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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.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1980

Process development for automated solar cell and module production. Task 4: Automated array assembly

A process sequence which can be used in conjunction with automated equipment for the mass production of solar cell modules for terrestrial use was developed. The process sequence was then critically analyzed from a technical and economic standpoint to determine the technological readiness of certain process steps for implementation. The steps receiving analysis were: back contact metallization, automated cell array layup/interconnect, and module edge sealing. For automated layup/interconnect, both hard automation and programmable automation (using an industrial robot) were studied. The programmable automation system was then selected for actual hardware development.

Source record↗
NASA NTRS1972

Batch fabrication process development for ferrite logic conductors

A process for fabricating ultrareliable magnetic ferrite logic circuits is described in which the conductors are formed by a combination of two batch type processes - photolithography and electroplating - and a mechanized writing process for completing conductors in the third dimension. Up to 4 turns, through an aperture 1 mm in diameter, are formed by the described process. The number of joints in the conductors is reduced by use of this process to only those which are required for input, output and power connections of a logic block. To demonstrate feasibility, 8-stage magnetic ring counter circuits have been fabricated.

Heckler, C. H., Jr.↗
NASA NTRS1999

Managing the Software Development Process

The goal of any software development project is to produce a product that is delivered on time, within the allocated budget, and with the capabilities expected by the customer and unfortunately, this goal is rarely achieved. However, a properly managed project in a mature software engineering environment can consistently achieve this goal. In this paper we provide an introduction to three project success factors, a properly managed project, a competent project manager, and a mature software engineering environment. We will also present an overview of the benefits of a mature software engineering environment based on 24 years of data from the Software Engineering Lab, and suggest some first steps that an organization can take to begin benefiting from this environment. The depth and breadth of software engineering exceeds this paper, various references are cited with a goal of raising awareness and encouraging further investigation into software engineering and project management practices.

Lubelczky, Jeffrey T.↗
NASA NTRS1997

Virtual Collaborative Simulation Environment for Integrated Product and Process Development

Deneb Robotics is a leader in the development of commercially available, leading edge three- dimensional simulation software tools for virtual prototyping,, simulation-based design, manufacturing process simulation, and factory floor simulation and training applications. Deneb has developed and commercially released a preliminary Virtual Collaborative Engineering (VCE) capability for Integrated Product and Process Development (IPPD). This capability allows distributed, real-time visualization and evaluation of design concepts, manufacturing processes, and total factory and enterprises in one seamless simulation environment.

Gulli, Michael A.↗
NASA NTRS1999

Software Development Processes Applied to Computational Icing Simulation

The development of computational icing simulation methods is making the transition form the research to common place use in design and certification efforts. As such, standards of code management, design validation, and documentation must be adjusted to accommodate the increased expectations of the user community with respect to accuracy, reliability, capability, and usability. This paper discusses these concepts with regard to current and future icing simulation code development efforts as implemented by the Icing Branch of the NASA Lewis Research Center in collaboration with the NASA Lewis Engineering Design and Analysis Division. With the application of the techniques outlined in this paper, the LEWICE ice accretion code has become a more stable and reliable software product.

Levinson, Laurie H.↗
NASA NTRS1998

Process Developed for Forming Urethane Ice Models

A new process for forming ice shapes on an aircraft wing was developed at the NASA Lewis Research Center. The innovative concept was formed by Lewis' Icing Research Tunnel (IRT) team, and the hardware was manufactured by Lewis' Manufacturing Engineering Division. This work was completed to increase our understanding of the stability and control of aircraft during icing conditions. This project will also enhance our evaluation of true aerodynamic wind tunnel effects on aircraft. In addition, it can be used as a design tool for evaluating ice protection systems.

Vannuyen, Thomas↗
NASA NTRS1993

The use of designed experiments in the process development of continuous propellant mixing

