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At least 703 records · Page 39
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Thermal Response of Thermoplastic Composite Tape During In-situ Consolidation Automated Fiber Placement Using a Laser Heat Source

Composite materials have tremendous potential in the design and manufacture of commercial aircraft due to their high strength-to-weight and stiffness-to-weight properties. However, the use of composite materials is currently limited by high cost and long manufacturing time. The National Aeronautics and Space Administration (NASA) initiated the Hi-rate Composite Aircraft Manufacturing (HiCAM) project to investigate promising composite processing technologies with a goal of vastly improving composite commercial aircraft manufacturing rate (4-6x faster than current production rates). Laser assisted automated fiber placement (AFP) of thermoplastics is a key technology that could increase speed of composite manufacturing, but the technology has not been fully developed. In-situ consolidation AFP of thermoplastics (ICAT) could reduce time and cost even further by eliminating the time and equipment required for post-consolidation. In this work, the thermal response of laser heated ICAT was investigated using forward looking infrared (FLIR) and embedded thermocouples (TCs) to better understand fusion between layers (autohesion). Detailed explanation of the algorithm to combine FLIR and TC data will be presented. In addition, the effect of robot speed on time above melting temperature was quantified.

Laser Heating↗
NASA NTRS2018

History and Status of ALSEP and the Apollo Lunar Data Project

A suite of automated scientific instruments (the Apollo Lunar Surface Experiment Package, or ALSEP) was installed at each of the landing sites of Apollo 12, 14, 15, 16, and 17 from 1969 to 1972. They operated from deployment until decommissioning on 30 September 1977. These data were continuously transmitted to Earth and saved on the Range Tapes, which were recorded at the Manned Space Flight Network stations. These data were also broken out by experiment and sent to the experiment Principal Investigators on what were called the P.I. Tapes. Starting in April 1973 the Range Tape data were stored in digital format on 7-track magnetic tapes, the ARCSAV Tapes. In February 1976, the handling of the Range Tapes was transferred to UT Galveston. They produced 9-track tapes referred to as the Work Tapes. Following the Apollo program the Range and ARCSAV tapes, which were never archived, were lost. The Work Tapes were archived at the National Space Science Data Center (NSSDC). Some investigators archived their individual experiment data with NSSDC as well, but much of the data had minimal documentation, were not in digital form, or were stored in difficult to translate formats. Data from many experiments were never delivered to the NSSDC. The Lunar Data Project was started to address the problem of both missing and not readily usable data. Our effort has resulted in recovery of some of the ARCSAV tapes, recovery and digitization of a large volume of Apollo scientific and technical documentation, and restoration of many ALSEP and other Apollo data collections. Restoration involves deciphering formats, assembling necessary ancillary data (metadata), and packaging data in digital format to be archived with the Planetary Data System (PDS). Recovery of the data from the ARCSAV tapes involved having the tapes read on special equipment and extracting the individual experiment data out of the integrated data stream. We will report on the history and status of the various recovery efforts.

Work Tapes↗
NASA NTRS2019

Spacecraft Adhesive Residue On-Composite Analysis

Tapes are used on space vehicles for numerous reasons. They are used for taping close ports, labeling, and even temporarily attaching something to the spacecraft. This project stemmed from the need to determine which tapes are most effective for our customer's space vehicle during its ground processing stage. During ground processing, there are multiple stages of building where workers need to use tape to temporarily stabilize or close something for a matter of seconds, days, weeks, or even a few months. After peeling these tapes off the flight hardware, the residue left behind by the tape poses potential risks that can lead to incidents, which may not be easily noticeable to the engineers. It is important to identify these issues since nothing can be done once it is in space. The purpose of this project is to assist in research to create an accessible reference for which tapes are preferred on common flight hardware surfaces. Five different substrates and eight tapes were selected for evaluation. The selected substrates were chosen because they comprise the most surface area on the vehicle. The tapes selected were either heritage or new contenders. The adhesive studies were performed for multiple dwell times to study the tendency of different tapes to leave residue behind on various substrates and quantifying that residue. Many other tests were performed to supplement the main objective of the project. These tests included adhesive solubility, peel adhesion, and SEM analyses.

