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At least 649 records · Page 36

All sources NASA NTRS DOE OSTI

NASA NTRSDate not supplied

Three-Dimensional Reconstruction of Defects and Structures in Additively Manufactured Parts with Automated Serial Sectioning

Metal additive manufacturing (AM) processes have been demonstrated to be effective at reducing costs and lead times associated with complex components for space flight applications. Laser powderbed fusion (L-PBF) is a commonly used AM technology due to the ability to produce complex parts with fine feature resolution in a wide variety of alloys and applications. L-PBF, like many other manufacturing processes, can produce minor flaws in parts when in nominal operation as well as process-escape defects when process abnormalities occur. The effects of the flaws and methods of detecting the flaws are a subject of interest to understand the difficulties in detecting these flaws with current technology and how much risk the flaws or defects pose to potential flight parts. Using a RoboMet.3D automated serial sectioning system, seeded defects as well as minor process flaws can be imaged and reconstructed in three dimensions to compare to non-destructive evaluation (NDE) techniques, such as x-ray computed tomography (CT), neutron CT, and in-situ monitoring. The RoboMet automates the metallography process by automatically grinding, polishing, and imaging samples in a single system and providing the control data for NDE comparisons to know the real size of defects built into coupons. These comparisons provide an understanding behind the technological limitations of the NDE techniques for different alloys. The same serial sectioning methods have also been utilized to characterize the surfaces of parts to reconstruct the surfaces and take measurements of internal features not easily examined with non-destructive methods. Using the RoboMet, fine lattice structures built with L-PBF have been characterized to determine the actual thicknesses of struts and density of the lattice structures. These structures have been used as finer build supports for the L-PBF process, designs for fine catalysts, and other design considerations for small components. The RoboMet data helps to inform the modeling and design efforts around these fine components.

additive manufacturing↗

DOE OSTI2020

The Analog Front-end for the LGAD Based Precision Timing Application in CMS ETL

The analog front-end for the Low Gain Avalanche Detector (LGAD) based precision timing application in the CMS Endcap Timing Layer (ETL) has been prototyped in a 65 nm CMOS mini-ASIC named ETROC0. Serving as the very first prototype of ETL readout chip (ETROC), ETROC0 aims to study and demonstrate the performance of the analog frontend, with the goal to achieve 40 to 50 ps time resolution per hit with LGAD (therefore reach about 30ps per track with two detector-layer hits per track). ETROC0 consists of preamplifier and discriminator stages, which amplifies the LGAD signal and generates digital pulses containing time of arrival and time over threshold information. This paper will focus on the design considerations that lead to the ETROC front-end architecture choice, the key design features of the building blocks, the methodology of using the LGAD simulation data to evaluate and optimize the front-end design. The ETROC0 prototype chips have been extensively tested using charge injection and the measured performance agrees well with simulation. The initial beam test results are also presented, with time resolution of around 33 ps observed from the preamplifier waveform analysis and around 41 ps from the discriminator pulses analysis. A subset of ETROC0 chips have also been tested to a total ionizing dose of 100 MRad with X-ray and no performance degradation been observed.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

Hybrid metal additive/subtractive machine tools and applications

Additive manufacturing creates parts by depositing a preform, typically layer by layer. Subtractive manufacturing involves removing material from a preform to create parts. Hybrid machine tools combine both additive and subtractive processes in the same workspace. They can be used to create parts that meet functional tolerance and surface finish requirements, or to create features that are difficult to produce using additive or subtractive processes alone. Here, this paper describes hybrid metal additive/subtractive machine tools. It covers design considerations, sensors and controls, process management, programming and software, and the impact on the design space. It also identifies future research challenges.