A continuous mix pilot plant was constructed at Aerojet Propulsion Division in Sacramento, California to develop a robust propellant mixing process for the full scale plant that was to be built at the NASA Advanced Solid Rocket Motor facility Yellow Creek, Mississippi. The plant was used to conduct dozens of subsystem and full system mixing tests for evaluation of equipment, processing methods, and control schemes for later use at the production plant. As a culmination to this work, a series of designed experiments were conducted using an eight run Taguchi analysis with four factors at two levels each to determine the primary effect of processing parameters on propellant ballistic and mechanical properties. The factors examined in these runs included the propellant production rate (454 (1000) and 622 kg/hr (1371 Ib/hr)), the product temperature out of the mixer (49 (120) and 63 deg C (145 deg F)), mixer screw speed (75 and 90 rpm), and the deaerator excess capacity (20 and 80 percent). Measured response variables included the uncured and cured density, Crawford Bomb liquid strand burning rates, and selected mechanical properties. The experiment revealed that several of the response variables displayed significant changes from run-to-run with the product temperature being the single most important factor. After concluding this experiment, a twenty-six hour confirmation run was conducted to verify the conclusions reached in the designed experiment. The extended run produced over 12,250 kgs (27,000 lbs) of propellant meeting all of the pre-run targeted properties including density (1.803 g/cc (0.065 lb/in(exp 3)) with a 0.12 percent coefficient of variation (CV) at 25 deg C (77 deg F)), liquid strand burn rate (0.889 cm/s (0.350 in/s) with a 0.69 percent CV at 4210 KPa (610 psig), 15.6 deg C (60 deg F)), nominal maximum stress (828 KPa (120 psig) with a 2.84 percent CV, S&E at 25 deg C (77 deg F), 5.08 cm/min (2 in/min)), strain at nominal maximum (47.4 percent with a 3.96 percent CV), and initial tangent modulus (5349 KPa (775 psig) with a 7.26 percent CV).

Campbell, J. A.↗
NASA NTRS1994

Automating the training development process for mission flight operations

Traditional methods of developing training do not effectively support the changing needs of operational users in a multimission environment. The Automated Training Development System (ATDS) provides advantages over conventional methods in quality, quantity, turnaround, database maintenance, and focus on individualized instruction. The Operations System Training Group at the JPL performed a six-month study to assess the potential of ATDS to automate curriculum development and to generate and maintain course materials. To begin the study, the group acquired readily available hardware and participated in a two-week training session to introduce the process. ATDS is a building activity that combines training's traditional information-gathering with a hierarchical method for interleaving the elements. The program can be described fairly simply. A comprehensive list of candidate tasks determines the content of the database; from that database, selected critical tasks dictate which competencies of skill and knowledge to include in course material for the target audience. The training developer adds pertinent planning information about each task to the database, then ATDS generates a tailored set of instructional material, based on the specific set of selection criteria. Course material consistently leads students to a prescribed level of competency.

Scott, Carol J.↗
NASA NTRS1997

Verification and Validation in a Rapid Software Development Process

The high cost of software production is driving development organizations to adopt more automated design and analysis methods such as rapid prototyping, computer-aided software engineering (CASE) tools, and high-level code generators. Even developers of safety-critical software system have adopted many of these new methods while striving to achieve high levels Of quality and reliability. While these new methods may enhance productivity and quality in many cases, we examine some of the risks involved in the use of new methods in safety-critical contexts. We examine a case study involving the use of a CASE tool that automatically generates code from high-level system designs. We show that while high-level testing on the system structure is highly desirable, significant risks exist in the automatically generated code and in re-validating releases of the generated code after subsequent design changes. We identify these risks and suggest process improvements that retain the advantages of rapid, automated development methods within the quality and reliability contexts of safety-critical projects.

Callahan, John R.↗
NASA NTRS2004

Optical Calibration Process Developed for Neural-Network-Based Optical Nondestructive Evaluation Method

A completely optical calibration process has been developed at Glenn for calibrating a neural-network-based nondestructive evaluation (NDE) method. The NDE method itself detects very small changes in the characteristic patterns or vibration mode shapes of vibrating structures as discussed in many references. The mode shapes or characteristic patterns are recorded using television or electronic holography and change when a structure experiences, for example, cracking, debonds, or variations in fastener properties. An artificial neural network can be trained to be very sensitive to changes in the mode shapes, but quantifying or calibrating that sensitivity in a consistent, meaningful, and deliverable manner has been challenging. The standard calibration approach has been difficult to implement, where the response to damage of the trained neural network is compared with the responses of vibration-measurement sensors. In particular, the vibration-measurement sensors are intrusive, insufficiently sensitive, and not numerous enough. In response to these difficulties, a completely optical alternative to the standard calibration approach was proposed and tested successfully. Specifically, the vibration mode to be monitored for structural damage was intentionally contaminated with known amounts of another mode, and the response of the trained neural network was measured as a function of the peak-to-peak amplitude of the contaminating mode. The neural network calibration technique essentially uses the vibration mode shapes of the undamaged structure as standards against which the changed mode shapes are compared. The published response of the network can be made nearly independent of the contaminating mode, if enough vibration modes are used to train the net. The sensitivity of the neural network can be adjusted for the environment in which the test is to be conducted. The response of a neural network trained with measured vibration patterns for use on a vibration isolation table in the presence of various sources of laboratory noise is shown. The output of the neural network is called the degradable classification index. The curve was generated by a simultaneous comparison of means, and it shows a peak-to-peak sensitivity of about 100 nm. The following graph uses model generated data from a compressor blade to show that much higher sensitivities are possible when the environment can be controlled better. The peak-to-peak sensitivity here is about 20 nm. The training procedure was modified for the second graph, and the data were subjected to an intensity-dependent transformation called folding. All the measurements for this approach to calibration were optical. The peak-to-peak amplitudes of the vibration modes were measured using heterodyne interferometry, and the modes themselves were recorded using television (electronic) holography.

