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NASA NTRS1978

Product pricing in the Solar Array Manufacturing Industry - An executive summary of SAMICS

Capabilities, methodology, and a description of input data to the Solar Array Manufacturing Industry Costing Standards (SAMICS) are presented. SAMICS were developed to provide a standardized procedure and data base for comparing manufacturing processes of Low-cost Solar Array (LSA) subcontractors, guide the setting of research priorities, and assess the progress of LSA toward its hundred-fold cost reduction goal. SAMICS can be used to estimate the manufacturing costs and product prices and determine the impact of inflation, taxes, and interest rates, but it is limited by its ignoring the effects of the market supply and demand and an assumption that all factories operate in a production line mode. The SAMICS methodology defines the industry structure, hypothetical supplier companies, and manufacturing processes and maintains a body of standardized data which is used to compute the final product price. The input data includes the product description, the process characteristics, the equipment cost factors, and production data for the preparation of detailed cost estimates. Activities validating that SAMICS produced realistic price estimates and cost breakdowns are described.

Chamberlain, R. G.↗

NASA NTRS1980

Manufacture of fiber-epoxy test specimens: Including associated jigs and instrumentation

Experimental work on the manufacture and strength of graphite-epoxy composites is considered. The correct data and thus a true assessment of the strength properties based on a proper and scientifically modeled test specimen with engineered design, construction, and manufacture has led to claims of a very broad spread in optimized values. Such behavior is in the main due to inadequate control during manufacture of test specimen, improper curing, and uneven scatter in the fiber orientation. The graphite fibers are strong but brittle. Even with various epoxy matrices and volume fraction, the fracture toughness is still relatively low. Graphite-epoxy prepreg tape was investigated as a sandwich construction with intermittent interlaminar bonding between the laminates in order to produce high strength, high fracture toughness composites. The quality and control of manufacture of the multilaminate test specimen blanks was emphasized. The dimensions, orientation and cure must be meticulous in order to produce the desired mix.

Mathur, S. B.↗

NASA NTRS1979

Space manufacturing III; Proceedings of the Fourth Conference, Princeton University, Princeton, N.J., May 14-17, 1979

Papers are presented on the various technological, political, economic, environmental and social aspects of large manufacturing facilities in space. Specific topics include the potential global market for satellite solar power stations in 2025, the electrostatic separation of lunar soil, methods for extraterrestrial materials processing, the socio-political status of efforts toward the development of space manufacturing facilities, the financing of space industrialization, the optimization of space manufacturing systems, the design and project status of Mass Driver Two, and the use of laser-boosted lighter-than-air-vehicles as heavy-lift launch vehicles. Attention is also given to systems integration in the development of controlled ecological life support systems, the design of a space manufacturing facility to use lunar materials, high performance solar sails, the environmental effects of the satellite power system reference design, the guidance, trajectory and capture of lunar materials ejected from the moon by mass driver, the relative design merits of zero-gravity and one-gravity space environments, consciousness alteration in space and the prospecting and retrieval of asteroids.

Grey, J.↗

NASA NTRS1983

A common geometric data-base approach for computer-aided manufacturing of wind-tunnel models and theoretical aerodynamic analysis

A more automated process to produce wind tunnel models using existing facilities is discussed. A process was sought to more rapidly determine the aerodynamic characteristics of advanced aircraft configurations. Such aerodynamic characteristics are determined from theoretical analyses and wind tunnel tests of the configurations. Computers are used to perform the theoretical analyses, and a computer aided manufacturing system is used to fabricate the wind tunnel models. In the past a separate set of input data describing the aircraft geometry had to be generated for each process. This process establishes a common data base by enabling the computer aided manufacturing system to use, via a software interface, the geometric input data generated for the theoretical analysis. Thus, only one set of geometric data needs to be generated. Tests reveal that the process can reduce by several weeks the time needed to produce a wind tunnel model component. In addition, this process increases the similarity of the wind tunnel model to the mathematical model used by the theoretical aerodynamic analysis programs. Specifically, the wind tunnel model can be machined to within 0.008 in. of the original mathematical model. However, the software interface is highly complex and cumbersome to operate, making it unsuitable for routine use. The procurement of an independent computer aided design/computer aided manufacturing system with the capability to support both the theoretical analysis and the manufacturing tasks was recommended.

See, M. J.↗

NASA NTRS1983

Process and quality verification controls for solid propellant manufacturing

It is pointed out that in-process tests to verify quality and detect discrepant propellant which could compromise motor performance are essential elements of the solid composite propellant manufacturing process. The successful performance of the 260SL-1 and 260SL-2 motors aptly verified the controls used for manufacturing the propellant. The present investigation is concerned with the selected control parameters, and their relationships to composition and final propellant properties. Control performance is evaluated by comparison with processing data experienced in the manufacture of the propellant for the 260SL-1 motor. It is found that the in-process quality verification controls utilized in the propellant manufacturing process for the 260-in. diameter motor contributed significantly to the confidence of successful and predictable motor performance.

