Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Manufacturing processes”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 613 records · Page 34
All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

A Status of the Advanced Space Transportation Program from Planning to Action

A Technology Plan for Enabling Commercial Space Business was presented at the 48th International Astronautical Congress in Turin, Italy. This paper presents a status of the program's accomplishments. Technology demonstrations have progressed in each of the four elements of the program; (1) Low Cost Technology, (2) Advanced Reusable Technology, (3) Space Transfer Technology and (4) Space Transportation Research. The Low Cost Technology program element is primarily focused at reducing development and acquisition costs of aerospace hardware using a "design to cost" philosophy with robust margins, adapting commercial manufacturing processes and commercial off-the-shelf hardware. The attributes of this philosophy for small payload launch are being demonstrated at the component, sub-system, and system level. The X-34 "Fastrac" engine has progressed through major component and subsystem demonstrations. A propulsion system test bed has been implemented for system-level demonstration of component and subsystem technologies; including propellant tankage and feedlines, controls, pressurization, and engine systems. Low cost turbopump designs, commercial valves and a controller are demonstrating the potential for a ten-fold reduction in engine and propulsion system costs. The Advanced Reusable Technology program element is focused on increasing life through high strength-to-weight structures and propulsion components, highly integrated propellant tanks, automated checkout and health management and increased propulsion system performance. The validation of rocket based combined cycle (RBCC) propulsion is pro,-,ressing through component and subsystem testing. RBCC propulsion has the potential to provide performance margin over an all rocket system that could result in lower gross liftoff weight, a lower propellant mass fraction or a higher payload mass fraction. The Space Transfer Technology element of the program is pursuing technology that can improve performance and dramatically reduce the propellant and structural mass of orbit transfer and deep space systems. Flight demonstration of ion propulsion is progressing towards launch. Ion propulsion is the primary propulsion for Deep Space 1; a flyby of comet West-kohoutek-lkemura and asteroid 3352 McAuliffe. Testing of critical solar-thermal propulsion subsystems have been accomplished and planning is continuing for the flight demonstration of an electrodynamic tether orbit transfer system. The forth and final element of the program, Space Transportation Research, has progressed in several areas of propulsion research. This element of the program is focused at long-term (25 years) breakthrough concepts that could bring launch costs to a factor of one hundred below today's cost or dramatically expand planetary travel and enable interstellar travel.

Lyles, Garry↗
NASA NTRS1998

The Development of an Edible Peanut Protein Film

The peanut is one of the crops chosen for use in NASA's Advanced Life Support Program (ALS). The peanut is a source of both oil and protein. After oil is extracted from the peanut, a protein rich flour remains. An edible peanut protein film is one use for this flour. Two types of film are developed for this study, one set of film contains 10% fat while the other set contains no fat. For film without fat the defatting of the peanut by the Soxhlet method is the first step in the manufacturing process of the film. Secondly, the protein is precipitated at its isoelectric point (pH 4.5) and centrifuged to separate the protein from the non-protein. After freeze-drying the protein it is milled in a ceramic ball mill to decrease particle size and sifted through a series of sieves to determine particle size distribution. Those particles retained on the 100 mesh sieves are utilized for film formation. Larger particles are re-ground and sifted. Five grams of protein is mixed with 50 mL of distilled water, 70 mL of 80% ethanol, 15 mL of 6N ammonium hydroxide and a plasticizer. This mixture is heated for 30 minutes until the temperature reaches 70 C. The mixture is then poured onto a level Teflon coated glass surface. After allowing the film to form overnight under a ventilation hood, it is manually removed from the plate. The processes and methods adopted have created flexible films of uniform thickness that are free of air bubbles. Thickness of films made from defatted peanut protein and partially defatted peanut protein were 0.10 Lm and 0.13 Lm respectively. Films with natural peanut fat are approximately three times as flexible and almost four times as strong as the films made without fat. Further research will be performed to evaluate its mechanical properties. This paper will greatly contribute to food preservation and waste management. Potential applications of this film are edible/biodegradable containers, wrapping for food preservation (against water, oxygen and oil), storage packets for seasonings or other ingredients and encapsulation for pharmaceutical use.

Patrick, N.↗
NASA NTRS1999

Surface Characterization and Contamination

Nondestructive characterization of surface contamination can play an extremely important role in improving quality in manufacturing processes. This area of interest led to the formation of a Surface Contamination Analysis Team (SCAT) at Marshall Space Flight Center, which is primarily concerned with critical bondlines and has provided the major focus for activities under this grant. In addition, determining minute levels of contamination on emerging aerospace systems fabricated from composites has also been an area of interest for which the methods being presented here can be used. Important considerations for the inspection methodologies are good sensitivity, large area coverage, robustness, portability and ease of use for normal production personnel. In parallel with the evaluation of detection methods, considerable effort has been made to developing good, uniform contamination films to use as calibration standards. This activity within itself has presented unique challenges. The development of NIR methods for detecting and identifying contaminants has been in progress for several years. Cooperative efforts between the University, NASA, and Thiokol Corporation has shown some useful results for implementation in both laboratory and on-line procedures.