McFadden, Saleah J.↗
DOE OSTI2022

Enhanced critical axial tensile strain limit of CORC ® wires: FEM and analytical modeling

Abstract Conductor on Round Core (CORC ® ) cables and wires are composed of spiraled high-temperature superconducting (HTS) rare-earth barium copper oxide (REBCO) tapes, wound in multiple layers, and can carry very high currents in background magnetic fields of more than 20 T. They combine isotropic flexibility and high resilience to electromagnetic and thermal loads. The brittle nature of HTS tapes limits the maximum allowable axial tensile strain in superconducting cables. An intrinsic tensile strain above about 0.45% will introduce cracks in the REBCO layer of straight HTS tapes resulting in irreversible damage. The helical fashion at which the REBCO tapes are wound around the central core allows tapes to experience only a fraction of the total axial tensile strain applied to the CORC ® wire. As a result, the critical strain limit of CORC ® wires can be increased by a factor of more than 10 that of REBCO tapes. Finite element (FE) and analytical models are developed to predict the performance of CORC ® wires under axial tensile strain. A parametric analysis is carried out by varying the winding angle, the Poisson’s ratio of the CORC ® wire core, the core diameter, and the tape width. The results show that a small variation in winding angle can have a significant impact on the cable’s axial tensile strain tolerance. While the radial contraction of the helically wound tapes in a CORC ® wire under axial tensile strain depends on its winding angle, it is mostly driven by the Poisson’s ratio of the central core, affecting the tape strain state and thus its performance. Contact pressure from multiple layers within the CORC ® wire also affects the CORC ® wire performance. The FE model can be used to optimize the cable design for specific application conditions, resulting in an irreversible strain limit of CORC ® cables and wires as high as 7%.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS1993

Architectural constructs of Ampex DST

The DST 800 automated library is a high performance, automated tape storage system, developed by AMPEX, providing mass storage to host systems. Physical Volume Manager (PVM) is a volume server which supports either a DST 800, DST 600 stand alone tape drive, or a combination of DST 800 and DST 600 subsystems. The objective of the PVM is to provide the foundation support to allow automated and operator assisted access to the DST cartridges with continuous operation. A second objective is to create a data base about the media, its location, and its usage so that the quality and utilization of the media on which specific data is recorded and the performance of the storage system may be managed. The DST tape drive architecture and media provides several unique functions that enhance the ability to achieve high media space utilization and fast access. Access times are enhanced through the implementation of multiple areas (called system zones) on the media where the media may be unloaded. This reduces positioning time in loading and unloading the cartridge. Access times are also reduced through high speed positioning in excess of 800 megabytes per second. A DST cartridge can be partitioned into fixed size units which can be reclaimed for rewriting without invalidating other recorded data on the tape cartridge. Most tape management systems achieve space reclamation by deleting an entire tape volume, then allowing users to request a 'scratch tape' or 'nonspecific' volume when they wish to record data to tape. Physical cartridge sizes of 25, 75, or 165 gigabytes will make this existing process inefficient or unusable. The DST cartridge partitioning capability provides an efficient mechanism for addressing the tape space utilization problem.

Johnson, Clay↗
NASA NTRS2011

A Method of Strengthening Composite/Metal Joints

The term tape setback method denotes a method of designing and fabricating bonded joints between (1) box beams or other structural members made of laminated composite (matrix/ fiber) materials and (2) metal end fittings used to fasten these structural members to other structural members. The basic idea of the tape setback method is to mask the bonded interface between the metallic end fitting and composite member such that the bond does not extend out to the free edges of the composite member. The purpose served by the tape setback method is to strengthen the joints by decoupling stress concentrations from edge defects, which can cause premature failures. A related prior method that serves a similar purpose, involving the use of tapered adherends at the joints, can be too difficult and costly to be acceptable in some applications. The tape setback method offers an easier, less costly alternative. The structural members to which the method was originally applied were box beams in the form of composite tubes having flat faces with rounded corners. The end fittings were plugs made of a low-thermal- expansion nickel/iron alloy (see figure). In computational-simulation studies of tensile and compressive loading of members without tape setback, stresses were found to be concentrated at the free end edges of the composite tubes, and inspection of members that had been subjected to real tension and compression tests showed that cracks started at the free end edges. As applied to these members, the tape setback method makes them less vulnerable to initiation of failure at edge defects produced during fabrication. In real tension tests of comparable members without and with tape setback, the average mean tensile strength of the members with tape setback was found to be 1.9 times that of the members without tape setback.

Polis, Daniel L.↗
DOE OSTI2022

Monitor for measuring mercury emissions

A mercury emissions monitor includes a mercury sensor tape configured to be fed in a reel-to-reel manner between first and second tape reels, wherein the mercury sensor tape includes a thin metallic film configured to form an amalgam with detected mercury. A mercury collection unit is configured to receive into a chamber a sample of a gas containing mercury, wherein the mercury collection unit is further configured to permit passage of portions of the mercury sensor tape through the chamber containing the gas sample so that the amalgam is formed with the thin metallic film. A mercury analysis unit includes a total reflection x-ray fluorescence (“TXRF”) system configured to perform a TXRF analysis of the amalgam, wherein the mercury analysis unit is configured to permit passage of the mercury sensor tape within a proximity of an XRF detector of the TXRF system. The mercury collection unit and the mercury analysis unit are positioned between the first and second tape reels so that the mercury sensor tape can move in a continuous manner from the first tape reel through the chamber of the mercury collection unit, then within sufficient proximity to the XRF detector, to be then taken up onto the second tape reel.