Rogers, C. J.↗

NASA NTRS1984

Design versus manufacturing data base management requirements

Data base management systems are valuable manufacturing and design tools as these disciplines are exceptionally information intensive, requiring precise organization and control of data processing and utilization. One such data base manager is the IPAD* system, which was originally developed to support the design process but was expanded to incorporate the additional needs of manufacturing. To set the stage, an overview of the design and manufacturing process is presented. The different functions of computers in these processes are then discussed. Finally, the design and manufacturing requirements for a data base manager are compared and contrasted.

Mckenna, E. G.↗

NASA NTRS1985

Onsite 40-kilowatt fuel cell power plant manufacturing and field test program

A joint Gas Research Institute and U.S. Department of Energy Program was initiated in 1982 to evaluate the use of fuel cell power systems for on-site energy service. Forty-six 40 kW fuel cell power plants were manufactured at the United Technologies Corporation facility in South Windsor, Connecticut, and are being delivered to host utilities and other program participants in the United States and Japan for field testing. The construction of the 46 fully-integrated power plants was completed in January 1985 within the constraints of the contract plan. The program has provided significant experience in the manufacture, acceptance testing, deployment, and support of on-site fuel cell systems. Initial field test results also show that these experimental power plants meet the performance and environmental requirements of a commercial specification. This Interim Report encompasses the design and manufacturing phases of the 40 kW Power Plant Manufacturing and Field Test program. The contract between UTC and NASA also provides UTC field engineering support to the host utilities, training programs and associated manuals for utility operating and maintenance personnel, spare parts support for a defined test period, and testing at UTC of a power plant made available from a preceding program phase. These activities are ongoing and will be reported subsequently.

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NASA NTRS1985

Space manufacturing utilizing the directional electrostatic accretion process

The Directional Electrostatic Accretion Process (DEAP) is described with respect to both the physical process and its application to manufacturing in space. This high precision portable manufacturing method will revolutionize current practices in manufacturing and repair of spacecraft and space structures. The cost effectiveness of this process will be invaluable to future space manufacturing projects.

Alan Mortensen↗

NASA NTRS1984

Space station automation study: Automation requriements derived from space manufacturing concepts,volume 2

Automation reuirements were developed for two manufacturing concepts: (1) Gallium Arsenide Electroepitaxial Crystal Production and Wafer Manufacturing Facility, and (2) Gallium Arsenide VLSI Microelectronics Chip Processing Facility. A functional overview of the ultimate design concept incoporating the two manufacturing facilities on the space station are provided. The concepts were selected to facilitate an in-depth analysis of manufacturing automation requirements in the form of process mechanization, teleoperation and robotics, sensors, and artificial intelligence. While the cost-effectiveness of these facilities was not analyzed, both appear entirely feasible for the year 2000 timeframe.

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NASA NTRS1987

Software for integrated manufacturing systems, part 1

For several years, a broad, unified approach to programming manufacturing cells, factory floors, and other manufacturing systems has been developed. It is based on a blending of distributed Ada, software components, generics and formal models. Among other things the machines and devices which make up the components, and the entire manufacturing cell is viewed as an assembly of software components. The purpose of this project is to reduce cost, increase the reliability and increase the flexibility of manufacturing software. An overview is given of the approach and an experimental generic factory floor controller that was developed using the approach is described. The controller is generic in the sense that it can control any one of a large class of factory floors making an arbitrary mix of parts.

Naylor, A. W.↗

NASA NTRS1987

Software for integrated manufacturing systems, part 2

Part 1 presented an overview of the unified approach to manufacturing software. The specific characteristics of the approach that allow it to realize the goals of reduced cost, increased reliability and increased flexibility are considered. Why the blending of a components view, distributed languages, generics and formal models is important, why each individual part of this approach is essential, and why each component will typically have each of these parts are examined. An example of a specification for a real material handling system is presented using the approach and compared with the standard interface specification given by the manufacturer. Use of the component in a distributed manufacturing system is then compared with use of the traditional specification with a more traditional approach to designing the system. An overview is also provided of the underlying mechanisms used for implementing distributed manufacturing systems using the unified software/hardware component approach.

Volz, R. A.↗

NASA NTRS1991

Manufacturing with the Sun

Concentrated solar radiation is now a viable alternative source for many advanced manufacturing processes. Researchers at the National Renewable Energy Laboratory (NREL) have demonstrated the feasibility of processes such as solar induced surface transformation of materials (SISTM), solar based manufacturing, and solar pumped lasers. Researchers are also using sunlight to decontaminate water and soils polluted with organic compounds; these techniques could provide manufacturers with innovative alternatives to traditional methods of waste management. The solar technology that is now being integrated into today's manufacturing processes offer greater potential for tomorrow, especially as applied to the radiation abundant environment available in space and on the lunar surface.

