SEARCH · Engineering Papers

Results for “AFP”

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.

SourceResearch connectionFrom yearThrough year

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

At least 73 records · Page 4

All sources NASA NTRS DOE OSTI

NASA NTRSDate not supplied

Consolidation of Braided Carbon Fiber/ Thermoplastic Tubes by Induction Heating

Thermoplastic composites have experienced renewed enthusiasm within the U.S. aerospace industry, due in part to opportunities for rapidly manufacturing large structures. Unlike the lengthy cure cycles required by thermosets, the thermoplastic matrix prepreg requires only heat and pressure to consolidate consecutive layers of material; with sufficient inter-ply contact time to develop a strong interface. The manufacturing requirements for thermoplastics provide manufacturing flexibility and of particular interest are in-situ consolidation processes; i.e consolidation during layup on a tool. In-situ consolidation removes the time-consuming and costly secondary processing step of autoclave or press consolidation. Process variables which contribute to laminate quality include temperature, heat transfer, inter-ply contact time, and consolidation pressure. Most of the work to date related to in-situ consolidation has been in conjunction with automated fiber placement (AFP), where prepreg tows are consolidated when placed on the tool. Considering this process for a braided structure adds complexity relative to AFP due to the rapid lay-down rate of the braider and simultaneous placement of a multiple prepreg tows. Processes considered for consolidation during AFP could not be applied to a braided part. Alternatively, a fully braided preform could be consolidated on the tool using well established thermoplastic welding techniques. The goal of this effort was to evaluate the effectiveness of induction welding to consolidate braided carbon fiber/thermoplastic composite tubes up to eight plies in thickness. The manufacturing process, thermal characterization, and initial mechanical property data of the consolidated tubes are reported.

In-situ consolidation, induction heating/welding, ↗

NASA NTRS2022

In-Situ Consolidation Automated Fiber Placement of Thermoplastic Composites for High-Rate Aircraft Manufacturing

The National Aeronautics and Space Administration (NASA) initiated the Hi-Rate Composites Aircraft Manufacturing (HiCAM) project in 2021 with the goal of significantly increasing composite structures manufacturing rate in the commercial aircraft industry. The technologies currently under investigation include resin infusion and automated fiber placement (AFP) of novel thermoset materials and thermoplastic composites. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA is particularly focused on assessing composite structure manufacturing utilizing an in-situ consolidation AFP of thermoplastics (ICAT) process employing a recently developed laser heating system. Two semi-crystalline polyaryletherketone thermoplastic tape materials were characterized to ascertain the ICAT process parameters at AFP placement speeds approaching 423 mm/s. The required laser power settings were determined at Electroimpact, measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. An overview of the HiCAM project as well as initial data from ICAT process characterizations are described.

laser heating↗

NASA NTRSDate not supplied

Laser Angle of Incidence Effects on in-Situ Consolidation of Automated Fiber Placement of Polyaryletherketone Composites

NASA and Electroimpact, Inc. ®†† in conjunction with other U.S. industry partners are performing research as a part of the NASA High-rate Composites for Aircraft Manufacturing (HiCAM) Project to fabricate thermoplastic panels using automated fiber placement (AFP) to increase manufacturing rates of aircraft structural composites. This work focuses on evaluating the in-situ consolidation AFP of thermoplastics (ICAT) process. Previous studies of the ICAT process using semi-crystalline, polyaryletherketone (PAEK) slit-tape have resulted in an adequate degree of intimate contact between plies; however, the resulting interlaminar strength have been less than laminates fabricated in an autoclave. To improve these properties, the effect of reducing the laser angle of incidence (AoI) during placement to increase the degree of auto-hesion was evaluated. The AoI of the laser assisted AFP head was varied between 12° and 16° to fabricate multiple quasi- isotropic and unidirectional test panels. Physics-based thermal models developed at the NASA Langley Research Center were utilized to predict the temperature profile. Laminate processing temperature was measured experimentally, and panel quality was evaluated by both non- destructive evaluation (NDE) as well as destructively by photo-microscopy. The effect on interlaminar strength was determined by short beam strength testing. Test results of carbon fiber laminates fabricated by ICAT using polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and low-melt polyaryletherketone (LM-PAEK) at various laser angles of incidence, placement temperatures and placement speeds are presented.

