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The following major processes involved in the production of crystalline-silicon solar cells were discussed: surface preparation, junction formation, metallization, and assembly. The status of each of these processes, and the sequence in which these processes are applied, were described as they were in 1975, as they were in 1985, and what they might be in the future.
This paper describes the architecture and capabilities of the Science Data Processing System (SDPS) for the EOS MLS. The SDPS consists of two major components--the Science Computing Facility and the Science Investigator-led Processing System. The Science Computing Facility provides the facilities for the EOS MLS Science Team to perform the functions of scientific algorithm development, processing software development, quality control of data products, and scientific analyses. The Science Investigator-led Processing System processes and reprocesses the science data for the entire mission and delivers the data products to the Science Computing Facility and to the Goddard Space Flight Center Earth Science Distributed Active Archive Center, which archives and distributes the standard science products.
A high resolution micro-CT system has been assembled and is being used to provide optimal characterization for ultra-thin wall space components. The Glenn Research Center NDE Sciences Team, using this CT system, has assumed the role of inspection vendor for the Advanced Stirling Convertor (ASC) project at NASA. This article will discuss many aspects of the development of the CT scanning for this type of component, including CT system overview; inspection requirements; process development, software utilized and developed to visualize, process, and analyze results; calibration sample development; results on actual samples; correlation with optical/SEM characterization; CT modeling; and development of automatic flaw recognition software. Keywords: Nondestructive Evaluation, NDE, Computed Tomography, Imaging, X-ray, Metallic Components, Thin Wall Inspection
The high-pressure carbon monoxide (HiPco) process, developed at Rice University, has been reported to produce single-walled carbon nanotubes from gas-phase reactions of iron carbonyl in carbon monoxide at high pressures (10-100 atm). Computational modeling is used here to develop an understanding of the HiPco process. A detailed kinetic model of the HiPco process that includes of the precursor, decomposition metal cluster formation and growth, and carbon nanotube growth was developed in the previous article (Part I). Decomposition of precursor molecules is necessary to initiate metal cluster formation. The metal clusters serve as catalysts for carbon nanotube growth. The diameter of metal clusters and number of atoms in these clusters are some of the essential information for predicting carbon nanotube formation and growth, which is then modeled by the Boudouard reaction with metal catalysts. Based on the detailed model simulations, a reduced kinetic model was also developed in Part I for use in reactor-scale flowfield calculations. Here this reduced kinetic model is integrated with a two-dimensional axisymmetric reactor flow model to predict reactor performance. Carbon nanotube growth is examined with respect to several process variables (peripheral jet temperature, reactor pressure, and Fe(CO)5 concentration) with the use of the axisymmetric model, and the computed results are compared with existing experimental data. The model yields most of the qualitative trends observed in the experiments and helps to understanding the fundamental processes in HiPco carbon nanotube production.
As part of NASA's intensive effort to incorporate quantitative risk assessment (QRA) tools in the Agency's decision-making process concerning Space Shuttle risk, NASA has developed a powerful risk assessment tool called the Quantitative Risk Assessment System (QRAS). The QRAS is a tool designed to estimate Space Shuttle risk and evaluate Space Shuttle upgrades. This paper presents an overview of the QRAS with focus on its application for evaluating the risk reduction due to proposed Space Shuttle upgrades. The application includes a case study from the Space Shuttle main engine (SSME). The QRAS overview section of the paper includes the QRAS development process, the technical approach to model development, the QRA quantification methods and techniques, and observations concerning the complex modeling involved in QRAS. The application section of the paper describes a practical case study using QRAS models for evaluating critical Space Shuttle Program upgrades, specifically a proposed SSME nozzle upgrade. This paper presents the method for evaluating the proposed upgrade by comparing the current nozzle (old design with well-established probabilistic models) to the channel wall nozzle (new design at the preliminary design level).