Workman, Gary L.↗
NASA NTRS1997

Proton Degradation of Light-Emitting Diodes

The severe degradation of optocouplers in space has been shown to be mainly due to proton displacement damage in the light-emitting diodes that are used within the optocouplers. However, a variety of LED technologies can be used in optocouplers and their sensitivity to proton displacement damage varies by about two orders of magnitude. Optocouplers are very simple hybrid devices, and the type of LED can be readily changed by the manufacturers with little cost impact. many optocoupler manufacturers purchase LEDs from outside sources with little knowledge or control of the manufacturing process used for the LED, leading to the possibility of very dramatic differences in radiation response (JPL has observed such differences for one type of optocoupler that is used in a hybrid power converter).

Johnston, A. H.↗
NASA NTRS2000

NARC Rayon Replacement Program for the Space Shuttle Reusable Solid Rocket Motor Nozzle: Screening Summary

Thiokol Corporation and NASA MSFC are jointly developing a replacement for North American Rayon Corporation (NARC) Aerospace Grade Rayon (1650/720 continuous filament), the precursor for the Carbon Cloth Phenolic (CCP) ablatives used in the Space Shuttle Reusable Solid Rocket Motor (RSRM) Nozzles. NARC discontinued production of Aerospace Grade Rayon in September 1997. NASA maintains a stockpile of NARC Rayon to support RSRM production through the summer of 2005. The program plan for selection and qualification of a replacement for NARC rayon was approved in August 1998. Screening activities began in February 1999. The intent of this paper is to provide a summary of the data generated during the screening phase of the NARC Rayon Replacement Program. Twelve cellulose based fibers (rayon and lyocell) were evaluated. These fibers were supplied by three independent vendors. Many of these fibers were carbonized by two independent carbonizers. Each candidate was tested according to standard acceptance test methods at each step of the manufacturing process. Additional testing was performed with the candidate CCPS, including hot fire tests, Process studies and mechanical and thermal characterization. Six of the twelve fiber candidates tested were dropped at the conclusion of Phase 1. The reasons for the elimination of these candidates included; difficulties in processing the material in the whitegoods, carbon and CCP forms; poor composite mechanical performance; and future availability concerns. The remaining six fibers demonstrated enough promise to merit continued evaluation and optimization of the CCP fabrication process. Note: Certain CCP data falls under the restrictions of US export laws, (ITAR, etc.) and will not be included in this paper.

Cook, R. V.↗
NASA NTRS2000

Validation of High Displacement Piezoelectric Actuator Finite Element Models

The paper presents the results obtained by using NASTRAN(Registered Trademark) and ANSYS(Regitered Trademark) finite element codes to predict doming of the THUNDER piezoelectric actuators during the manufacturing process and subsequent straining due to an applied input voltage. To effectively use such devices in engineering applications, modeling and characterization are essential. Length, width, dome height, and thickness are important parameters for users of such devices. Therefore, finite element models were used to assess the effects of these parameters. NASTRAN(Registered Trademark) and ANSYS(Registered Trademark) used different methods for modeling piezoelectric effects. In NASTRAN(Registered Trademark), a thermal analogy was used to represent voltage at nodes as equivalent temperatures, while ANSYS(Registered Trademark) processed the voltage directly using piezoelectric finite elements. The results of finite element models were validated by using the experimental results.

Taleghani, B. K.↗
NASA NTRS2000

Microstructural and Mechanical Property Characterization of Shear Formed Aerospace Aluminum Alloys

Advanced manufacturing processes such as near-net-shape forming can reduce production costs and increase the reliability of launch vehicle and airframe structural components through the reduction of material scrap and part count and the minimization of joints. The current research is an investigation of the processing-microstructure-property relationships for shear formed cylinders of the Al-Cu-Li-Mg-Ag alloy 2195 for space applications and the Al-Cu-Mg-Ag alloy C415 for airframe applications. Cylinders which had undergone various amounts of shear-forming strain were studied to correlate the grain structure, texture, and mechanical properties developed during and after shear forming.