Decker, Arthur J.↗
NASA NTRS1978

Silicon solar cell process development, fabrication and analysis

A program plan, baseline process, measurement program and quality control plan were generated. Cutting operations were completed on the silicon sheet material. The first fabrication run of polycrystalline silicon into solar cells by baseline process was completed. Average conversion efficiency for solar cells fabricated by the baseline process from sheet and measured at air mass zero was 10.4%, compared with the control cells, fabricated from single crystal CZ silicon, whose average conversion efficiency was 12.2%.

Source record↗
NASA NTRS1986

Processes and process development in Japan

The commercialization of solar power generation necessitates the development of low cost manufacturing method of silicon suitable for solar cells. The manufacturing methods of semiconductor grade silicon (SEG-Si) and the development of solar grade silicon (SOG-Si) in foreign countries was investigated. It was concluded that the most efficient method of developing such materials was the hydrogen reduction process of trichlorosilane (TCS), using a fluidized bed reactor. The low cost reduction of polysilicon requires cost reductions of raw materials, energy, labor, and capital. These conditions were carefully reviewed. The overall conclusion was that a development program should be based on the TCS-FBR process and that the experimental program should be conducted in test facilities capable of producing 10 tons of silicon granules per year.

Noda, T.↗
NASA NTRS1991

An evaluation of a DO-178A software development process

The guidance and control software (GCS) experiment is an effort to generate realistic software failure data by developing three implementations of a guidance and control software application according to the Radio Technical Commission for Aeronautics RTCA/DO-178A guidelines. The authors describe their approach for evaluating the DO-178A guidelines and give results from the development and verification process for the Pluto implementation. The other names are Mercury and Earth. The preliminary analysis of the Pluto implementation has already yielded some results that will be interesting to track for the other implementations.

Shagnea, Anita M.↗
NASA NTRS2017

Vacuum Infusion Process Development for Conformal Ablative Thermal Protection System Materials

Conformal ablators are low density composite materials comprised of a flexible carbon felt based fibrous substrate and a high surface area phenolic matrix. These materials are fabricated to near net shape by molding the substrate, placing in a rigid matched mold and infusing with liquid resin through a vacuum assisted process. The open mold process, originally developed for older rigid substrate ablators, such as PICA, wastes a substantial amount of resin. In this work, a vacuum infusion process a type of liquid composite molding where resin is directly injected into a closed mold under vacuum is advanced for conformal ablators. The process reduces waste over the state-of-the-art technique. Small, flat samples of Conformal Phenolic Impregnated Carbon Ablator are infused using the new approach and subjected to a range of curing configurations and conditions. Resulting materials are inspected for quality and compared to material produced using the standard process. Lessons learned inform subsequent plans for process scale up.

TPS↗
NASA NTRS1981

OSTA/ADS standards development process

A phased approach to data systems standards was developed. The standards survey, user requirements, methodology survey, and evaluation criteria were completed. Remaining to be done are data system planning interim standards, a concept for implementation of a core applications data service, a data systems policy definition, and full capability data services definition.

Walton, B.↗
NASA NTRS2002

Computed Tomography and Thermography Increases CMC Material and Process Development Efficiency and Testing Effectiveness

Nondestructive characterization techniques have been used to steer development and testing of CMCs. Computed tomography is used to determine the volumetric integrity of the CMC plates and components. Thermography is used to determine the near surface integrity of the CMC plates and components. For process and material development, information such as density uniformity, part delamination, and dimensional tolerance conformity is generated. The information from the thermography and computed tomography is correlated and then specimen cutting maps are superimposed on the thermography images. This enables for tighter data and potential explanation of off nominal test data. Examples of nondestructive characterization utilization to make decisions in process and material development and testing are presented.

Effinger, Michael↗