The Engineering Services Contract (ESC) and Information Management Communication Support contract (IMCS) at Kennedy Space Center (KSC) provide services to NASA in respect to flight and ground systems design and development. These groups provides the necessary tools, aid, and best practice methodologies required for efficient, optimized design and process development. The team is responsible for configuring and implementing systems, software, along with training, documentation, and administering standards. The team supports over 200 engineers and design specialists with the use of Windchill, Creo Parametric, NX, AutoCAD, and a variety of other design and analysis tools.
The Software Engineering Process Simulation (SEPS) model is described which was developed at JPL. SEPS is a dynamic simulation model of the software project development process. It uses the feedback principles of system dynamics to simulate the dynamic interactions among various software life cycle development activities and management decision making processes. The model is designed to be a planning tool to examine tradeoffs of cost, schedule, and functionality, and to test the implications of different managerial policies on a project's outcome. Furthermore, SEPS will enable software managers to gain a better understanding of the dynamics of software project development and perform postmodern assessments.
Metal additive manufacturing (AM) processes are being used to enable economical manufacturing of legacy alloys as well as advancing new alloys. Laser powder bed fusion (L-PBF) is a metal AM process that has high maturity and being used to produce a variety of parts for space applications including complex propulsion components. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique space applications such as high-pressure hydrogen environments. NASA HR-1 is a high strength Fe-Ni based superalloy designed to resist high pressure hydrogen environment embrittlement (HEE), oxidation, and corrosion that has been successfully adapted to laser powder directed energy deposition (LP-DED). Insights gained from the NASA HR-1 development for LP-DED have guided the development process for L-PBF. However, adapting NASA HR-1 to L-PBF posed new challenges due to the distinct differences between the additive manufacturing processes. During parameter development, sensitivities were observed in post-processing that necessitated additional optimization of heat treatments. Additionally, the variations in thickness and how it influenced the microstructural response during heat treatment was characterized. Understanding these sensitivities is important to qualification of the material in a L-PBF machine. This ensures that the microstructures and properties of the material maintain consistency in production. This presentation will cover parameter development along with post-processing challenges and solutions will be discussed in addition to key material properties as it pertains to application performance and qualification per NASA-STD-6030. Improvements made by developing a derivative alloy, NASA HR-2, will be highlighted through preliminary small scale parameter development, material characterization, and initial property testing.
Martin Marietta fabricated a hat-section-stiffened compression panel of graphite/epoxy composite that was analyzed to optimize the structural configuration and material distribution. The fabrication processes developed were modified following the appearance of several problems associated with the unique physical properties of the material. Quality control processes were developed, with emphasis in the areas of ultrasonics and X-ray.
The primary objective of this effort was to develop a method for suppressing convective flows during the growth of mercurous chloride crystals by vapor transport in closed tubes to levels approaching those obtained in the microgravity environment. Mercurous chloride was chosen because it is a technologically interesting acoustical optical material whose optical properties are believed to be affected by convective flows. Since the Grashof number scales as the cube of the smallest dimension in the flow system, reduction of the size scale can be extremely effective in reducing unwanted convective flows. However, since materials of practical interest must be grown at least on the cm scale, reduction of the overall growth system is not feasible. But if the region just above the growing crystal could be restricted to a few mm, considerable reduction in flow velocity would result. By suspending an effusive barrier in the growth ampoule just above the growth interface, it should be possible to reduce the convective velocity in this vicinity to levels approaching flows in microgravity. If successful, this growth technique will offer a screening test for proposed space experiments that involve vapor transport to see if reduction of convection will result in improved material and will set a new standard against which the improvements obtained in microgravity may be judged. In addition, it may provide an improved method for preparing materials on Earth whose growth is affected adversely by convection. If the properties of this material can be improved there is a potential commercial interest from Brimrose Inc., who has agreed to fabricate and test devices from the crystals we have grown. This report describes the development of the growth facility, the purification processes developed for preparing the starting material, and the results from growth experiments with and without the effusive baffle. Mercurous chloride turned out to be a more difficult material to deal with than originally anticipated. At growth temperatures, it is extremely sensitive to practically any impurity which causes it to form oxychlorides and/or to decompose into elemental mercury and bichloride of mercury. We were unable to find a suitable method for protecting the magnetic material used to suspend the effusion barrier from the attack of mercurous chloride vapor. Although we were successful in growing single crystals of mercurous chloride without the effusion baffle, they exhibited severe microcracking which we attribute to wall-induced thermal stresses. This leads us to believe that uncontrolled convection may not be the most important problem in the development of this material and a new growth process was attempted that eliminates the wall-induced stress. Unfortunately, the grant ran out before this new method could be adequately tested.