Troeger, Lillianne P.↗
NASA NTRS2001

Free Vibration of Uncertain Unsymmetrically Laminated Beams

Monte Carlo Simulation and Stochastic FEA are used to predict randomness in the free vibration response of thin unsymmetrically laminated beams. For the present study, it is assumed that randomness in the response is only caused by uncertainties in the ply orientations. The ply orientations may become random or uncertain during the manufacturing process. A new 16-dof beam element, based on the first-order shear deformation beam theory, is used to study the stochastic nature of the natural frequencies. Using variational principles, the element stiffness matrix and mass matrix are obtained through analytical integration. Using a random sequence a large data set is generated, containing possible random ply-orientations. This data is assumed to be symmetric. The stochastic-based finite element model for free vibrations predicts the relation between the randomness in fundamental natural frequencies and the randomness in ply-orientation. The sensitivity derivatives are calculated numerically through an exact formulation. The squared fundamental natural frequencies are expressed in terms of deterministic and probabilistic quantities, allowing to determine how sensitive they are to variations in ply angles. The predicted mean-valued fundamental natural frequency squared and the variance of the present model are in good agreement with Monte Carlo Simulation. Results, also, show that variations between plus or minus 5 degrees in ply-angles can affect free vibration response of unsymmetrically and symmetrically laminated beams.

Kapania, Rakesh K.↗
NASA NTRS2001

Assessment of the State-of-the-Art in the Design and Manufacturing of Large Composite Structure

This viewgraph presentation gives an assessment of the state-of-the-art in the design and manufacturing of large component structures, including details on the use of continuous fiber reinforced polymer matrix composites (CFRP) in commercial and military aircraft and in space launch vehicles. Project risk mitigation plans must include a building-block test approach to structural design development, manufacturing process scale-up development tests, and pre-flight ground tests to verify structural integrity. The potential benefits of composite structures justifies NASA's investment in developing the technology. Advanced composite structures technology is enabling to virtually every Aero-Space Technology Enterprise Goal.

Harris, C. E.↗
NASA NTRS2001

Advanced Finite Element Modeling of Low Cycle Fatigue Crack Growth

This document (a viewgraph presentation) assumes a crack-like defect of a size which may be missed in inspection will exist in most critical location of any critical structure or component. Flaw existence assumption is usually, but not always, conservative based on past experiences in NASA and knowledge of manufacturing processes. Cyclic, environmental, and sustained loads used to generate stresses on models. Fracture Mechanics analysis used to predict crack growth and residual strength. Must show that defective structure will still provide four times required mission lifetime. Special exemptions cover redundant structures, low risk parts, etc. Assessments require specialized software tools, experienced analysts, and reliable material crack growth rate test database.

Gregg, Wayne↗
NASA NTRS2001

Microstructural Investigation of High Emittance Glass Coatings on Fibrous Ceramic Insulation

This viewgraph presentation provides an overview of the Space Shuttle Thermal Protection System (TPS) and the various products incorporated in the TPS. There are three tile systems which include pure silica, fibrous refractory composite insulation (FRCI), and alumina enhanced thermal barrier (AETB). Coating systems include reaction cured glass (RCG) and toughened uni-piece insulation (TUFI). The microstructures of these systems are explored as are the manufacturing processes associated with each. Microstructural investigation using methods such as automated X-ray spectral image analysis (AXSIA) is a crucial part of understanding the mechanical nature of these systems.

Ellerby, Don↗
NASA NTRS2001

Displacement Models for THUNDER Actuators having General Loads and Boundary Conditions

This paper summarizes techniques for quantifying the displacements generated in THUNDER actuators in response to applied voltages for a variety of boundary conditions and exogenous loads. The PDE (partial differential equations) models for the actuators are constructed in two steps. In the first, previously developed theory quantifying thermal and electrostatic strains is employed to model the actuator shapes which result from the manufacturing process and subsequent repoling. Newtonian principles are then employed to develop PDE models which quantify displacements in the actuator due to voltage inputs to the piezoceramic patch. For this analysis, drive levels are assumed to be moderate so that linear piezoelectric relations can be employed. Finite element methods for discretizing the models are developed and the performance of the discretized models are illustrated through comparison with experimental data.

Wieman, Robert↗
NASA NTRS2001

A Fiber-Optic Probe Design for Combustion Chamber Flame Detection Applications-Design Criteria, Performance Specifications, and Fabrication Technique

This paper documents the design and development of the fiber-optic probes utilized in the flame detection systems used in NASA Langley Research Center's 8-Foot High Temperature Tunnel (8-ft HTT). Two independent flame detection systems are utilized to monitor the presence and stability of the main-burner and pilot-level flames during facility operation. Due to the harsh environment within the combustor, the successful development of a rugged and efficient fiber-optic probe was a critical milestone in the development of these flame detection systems. The final optical probe design for the two flame detection systems resulted from research that was conducted in Langley's 7-in High Temperature Pilot Tunnel (7-in HTT). A detailed description of the manufacturing process behind the optical probes used in the 8-ft HTT is provided in Appendix A of this report.