Laser↗

DOE OSTI2015

Characterization of silicon 3D pixel detectors for the ATLAS Forward Physics experiment

The ATLAS Forward Physics (AFP) project aims to measure protons scattered under a small angle from the pp collisions in ATLAS. In order to perform such measurements, a new silicon tracker, together with a time-of-flight detector for pile-up removal, are planned to be installed at ∼210 m from the interaction point and at 2-3 mm from the LHC proton beam. To cope with such configuration and maximize the physics outcome, the tracker has to fulfil three main requirements: endure highly non-uniform radiation doses, due to the very inhomogeneous beam profile, have slim and efficient edges to improve the acceptance of the tracker, and provide good position resolution. Recent laboratory and beam test characterization results of AFP prototypes will be presented. Slim-edged 3D pixel detectors down to 100-200 μm were studied and later non-uniformly irradiated (with a peak fluence of several 10{sup 15} n{sub eq}/cm{sup 2}) to determine the fulfilment of the AFP requirements. (authors)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS2015

Center Planning and Development: Multi-User Spaceport Initiatives

The Vehicle Assembly building at NASAs Kennedy Space Center has been used since 1966 to vertically assemble every launch vehicle, since the Apollo Program, launched from Launch Complex 39 (LC-39). After the cancellation of the Constellation Program in 2010 and the retirement of the Space Shuttle Program in 2011, the VAB faced an uncertain future. As the Space Launch System (SLS) gained a foothold as the future of American spaceflight to deep space, NASA was only using a portion of the VABs initial potential. With three high bays connected to the Crawler Way transportation system, the potential exists for up to three rockets to be simultaneously processed for launch. The Kennedy Space Center (KSC) Master plan, supported by the Center Planning and Development (CPD) Directorate, is guiding Kennedy toward a 21st century multi-user spaceport. This concept will maintain Kennedy as the United States premier gateway to space and provide multi-user operations through partnerships with the commercial aerospace industry. Commercial aerospace companies, now tasked with transporting cargo and, in the future, astronauts to the International Space Station (ISS) via the Commercial Resupply Service (CRS) and Commercial Crew Program (CCP), are a rapidly growing industry with increasing capabilities to make launch operations more economical for both private companies and the government. Commercial operations to Low Earth Orbit allow the government to focus on travel to farther destinations through the SLS Program. With LC-39B designated as a multi-use launch pad, companies seeking to use it will require an integration facility to assemble, integrate, and test their launch vehicle. An Announcement for Proposals (AFP) was released in June, beginning the process of finding a non-NASA user for High Bay 2 (HB2) and the Mobile Launcher Platforms (MLPs). An Industry Day, a business meeting and tour for interested companies and organizations, was also arranged to identify and answer any additional questions posed by potential proposers. After amending the AFP and posting additional material for potential users to consider, proposals are being accepted until July 31, at which point they will be evaluated to determine the proposer which best meets the objectives of the government. By identifying VAB HB2 as available and seeking proposals from the commercial sector for VAB HB2 and MLP use, Center Planning and Development is ensuring Kennedy Space Centers relevance in the evolving launch industry of the 21st century.

AFP↗

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 NTRS2023

Automated Fiber Placement Through Thickness Defect Stacking Optimization

In its 2022 commercial market outlook, Boeing forecasted an 80% increase in the global fleet through 2041 compared to 2019 pre-pandemic levels. This sharp rise in demand will drive pressure onto airframe manufacturers to ramp up production and find more efficient ways to design and manufacture airplanes. Complicating this challenge is the industry’s recent transformation from traditional metal-based airframes towards hybrid composite-metal aircraft. While composites have been used in aviation for decades, aircraft manufacturers are still struggling to design and manufacture quality parts at a high rate. Automated Fiber Placement (AFP) is one of the main manufacturing techniques used to produce large-scale composite parts. After a design has been created, a manufacturing strategy has to be developed based on the working material, part geometry, and machine capabilities. This process planning stage is essential to the AFP workflow and currently requires a high level of manual input from an experienced process planner. In an effort to automate and optimize this stage, the Computer Aided Process Planning (CAPP) module was developed. CAPP assists process planners in identifying optimal starting point location and layup strategy for each ply of a laminate. This Ply-Level Optimization (PLO) phase operates on the quantification of ply quality through predictable geometry-based defects such as gaps, overlaps, angle deviation, and steering. As you move from PLO to Laminate-Level Optimization (LLO) the design space grows exponentially, emphasizing the need for automated optimization. The work presented in this thesis expands CAPP’s functionality by comparing the planned fiber paths through the thickness of the laminate to mitigate stacked area defects and achieve an optimal laminate-level manufacturing strategy. Within CAPP, predicted gap and overlap defects are imported from Vericut Composites Programming (VCP) and then discretized to streamline the through-thickness comparison. Two objective functions are used to score different combinations of ply layup strategies based on defect stacking both globally and locally. Four combinatorial optimization algorithms were coupled with these objective functions to investigate the laminate-level manufacturing strategy design space and converge on the optimal plan. These algorithms were evaluated based on accuracy and efficiency through virtual testing on a complex tool surface. A separate LLO approach was developed to achieve near-optimal laminates in significantly less time. The end result is a software package which greatly reduces the required input from process planners, shortening the design-build cycle time and improving part quality.