Kumar, Nalin↗
DOE OSTI2023

Reinforcement learning for real-time process control in high-temperature superconductor manufacturing

With high efficiency and low energy loss, high-temperature superconductors (HTS) have demonstrated their profound applications in various fields, such as medical imaging, transportation, accelerators, microwave devices, and power systems. The high-field applications of HTS tapes have raised the demand for producing cost-effective tapes with long lengths in superconductor manufacturing. However, achieving the uniform and enhanced performance of a long HTS tape is challenging due to the unstable growth conditions in the manufacturing process. Although it is confirmed that the process parameters during the advanced metal organic chemical vapor deposition (A-MOCVD) process influence the uniformity of the produced HTS tapes, the high-dimensional process parameter signals and their complicated interactions make it difficult to develop an effective control policy. In this paper, we propose a local measure for the uniformity of HTS tapes to provide instant feedback for our control policy. Then, we model the manufacturing of HTS tapes as a Markov decision process (MDP) with continuous state and action spaces to assess the instant reward in real time in our feedback control model. As our MDP involves continuous and high-dimensional state and action spaces, a neural fitted Q-iteration (NFQ) algorithm is adopted to solve the MDP with artificial neural network (ANN) function approximation. The collinearity of process parameters can restrict our capability of adjusting the process parameters, which is addressed by the principal component analysis (PCA) in our method. The control policy adjusts the PCA of process parameters using the NFQ algorithm. In conclusion, based on our case studies on real A-MOCVD dataset, the obtained control policy increases the average uniformity of tapes by 5.6% and performs especially well on sample HTS tapes with a low uniformity.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS1988

Method of Attaching Strain Gauges to Various Materials

A method is provided to bond strain gauges to various materials. First, a tape with an adhesive backing is placed across the inside of the fixture frame. The strain gauge is flatly placed against the adhesive backing and coated with a thin, uniform layer of adhesive. The tape is then removed from the fixture frame and placed, strain gauge side down, on the material to be tested. If the material is a high reluctance material, the induction heating source is placed on the tape. If the material is a low reluctance material, a plate with a ferric side and a rubber side is placed, ferric side down, onto the tape. The induction heating source is then placed upon the rubber side. If the material is an insulator material, a ferric plate is placed on the tape. The induction heating source is then placed on the ferric plate. The inductive heating source then generates frequenty from 60 to 70 kilocycles to inductively heat either low reluctance material, ferric side, of ferric plate and provides incidental pressure of approximately five pounds per square inch to the tape for two minutes, thoroughly curing the adhesive. The induction heating source, and, if necessary, the plate or ferric plate, are then removed from the tape after one minute. The tape is then removed from the bonded strain gauge.

Schott, Timothy D.↗
NASA NTRS1991

Multilayer ceramic oxide solid electrolyte for fuel cells and electrolysis cells

A unitary layered ceramic structure is disclosed which comprises co-sintered layers. The co-sintered structure comprises a sintered central layer of yttria stabilized zirconia (YSZ) which is about 8 mole percent yttria and having a density of at least about 95% of theoretical, and sintered outer layers of strontium lanthanum manganite (LSM) having the approximate molecular composition La.sub.0.8 Sr.sub.0.2 MnO.sub.3, having a density from about 50 to about 60% of theoretical, and having interconnected porosity from about 40 to 50% with an interconnected pore diameter from about one micron to about five microns. The sintered central layer is sandwiched by and bonded and sintered to the outer layers and is essentially free of significant amounts of manganese. A process for making the unitary composition-of-matter is also disclosed which involves tape casting a LSM tape and then on top thereof casting a YSZ tape. The process comprises presintering LSM powder at 1250.degree. F., crushing the presintered commercially available LSM powder, forming a slurry with the crushed LSM, a binder and solvent, tape casting the slurry and allowing the slurry to air dry. A mixture of commercially available submicron size particle YSZ powder is milled with a dispersant and solvent to disperse the YSZ particles thereby forming a dispersed YSZ slurry. The YSZ slurry is then tape cast on the dried LSM tape. If desired, a third layer of LSM can be cast on top of the dried YSZ layer. After drying the composite LSM/YSZ and LSM/YSZ/LSM tapes are fired at 1300.degree. C. No migration of manganese into the YSZ layer was observed with scanning electron microscope/edax in the sintered multilayer tape.

Schroeder, James E.↗