Borg, Stephen E.↗
NASA NTRS1995

Designing Flight-Deck Procedures

A complex human-machine system consists of more than merely one or more human operators and a collection of hardware components. In order to operate a complex system successfully, the human-machine system must be supported by an organizational infrastructure of operating concepts, rules, guidelines, and documents. The coherency of such operating concepts, in terms of consistency and logic, is vitally important for the efficiency and safety of any complex system. In high-risk endeavors such as aircraft operations, space flight, nuclear power production, manufacturing process control, and military operations, it is essential that such support be flawless, as the price of operational error can be high. When operating rules are not adhered to, or the rules are inadequate for the task at hand, not only will the system's goals be thwarted, but there may also be tragic human and material consequences. To ensure safe and predictable operations, support to the operators, in this case flight crews, often comes in the form of standard operating procedures. These provide the crew with step-by-step guidance for carrying out their operations. Standard procedures do indeed promote uniformity, but they do so at the risk of reducing the role of human operators to a lower level. Management, however, must recognize the danger of over-procedurization, which fails to exploit one of the most valuable assets in the system, the intelligent operator who is "on the scene." The alert system designer and operations manager recognize that there cannot be a procedure for everything, and the time will come in which the operators of a complex system will face a situation for which there is no written procedure. Procedures, whether executed by humans or machines, have their place, but so does human cognition.

Degani, Asaf↗
NASA NTRS2001

General Overview of the ODC Elimination Effort of the RSRM Program

The purpose of the ODC Elimination Program of the Space Shuttle RSRM Program is to eliminate the usage of 1, 1, 1 trichloroethane (TCA) in all RSRM (Reusable Solid Rocket Motor) manufacturing processes. This program consists of the following phases and objectives: Phase 0 - Convert to greaseless shipping of metal components. Phase 1 - Eliminate TCA vapor degreasing and usage in propellant cleaning operations. Phase 2 - Eliminate TCA usage for hand cleaning operations. Each phase reduces peak TCA consumption (about 1.4 million pounds in 1989) by about 29, 61, and 10 percent, respectively. Phase 0 was completed in 1992, Phase 1 in 1997, and Phase 2 is in progress (about 75% complete). TCA replacement objectives are accomplished by are a series of subscale, full-scale, and static testing outlined by the NASA-funded, ODC Elimination Program.

Evans, Kurt↗
NASA NTRS2002

The Steady Flow Resistance of Perforated Sheet Materials in High Speed Grazing Flows

A study was conducted to determine the effects of high speed grazing air flow on the acoustic resistance of perforated sheet materials used in the construction of acoustically absorptive liners placed in commercial aircraft engine nacelles. Since DC flow resistance of porous sheet materials is known to be a major component of the acoustic resistance of sound suppression liners, the DC flow resistance of a set of perforated face-sheets and linear 'wiremesh' face-sheets was measured in a flow duct apparatus (up to Mach 0.8). Samples were fabricated to cover typical variations in perforated face-sheet parameters, such as hole diameter, porosity and sheet thickness, as well as those due to different manufacturing processes. The DC flow resistance data from perforated sheets were found to correlate strongly with the grazing flow Mach number and the face-sheet porosity. The data also show correlation against the boundary layer displacement thickness to hole-diameter ratio. The increase in resistance with grazing flow for punched aluminum sheets is in good agreement with published results up to Mach 0.4, but is significantly larger than expected above Mach 0.4. Finally, the tests demonstrated that there is a significant increase in the resistance of linear 'wiremesh' type face-sheet materials.

Syed, Asif A.↗
NASA NTRS1993

Scheduling Software

Advanced Scheduling Environment is a software product designed and marketed by AVYX, Inc. to provide scheduling solutions for complex manufacturing environments. It can be adapted to specific scheduling and manufacturing processes and has led to substantial cost savings. The system was originally developed for NASA use in scheduling Space Shuttle flights and satellite activities. AVYX, Inc. is an offshoot of a company formed to provide computer-related services to NASA. TREES-plus, the company's initial product became the programming language for the advanced scheduling environment system.

Source record↗
NASA NTRS1984

Flame Resistant Foam

Solimide manufactured by Imi-Tech Corporation, is a lightweight fire resistant material produced under a manufacturing process that allows it to be uniformly foamed. Can be produced in a variety of densities and structural configurations and remains resilient under exposure to temperatures ranging from minus 300 to plus 500 degrees Fahrenheit. Is resistant to open flame and generates virtually no smoke or toxic by-products. Used in aircraft for its superior damping characteristics, lighter weight and fire barrier properties, it's also applicable to ships and surface transportation systems such as transit cars, trains, buses and automobiles.

Source record↗