AFP↗

NASA NTRSDate not supplied

ISAAC Integrated Structural Assembly of Advanced Composites

The NASA Langley Research Center obtained the Integrated Structural Assembly of Advanced Composites (ISAAC) robotic system in 2014 to add state-of-the-art automated manufacturing of composites to our traditional in-house design, analysis, and experimentation capabilities. ISAAC is used to explore fabrication of parts with novel designs and for research into new composite manufacturing techniques. Automated fiber placement (AFP) was the initial manufacturing capability on ISAAC and has been used to support a range of aeronautics and space projects including the Advanced Composites Project (ACP), Composites for Exploration Upper Stage (CEUS), and Advanced Air Transportation Technologies (AATT). In addition to AFP, ISAAC can now provide through-thickness reinforcement of composites by adding stitches through dry fabric prior to resin infusion. Stitching is of interest since it can improve damage tolerance, reduce final assembly time, and reduce inspection requirements. ISSAC can stitch traditional single-needle seams and perform stitching operations using two needles when access is only available to one side of the part. Stitching capability is being advanced in the High-Rate Composites Aircraft Manufacturing (HiCAM) project today. This lecture will describe the work with ISAAC today and new exciting plans for the future.

automated fiber placement↗

NASA NTRSDate not supplied

Integration of Structural Analysis and Manufacturing Process Planning for Global Optimization with Automated Fiber Placement

Design of mass-efficient composite structures intended for Automated Fiber Placement (AFP) requires close interaction between structural analysis and manufacturing process planning. Tools exist for each of these disciplines, but software interplay has been insufficient for rapid and efficient design iteration. Within the NASA Advanced Composites Consortium (ACC), the Design for Manufacturing (DFM) task has made significant progress towards linking these disciplines and respective software – HyperX (design), CAPP (process planning), and VCP (tool path generation). The initial focus in previous work was on data exchange between disciplines. The ability to both export and consume composite design and manufacturing data to and from each tool. This paper focuses on the effort to automate and streamline the connection between the tools listed above, with the goal of being able to automatically generate a composite AFP design that is mass-efficient and manufacturable. The optimization method being pursued is a bi-level approach, where each tool performs optimization within its discipline. The optimization in HyperX is focused on mass and laminate strength, while CAPP is focused on maximizing manufacturability. VCP is used to generate fiber paths for each design iteration. These sub-processes are wrapped with a global level optimization, driven by HyperX, used to converge the design. This paper describes the current state of this effort, which is a completed HyperX-VCP iteration loop and initial work on the HyperX-CAPP iteration loop. Additionally, example results are shown for a wind blade structure with double curvature.

Automated Fiber Placement↗

DOE OSTI2019

Population-based assessment of the national comprehensive cancer network recommendations for baseline imaging of hepatocellular carcinoma

This analysis aims to evaluate the performance characteristics of alternative baseline imaging thresholds in a cohort of hepatocellular carcinoma (HCC) patients from the Surveillance, Epidemiology, and End Results (SEER) database. HCC patients within the SEER database (2010–2015) who had complete information on clinical T and N stages as well as complete information on metastatic sites were eligible for the current study. Various performance characteristics associated with baseline imaging were investigated, including specificity, sensitivity, positive likelihood ratio (LR), negative LR, number needed to investigate (NNI), negative predictive value (NPV), positive predictive value (PPV), and accuracy. A total of 27,201 HCC patients were included. Based on current recommendations that advocate for the use of cross-sectional chest imaging in all newly diagnosed cases of HCC, these recommendations would yield a PPV of 5.0% for the detection of lung metastases. This would translate to an NNI of 20.0. When T1N0 patients were excluded from routine chest or bone imaging, this resulted in a PPV of 6.8% for the identification of lung metastases and an NNI of 14.7. Likewise, this translated to a PPV of 4.6% for the identification of bone metastases and an NNI of 21.7. Similarly, when patients with T1N0 disease and normal alpha-fetoprotein (AFP) were excluded from routine imaging, this resulted in a PPV of 5.6% for the identification of lung metastases and an NNI of 17.8. Also, this translated to a PPV of 3.8% for the identification of bone metastases and an NNI of 26.3. The current study suggests that the omission of routine baseline chest imaging may be considered in selected patients with asymptomatic early-stage HCC and normal AFP.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

