimize risk or, alternatively, to minimize the resources needed to reduce risk to an acceptable level. The end result of the work reported here is a means to optimize quality-assurance processes used in developing software. This is achieved by combining two prior programs in an innovative manner

Chang, Chau-Lyan↗

Evaluation of Hands-Free Devices for the Display of Maintenance Procedures

Over the past year, NASA's focus has turned to crewed long duration and exploration missions. On these journeys, crewmembers will be required to execute thousands of procedures to maintain life support systems, check out space suits, conduct science experiments, and perform medical exams. To support the many complex tasks crewmembers undertake in microgravity, NASA is interested in providing crewmembers a hands-free work environment to promote more efficient operations. The overarching objective is to allow crewmembers to use both of their hands for tasks related to their mission, versus holding a paper manual or interacting with a display. The use of advanced, hands-free tools will undoubtedly make the crewmembers task easier, but they can also add to overall task complexity if not properly designed. A leading candidate technology for supporting a hands-free environment is the Head-Mounted Display (HMD). A more recent technology (e-book reader) that could be easily temp-stowed near the work area is also a potential hands-free solution. Previous work at NASA involved the evaluation of several commercially available HMDs for visual quality, comfort, and fit, as well as suitability for use in microgravity. Based on results from this work, three HMDs were selected for further evaluation (along with an e-book reader), using International Space Station (ISS)-like maintenance procedures. Two evaluations were conducted in the Space Station Mockup and Trainer Facility (SSMTF) located at the NASA Johnson Space Center (building 9). The SSMTF is a full scale, medium fidelity replica of the pressurized portions of the ISS. It supports crew training such as ingress and egress, habitability, and emergency procedures. In each of the two evaluations, the participants performed two maintenance procedures. One maintenance procedure involved inspecting air filters in a life support system and replacing them with a clean filter if one were found to be contaminated. The second maintenance procedure focused on working in a confined space; specifically, pulling down a rack to inspect wiring configurations, and rewiring in a different pattern. The maintenance procedures were selected to assess mobility, tool use, and access to multiple document sources during task performance. That is, the participant had to move from rack to rack, use a wrench, a camera, etc., replace components, and refer to diagrams to complete tasks. A constraint was imposed that the ISS-like format of the procedures was to be retained, and not modified or optimized for the electronic device ("plug and play" approach). This was based on future plans to test with real procedures on ISS.

Ronald B Hoffman↗

A Visual Analytic Platform for Interactive Validation of Human Mobility Simulations

Human mobility insights guide domain experts in an array of decisions, including critical infrastructure design, disaster response, epidemic modeling, national security, and policy making. Due to the inherent noise and privacy concerns in real-world individual-level mobility data, it is often preferred to leverage simulators that generate synthetic mobility data instead. However, it is critical to inspect and validate the output of such simulators to ensure the synthetic data is aligned with the characteristics of the population and the area of interest known to domain experts. While there exist many quantitative approaches for validating synthetic data, we argue it is also important to also validate such data qualitatively to capture aspects that are known to domain experts but difficult to quantify. In this work, we demonstrate a visual analytic platform that empowers domain experts to interact with their simulation outputs along spatial and temporal dimensions. By augmenting automated techniques and human skills, our visual analytic platform is a step towards interactive capabilities for model steering and quality control of mobility simulators.

Monadjemi, Shayan↗