42 ENGINEERING↗

DOE OSTI2021

Implementation and Verification of Cable Bending Stiffness in MoorDyn

The relatively large motions experienced by floating wind turbines and wave energy converters pose a challenge for power cables, whose internal components provide significant bending resistance and are sensitive to deformation. The behavior and associated design considerations of power cables in these highly dynamic applications make coupled analysis relevant for design. Bending stiffness capabilities have recently been added to the lumped-mass mooring dynamics model MoorDyn to enable simulation of dynamic power cables. MoorDyn is a common modeling choice for floating wind energy simulation (often coupled with OpenFAST) and floating wave energy converter simulation (often coupled with WEC-Sim) but the model’s previous line elasticity formulation only considered axial stiffness. To properly capture the dynamics of power cables, a bending stiffness model has been added that approximates cable curvature based on the difference in tangent vectors of adjacent elements. The resulting bending moment is realized by applying forces on adjacent nodes, enabling cable modeling while leaving the underlying lumped-mass formulation unchanged. In this paper, the new bending stiffness implementation is verified in static conditions against analytical solutions and then in a dynamic power cable scenario in comparison with the commercial simulator OrcaFlex. The dynamic scenario uses prescribed motions and includes wave loadings on the cable. Results indicate correct implementation of bending stiffness and show close agreement with OrcaFlex.

50 EE - Wind and Water Power Program - Water (EE-4↗

NASA NTRS1974

Optimal filter design subject to output sidelobe constraints - Theoretical considerations

The design of filters for detection and estimation in radar and communications systems is considered, with inequality constraints on the maximum output sidelobe levels. A constrained optimization problem in Hilbert space is formulated, incorporating the sidelobe constraints via a partial ordering of continuous functions. Generalized versions (in Hilbert space) of the Kuhn-Tucker and duality theorems allow the reduction of this problem to an unconstrained one in the dual space of regular Borel measures.

Fortmann, T. E.↗

NASA NTRS1983

Design, development and flight test of a demonstration advanced avionics system

The design of integrated avionics suitable for general aviation was examined. The program emphasizes the use of data busing, distributed microprocessors, shared electronic displays and data entry devices, and improved functional capability. Design considerations includes cost, reliability, maintainability, and modularity. A demonstration advanced avionics system (DAAS) was designed, built, and flight tested in a Cessna 402, twin engine, general aviation aircraft. The DAAS, and the system architecture are described.

Denery, D. G.↗

NASA NTRS1983

Registration accuracy and attitude accuracy

Since higher spatial resolution is desired by many applications disciplines coupled with registration in the sub-to-1 pixel range, improved registration accuracy has become necessary. The trend is likely to continue, with image data resolution of 10 meters or less being a routine requirement before the end of this decade. This registration accuracy can only be achieved by the combination of registration and attitude accuracy. This report described the need for improving the attitude accuracy. The relationship between registration accuracy and attitude accuracy is shown, along with criteria for design consideration in establishing adequate attitude accuracy. A precise on-board attitude control system design is essential to provide the attitude accuracy needed to support the subpixel accuracy required for registration of higher resolution images.

Fang, A. C.↗

NASA NTRS2003

The James Webb Telescope Instrument Suite Layout: Optical System Engineering Considerations for a Large, Deployable Space Telescope

The James Webb Space Telescope (JWST) is a space-based, infrared observatory designed to study the early stages of galaxy formation in the Universe. The telescope will be launched into an elliptical orbit about the second Lagrange point and passively cooled to 30-50 K to enable astronomical observations from 0.6 to 28 microns. A group from the NASA Goddard Space Flight Center and the Northrop Grumman Space Technology prime contractor team has developed an optical and mechanical layout for the science instruments within the JWST field of view that satisfies the telescope s high-level performance requirements. Four instruments required accommodation within the telescope's field of view: a Near-Infrared Camera (NIRCam) provided by the University of Arizona; a Near-Mared Spectrometer (NIRSpec) provided by the European Space Agency; a Mid-Infrared Instrument (MIRI) provided by the Jet Propulsion Laboratory and a European consortium; and a Fine Guidance Sensor (FGS) with a tunable filter module provided by the Canadian Space Agency. The size and position of each instrument's field of view allocation were developed through an iterative, concurrent engineering process involving the key observatory stakeholders. While some of the system design considerations were those typically encountered during the development of an infrared observatory, others were unique to the deployable and controllable nature of JWST. This paper describes the optical and mechanical issues considered during the field of view layout development, as well as the supporting modeling and analysis activities.