DOE OSTI2022

Characterization of the miniPlanacon XPM85112-S-R2D2 MCP-PMT with custom modified backend electronics

We report the results of the measurements of three pieces of the new Photonis miniPLANACON microchannel-plate photomultipliers (MCP-PMTs) intended for use in the demanding environment of the Large Hadron Collider (LHC) beamline as a part of the AFP Time-of-Flight detector. These photomultipliers were modified in cooperation with the manufacturer by using a custom backend and were subjected to numerous tests, with the focus on the rate capability and crosstalk behaviour. We determined that the two of them with a lower MCP resistance are able to operate without significant saturation at an anode current density of 1 μA/cm 2 . These two are, therefore, suitable for the intended use and are currently installed as part of the AFP detector packages.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2018

Structure-Guided Analyses of a Key Enzyme Involved in the Biosynthesis of an Antivitamin

RosB catalyzes the formation of 8-aminoriboflavin 5'-phosphate (AFP), the key intermediate in roseoflavin biosynthesis, from the metabolic precursors riboflavin 5'-phosphate (RP, also known as FMN) and glutamate. Here, the conversion of the aromatic methyl group at position 8 in RP into the aromatic amine in AFP occurs via two intermediates, namely, the aldehyde 8-formyl-RP and the acid 8-carboxy-RP. To gain insights into the mechanism for this chemically challenging transformation, we utilized a structure-based approach to identify active site variants of RosB that stall the reaction at various points along the reaction coordinate. Crystal structures of individual variants in complex with different reaction intermediates, identified via mass spectroscopic analysis, illuminate conformational changes that occur at the active site during multistep conversion. These studies provide a plausible route for the progression of the reaction and a molecular rationale for the mechanism of this unusual biocatalyst.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2016

Structure and collective dynamics of hydrated anti-freeze protein type III from 180 K to 298 K by X-ray diffraction and inelastic X-ray scattering

We investigated hydrated antifreeze protein type III (AFP III) powder with a hydration level h (=mass of water/mass of protein) of 0.4 in the temperature range between 180 K and 298 K using X-ray diffraction and inelastic X-ray scattering (IXS). The X-ray diffraction data showed smooth, largely monotonic changes between 180 K and 298 K without freezing water. Meanwhile, the collective dynamics observed by IXS showed a strong change in the sound velocity at 180 K, after being largely temperature independent at higher temperatures (298–220 K). We interpret this change in terms of the dynamic transition previously discussed using other probes including THz IR absorption spectroscopy and incoherent elastic and quasi-elastic neutron scattering. This finding suggests that the dynamic transition of hydrated proteins is observable on the subpicosecond time scale as well as nano- and pico-second scales, both in collective dynamics from IXS and single particle dynamics from neutron scattering. Moreover, it is most likely that the dynamic transition of hydrated AFP III is not directly correlated with its hydration structure.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2019

All-Optical Processing with Dynamic Frequency Transformations

We propose an all-optical frequency processor (AFP) for transparent optical networking, based on optical pulse shaping and electro-optic phase modulation. We numerically examine the AFP for frequency channel hopping and broadcasting operations, and show the required number of components scales favorably with the network size.

Lu, Hsuan-Hao↗

DOE OSTI2019

All-Optical Frequency Processor for Networking Applications

Herein, we propose an electro-optic approach for transparent optical networking, in which frequency channels are actively transformed into any desired mapping in a wavelength-multiplexed environment. Based on electro-optic phase modulators and Fourier-transform pulse shapers, our all-optical frequency processor (AFP) is examined numerically for the specific operations of frequency channel hopping and broadcasting, and found capable of implementing these transformations with favorable component requirements. Extending our analysis via a mutual-information–based metric for system optimization, we show how to optimize transformation performance under limited resources in a classical context, contrasting the results with those found using metrics motivated by quantum information, such as fidelity and success probability. Given its compatibility with on-chip implementation, as well as elimination of optical-to-electrical conversion in frequency channel switching, the AFP looks to offer valuable potential in silicon photonic network design, as well as the realization of high-dimensional frequency-bin gates.