The Friction Stir Welding process developed by The Welding Institute (TWI) has found application throughout the transportation industry. This technique has proven to be a viable joining process for aluminum alloys, producing virtually defect free welds with improved mechanical properties as compared to conventional fusion welding. Lockheed Martin Space Systems - Michoud Operations has been developing this technology for application on aluminum 2219 and 2195 cryogenic tankage since 1995. This effort will come to fruition with implementation on the longitudinal welds of the External Fuel Tank (ET) of the Shuttle. To this end, sub-and full-scale demonstration programs coupled with process development and optimization have been complete. Full size ET tool has been designed, fabricated and are being installed at the Michoud Assembly Facility. Upon completion of the tooling certification and materials allowables testing, production will commence. This implementation will result in increased reliability and safety of flight for the Shuttle.
This paper describes the process of implementing a complex communications protocol that provides reliable delivery of data in multicast-capable, packet-switching telecommunication networks. The protocol, called the Reliable Multicasting Protocol (RMP), was developed incrementally using a combination of formal and informal techniques in an attempt to ensure the correctness of its implementation. Our development process involved three concurrent activities: (1) the initial construction and incremental enhancement of a formal state model of the protocol machine; (2) the initial coding and incremental enhancement of the implementation; and (3) model-based testing of iterative implementations of the protocol. These activities were carried out by two separate teams: a design team and a V&V team. The design team built the first version of RMP with limited functionality to handle only nominal requirements of data delivery. This initial version did not handle off-nominal cases such as network partitions or site failures. Meanwhile, the V&V team concurrently developed a formal model of the requirements using a variant of SCR-based state tables. Based on these requirements tables, the V&V team developed test cases to exercise the implementation. In a series of iterative steps, the design team added new functionality to the implementation while the V&V team kept the state model in fidelity with the implementation. This was done by generating test cases based on suspected errant or off-nominal behaviors predicted by the current model. If the execution of a test in the model and implementation agreed, then the test either found a potential problem or verified a required behavior. However, if the execution of a test was different in the model and implementation, then the differences helped identify inconsistencies between the model and implementation. In either case, the dialogue between both teams drove the co-evolution of the model and implementation. We have found that this interactive, iterative approach to development allows software designers to focus on delivery of nominal functionality while the V&V team can focus on analysis of off nominal cases. Testing serves as the vehicle for keeping the model and implementation in fidelity with each other. This paper describes (1) our experiences in developing our process model; and (2) three example problems found during the development of RMP. Although RMP has provided our research effort with a rich set of test cases, it also has practical applications within NASA. For example, RMP is being considered for use in the NASA EOSDIS project due to its significant performance benefits in applications that need to replicate large amounts of data to many network sites.
This paper describes the process of implementing a complex communications protocol that provides reliable delivery of data in multicast-capable, packet-switching telecommunication networks. The protocol, called the Reliable Multicasting Protocol (RMP), was developed incrementally using a combination of formal and informal techniques in an attempt to ensure the correctness of its implementation. Our development process involved three concurrent activities: (1) the initial construction and incremental enhancement of a formal state model of the protocol machine; (2) the initial coding and incremental enhancement of the implementation; and (3) model-based testing of iterative implementations of the protocol. These activities were carried out by two separate teams: a design team and a V&V team. The design team built the first version of RMP with limited functionality to handle only nominal requirements of data delivery. In a series of iterative steps, the design team added new functionality to the implementation while the V&V team kept the state model in fidelity with the implementation. This was done by generating test cases based on suspected errant or offnominal behaviors predicted by the current model. If the execution of a test was different between the model and implementation, then the differences helped identify inconsistencies between the model and implementation. The dialogue between both teams drove the co-evolution of the model and implementation. Testing served as the vehicle for keeping the model and implementation in fidelity with each other. This paper describes (1) our experiences in developing our process model; and (2) three example problems found during the development of RMP.