Bos, Brent↗

NASA NTRSDate not supplied

An Evaluation of Composite Primary Structure for Habitat Modules

Boeing studied the use of composite structures in deep space habitats. Compared to metallic modules, composite structures offer increased strength and stiffness with reduced mass. The study evaluated the design considerations and the mass benefits of an all composite primary structure. The composite module design included a continuous pressure shell, composite longerons, and circumferential ring frames. The composite material selected was a high strength carbon fiber and epoxy slit tape prepreg. The manufacturing involved automated fiber placement and utilizing existing facilities and autoclaves. Analysis showed a 33% reduction in primary structure mass and an overall net reduction of nearly 1900 kg compared to metallic modules. The composite module demonstrated improved mass efficiency and opens new possibilities for mission performance in deep space exploration.

Composite↗

DOE OSTI2020

Implementation and Verification of Cable Bending Stiffness in MoorDyn: Preprint

Cable bending stiffness capabilities have been added to MoorDyn to enable modeling of dynamic power cables. The relatively large motions experienced by floating wind turbines and wave energy converters pose a challenge for power cables, whose internal components provide significant bending resistance and are sensitive to deformation. The behavior and associated design considerations of power cables in these highly dynamic applications make coupled analysis relevant for design. MoorDyn is a lumped-mass mooring dynamics model that is used for floating wind energy simulation (often coupled with OpenFAST) and floating wave energy converter simulation (often coupled with WEC-Sim). Its existing line elasticity formulation considers axial stiffness only. To properly capture the dynamics of power cables, a cable bending stiffness model has been added that approximates cable curvature based on the difference in tangent vectors of adjacent line elements. The resulting bending moment is realized by applying forces on adjacent nodes, leaving the underlying lumped-mass formulation unchanged. The bending stiffness implementation is verified in static conditions against analytical solutions and then in a dynamic power cable scenario in comparison with OrcaFlex. The dynamic scenario uses prescribed motions and includes wave loadings on the cable. Results indicate correct implementation of bending stiffness and show close agreement with OrcaFlex.

50 EE - Wind and Water Power Program - Water (EE-4↗

NASA NTRS1972

Full scale subsonic wind tunnel requirements and design studies

The justification and requirements are summarized for a large subsonic wind tunnel capable of testing full-scale aircraft, rotor systems, and advanced V/STOL aircraft propulsion systems. The design considerations and constraints for such a facility are reviewed, and the trades between facility test capability and costs are discussed. The design studies showed that the structural cost of this facility is the most important cost factor. For this reason (and other considerations such as requirements for engine exhaust gas purging) an open-return wind tunnel having two test sections was selected. The major technical problem in the design of an open-return wind tunnel is maintaining good test section flow quality in the presence of external winds. This problem has been studied extensively, and inlet and exhaust systems which provide satisfactory attenuation of the effects of external winds on test section flow quality were developed.

Kelly, M. W.↗

DOE OSTI2021

Fast switching magnet for heavy ion beam separation

This paper presents the design for a switching magnet capable of deflecting 6.5 MeV/u heavy-ion beams with mass-to-charge ratio of 7 by 10 degrees. This magnet can produce variable flat-top pulses from 1 to 30 ms with rise and fall times of less than 0.5 ms at a variable duty cycle of 3–91% into a heavily inductive load. The magnet has a laminated, iron dominated, H-shaped core. Directly-cooled copper pancake coils energize the magnet. We present the magnet design considerations, including the results of extensive computer modeling. Finally, we also present the conceptual engineering design and the studies of magnet yoke fabrication.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

A Radiation-Hard 8-Channel 15-Bit 40-MSPS ADC for the ATLAS Liquid Argon Calorimeter Readout