Murphy, Lawrence M.↗

NASA NTRS1992

Manufacturing Technology Information Analysis Center: Knowledge Is Strength

The Center's primary function is to facilitate technology transfer within DoD, other government agencies and industry. The DoD has recognized the importance of technology transfer, not only to support specific weapon system manufacture, but to strengthen the industrial base that sustains DoD. MTIAC uses an experienced technical staff of engineers and information specialists to acquire, analyze, and disseminate technical information. Besides ManTech project data, MTIAC collects manufacturing technology from other government agencies, commercial publications, proceedings, and various international sources. MTIAC has various means of disseminating this information. Much of the technical data is on user accessible data bases. The Center researches and writes a number of technical reports each year and publishes a newsletter monthly. Customized research is performed in response to specific inquiries from government and industry. MTIAC serves as a link between Government and Industry to strengthen the manufacturing technology base through the dissemination of advanced manufacturing information.

Safar, Michal↗

NASA NTRS1992

Composite intermediate case manufacturing scale-up for advanced engines

This Manufacturing Technology for Propulsion Program developed a process to produce a composite intermediate case for advanced gas turbine engines. The method selected to manufacture this large, complex part uses hard tooling for surfaces in the airflow path and trapped rubber to force the composite against the mold. Subelements were manufactured and tested to verify the selected design, tools, and processes. The most significant subelement produced was a half-scale version of a composite intermediate case. The half-scale subelement maintained the geometry and key dimensions of the full-scale case, allowing relevant process development and structural verification testing to be performed on the subelement before manufacturing the first full-scale case.

Ecklund, Rowena H.↗

NASA NTRS1996

Program Simulates A Modular Manufacturing System

SSE computer program provides simulation environment for modeling manufacturing systems containing relatively small numbers of stations and operators. Designed to simulate manufacturing of apparel, also used in other manufacturing domains. Excellent for small or medium-size firms including those lacking expertise to develop detailed models or have only minimal knowledge in describing manufacturing systems and in analyzing results of simulations on mathematical models. User does not need to know simulation language to use SSE. Used to design new modules and to evaluate existing modules. Originally written in Turbo C v2.0 for IBM PC-compatible computers running MS-DOS and successfully implemented by use of Turbo C++ v3.0.

Schroer, Bernard J.↗

NASA NTRS1995

Risks and reliability of manufacturing processes as related to composite materials for spacecraft structures

Fabricating primary aircraft and spacecraft structures using advanced composite materials entail both benefits and risks. The benefits come from much improved strength-to-weight ratios and stiffness-to-weight ratios, potential for less part count, ability to tailor properties, chemical and solvent resistance, and superior thermal properties. On the other hand, the risks involved include high material costs, lack of processing experience, expensive labor, poor reproducibility, high toxicity for some composites, and a variety of space induced risks. The purpose of this project is to generate a manufacturing database for a selected number of materials with potential for space applications, and to rely on this database to develop quantitative approaches to screen candidate materials and processes for space applications on the basis of their manufacturing risks including costs. So far, the following materials have been included in the database: epoxies, polycyanates, bismalemides, PMR-15, polyphenylene sulfides, polyetherimides, polyetheretherketone, and aluminum lithium. The first four materials are thermoset composites; the next three are thermoplastic composites, and the last one is is a metal. The emphasis of this database is on factors affecting manufacturing such as cost of raw material, handling aspects which include working life and shelf life of resins, process temperature, chemical/solvent resistance, moisture resistance, damage tolerance, toxicity, outgassing, thermal cycling, and void content, nature or type of process, associate tooling, and in-process quality assurance. Based on industry experience and published literature, a relative ranking was established for each of the factors affecting manufacturing as listed above. Potential applications of this database include the determination of a delta cost factor for specific structures with a given process plan and a general methodology to screen materials and processes for incorporation into the current conceptual design optimization of future spacecrafts as being coordinated by the Vehicle Analysis Branch where this research is being conducted.

Bao, Han P.↗

NASA NTRS1999

Optical Evaluation of an As-Manufactured Compound Secondary Concentrator

Secondary concentrators are needed in solar thermal propulsion to further concentrate the energy collected by large lightweight primary concentrators. Although the physics of secondary concentrators has been worked out in detail and the manufacturing has been successfully completed for a ground demonstration, there is a need to quantify the specific performance of as-manufactured concentrators. This paper summarizes the properties of a secondary concentrator manufactured for the Integrated Solar Upper Stage engine ground demonstration in 1997 and presents data obtained from the optic that describe the performance of the as-manufactured component.

Jaworske, Donald A.↗

NASA NTRS1999

Optical Evaluation of an As-Manufactured Compound Secondary Concentrator

Jaworske, Donald A.↗