This paper describes the process of implementing a complex communications protocol that provides reliable delivery of data in multicast-capable, packet-switching telecommunication networks. The protocol, called the Reliable Multicasting Protocol (RMP), was developed incrementally using a combination of formal and informal techniques in an attempt to ensure the correctness of its implementation. Our development process involved three concurrent activities: (1) the initial construction and incremental enhancement of a formal state model of the protocol machine; (2) the initial coding and incremental enhancement of the implementation; and (3) model-based testing of iterative implementations of the protocol. These activities were carried out by two separate teams: a design team and a V&V team. The design team built the first version of RMP with limited functionality to handle only nominal requirements of data delivery. In a series of iterative steps, the design team added new functionality to the implementation while the V&V team kept the state model in fidelity with the implementation. This was done by generating test cases based on suspected errant or off-nominal behaviors predicted by the current model. If the execution of a test was different between the model and implementation, then the differences helped identify inconsistencies between the model and implementation. The dialogue between both teams drove the co-evolution of the model and implementation. Testing served as the vehicle for keeping the model and implementation in fidelity with each other. This paper describes (1) our experiences in developing our process model; and (2) three example problems found during the development of RMP.
Beginning research into a noisy communication channel analogy of software development process productivity, in order to establish quantifiable behavior and theoretical bounds is discussed. The analogy leads to a fundamental mathematical relationship between human productivity and the amount of information supplied by the developers, the capacity of the human channel for processing and transmitting information, the software product yield (object size) the work effort, requirements efficiency, tool and process efficiency, and programming environment advantage. An upper bound to productivity is derived that shows that software reuse is the only means that can lead to unbounded productivity growth; practical considerations of size and cost of reusable components may reduce this to a finite bound.
Low-energy ion implantation processes for the automated production of silicon solar cells were investigated. Phosphorus ions at an energy of 10 keV and dose of 2 x 10 to the 15th power/sq cm were implanted in silicon solar cells to produce junctions, while boron ions at 25 keV and 5 x 10 to the 15th power were implanted in the cells to produce effective back surface fields. An ion implantation facility with a beam current up to 4 mA and a production throughput of 300 wafers per hour was designed and installed. A design was prepared for a 100 mA, automated implanter with a production capacity of 100 MW sub e/sq cm per year. Two process sequences were developed which employ ion implantation and furnace or pulse annealing. A computer program was used to determine costs for junction formation by ion implantation and various furnace annealing cycles to demonstrate cost effectiveness of these methods.
New chemical-vapor deposition (CVD) process developed for fabricating lightweight Si/SiC mirrors. Process involves three CVD steps: to produce faceplate of mirror; to form lightweight back structure deposited integrally with faceplate; and to deposit layer of optical-grade material onto front surface of faceplate. Figure and finish of mirror fabricated into this latter material. Produces dense, highly pure polycrystalline materials polished to surface figures of high precision and finish.
The NASA High Speed Research (HSR) Program is intended to establish a technology base enabling industry development of an economically viable and environmentally acceptable second generation high speed civil transport (HSCT). The objective of the Configuration Aerodynamics task of the program is the development of aerodynamic drag reduction, stability and control, and propulsion airframe integration technologies required to support the HSCT development process. Aerodynamic design tools are being developed, evaluated, and validated through ground based experimental testing. In addition, methods for ground to flight scaling are being developed and refined.