The custom design of a radiation-hardened, 8-channel, 40-MSPS, 15-bit resolution, 14.2-bit dynamic range, 11.4-ENOB ADC data acquisition ASIC fabricated in a commercial 65-nm triple-well CMOS technology is presented. The ADC is developed for and integrates seamlessly into the readout system for the ATLAS liquid argon (LAr) calorimeter in the high-luminosity large hadron collider (HLLHC) upgrade at CERN, which will require a total of 364 936 ADC channels. A three-stage MDAC+SAR pipelined ADC architecture was designed to meet the physics requirements and scientific goals of the ATLAS experiment. The ADC is a fully self-contained data acquisition system that includes foreground calibration, digital data processing, digital control, and supporting circuitry. The measured performance shows the ADC achieves a competitive dynamic range and SNDR, and it meets or exceeds the ATLAS analog requirements. Radiation tolerance and scalability design considerations were implemented at the device-, circuit-, and system-level. Radiation-hardening-by-design techniques used include redundancy for digital circuits, the use of MiM capacitors, and a hybrid RC-DAC for the ADC core. The ADC ASIC was demonstrated to be robust against the effects of the intense radiation expected in the HL-LHC experimental environment.

DAQ↗

NASA NTRS1984

Solar array: Plasma interactions

Interactions between space systems and their orbital particle and field environments have significant impact on the system's operation and life. Interactions such as radiation damage and aerodynamic drag are considered in designing space systems. There are, however, a number of orbital environmental interactions which become important design considerations only for large or high power systems. Their impact is assessed to ensure successful design. Interactions between higher voltage solar arrays and the space plasma which are of critical concern in designing large orbital photovoltaic power systems are outlined.

Purvis, C. K.↗

NASA NTRS1991

Structural integrity of future aging airplanes

A multitude of design considerations is involved in ensuring the structural integrity of Boeing jet transports that have common design concepts validated by extensive analyses, tests, and three decades of service. As airplanes approach their design service objectives, the incidences of fatigue and corrosion may become widespread. Continuing airworthiness of the aging jet fleet requires diligent performance from the manufacturer, the airlines, and airworthiness authorities. Aging fleet support includes timely development of supplemental structural inspection documents applicable to selected older airplanes, teardown inspections of high-time airframes retired from service, fatigue testing of older airframes, and structural surveys of more than 130 airplanes operated throughout the world. Lessons learned from these activities are incorporated in service bulletin recommendations, production line modifications, and design manual updates. An overview of traditional Boeing fleet support activities and the anticipated benefits for future generations of commercial airplanes based on the continuous design improvement process are presented.

Aging Aircraft↗

NASA NTRS1985

Debris impact on Earth-orbiting spacecraft

The accumulation of Earth-orbiting space debris leads to important new design considerations. Some 5,000 orbiting objects, many of them explosion fragments, are currently being tracked and future collision of these objects with each other is predicted. These collisions will occur at high velocities. Each collision will be explosive, ejecting thousands, of new orbiting objects, in turn increasing the frequency of future collisions. The debris population may thus become self-regenerative, and the future flux of orbiting debris will exceed that of meteoroids. As a result, a large space structure in Earth-orbit for several years has a significant probability of impact by debris objects. As a design problem, debris impact is significantly different from meteoroid impact. Protection against such large objects may require structural measures. The consideration of debris impact in the design of large, Earth-orbiting spacecraft is recommended.

Smith, D. G.↗

NASA NTRS1981

Monolithically integrated active optical devices

Considerations relevant to the monolithic integration of optical detectors, lasers, and modulators with high speed amplifiers are discussed. Some design considerations for representative subsystems in the GaAs-AlGaAs and GaInAs-InP materials systems are described. Results of a detailed numerical design of an electro-optical birefringent filter for monolithic integration with a laser diode is described, and early experimental results on monolithic integration of broadband MESFET amplifiers with photoconductive detectors are reported.

Ballantyne, J.↗

NASA NTRS1971

Instrumentation for radio astronomy measurements aboard the IMP-I spacecraft

The design considerations and performance parameters of a satellite-borne instrumentation system are discussed. The system is designed to make radio astronomy measurements at eight discrete frequencies from 50 kHz to 3.53 MHz. These measurements are to detect solar and Jovian radio frequency bursts and to determine the average cosmic background radiation level down to 50 kHz. Procedures used for preflight and inflight calibration of the radiometer and the ground support equipment used for preflight testing are described.

Haddock, F. T.↗