42 ENGINEERING↗

DOE OSTI2015

Report on the 2011 Critical Assessment of Function Annotation (CAFA) meeting

The Critical Assessment of Function Annotation meeting was held July 14-15, 2011 at the Austria Conference Center in Vienna, Austria. There were 73 registered delegates at the meeting. We thank the DOE for this award. It helped us organize and support a scientific meeting AFP 2011 as a special interest group (SIG) meeting associated with the ISMB 2011 conference. The conference was held in Vienna, Austria, in July 2011. The AFP SIG was held on July 15-16, 2011 (immediately preceding the conference). The meeting consisted of two components, the first being a series of talks (invited and contributed) and discussion sections dedicated to protein function research, with an emphasis on the theory and practice of computational methods utilized in functional annotation. The second component provided a large-scale assessment of computational methods through participation in the Critical Assessment of Functional Annotation (CAFA). The meeting was exciting and, based on feedback, quite successful. There were 73 registered participants. The schedule was only slightly different from the one proposed, due to two cancellations. Dr. Olga Troyanskaya has canceled and we invited Dr. David Jones instead. Similarly, instead of Dr. Richard Roberts, Dr. Simon Kasif gave a closing keynote. The remaining invited speakers were Janet Thornton (EBI) and Amos Bairoch (University of Geneva).

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1990

IUE observations of comets P/Brorsen-Metcalf and Okazaki-Levy-Rudenko

Comet P/Brorsen-Metcalf (1989c) was observed with the International Ultraviolet Explorer (IUE) on several dates from 27 July 1989 through 5 August 1989; comet Okazaki-Levy-Rudenko (1989r) was observed in low dispersion with IUE on 2 and 22 December 1989. The water production rates for P/Brorsen-Metcalf were derived from OH measurements using the vectorial model of Festou (1981). Included also are the water production rates for Okazaki-Levy-Rudenko. Two estimates of the water production rate from the O I emission around 1304 A(octogons) are included. The ultraviolet continuum was not reliably measurable in comet P/Brorsen-Metcalf in most of the spectra, but Afp is approximately 30 cm for 2 August. For the comet Okazaki-Levy-Rudenko, an Afp = 50 cm was derived for 22 December. Both comets have very little dust compared to other recently observed comets. The ratio of CS to water production rates are presented. Relative to water, both comets had less CS than P/Halley in the same range of heliocentric distances. The CS production rates were obtained from a Haser model, assuming a short-lived parent (CS2). Because the dynamic range of the IUE spectrographs are limited, not all species can be measured in each spectrum. The P/Brorsen-Metcalf spectra from 31 July and 3 August were obtained from the NSSDC Archives. Due to the observing technique used for these spectra, the exposure time and hence, the brightnesses and derived quantities have a small uncertainty associated with them.

Roettger, E. E.↗

NASA NTRS1997

Advanced Technology Composite Fuselage - Manufacturing

The goal of Boeing's Advanced Technology Composite Aircraft Structures (ATCAS) program is to develop the technology required for cost-and weight-efficient use of composite materials in transport fuselage structure. Carbon fiber reinforced epoxy was chosen for fuselage skins and stiffening elements, and for passenger and cargo floor structures. The automated fiber placement (AFP) process was selected for fabrication of stringer-stiffened and sandwich skin panels. Circumferential and window frames were braided and resin transfer molded (RTM'd). Pultrusion was selected for fabrication of floor beams and constant-section stiffening elements. Drape forming was chosen for stringers and other stiffening elements cocured to skin structures. Significant process development efforts included AFP, braiding, RTM, autoclave cure, and core blanket fabrication for both sandwich and stiffened-skin structure. Outer-mold-line and inner-mold-line tooling was developed for sandwich structures and stiffened-skin structure. The effect of design details, process control and tool design on repeatable, dimensionally stable, structure for low cost barrel assembly was assessed. Subcomponent panels representative of crown, keel, and side quadrant panels were fabricated to assess scale-up effects and manufacturing anomalies for full-scale structures. Manufacturing database including time studies, part quality, and manufacturing plans were generated to support the development of designs and analytical models to access cost, structural performance, and dimensional tolerance.

Wilden, K. S.↗