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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

The Second European Service Module (ESM-2) Evolutions, Production and Challenges

This paper presents an overview of the Second European Service Module (ESM-2), the second in a series of European Service Modules produced as part of the Barter agreement between NASA and ESA for the Orion Program. The European Industrial consortium is led by the ESA prime contractor Airbus Defence and Space in Bremen. ESA and Airbus signed the ESM-2 contract on 16 February 2017, for this key element of the Orion Exploration Mission 2 (EM-2). EM-2 is the first crewed mission for Orion and will take astronauts farther into the solar system than humanity has ever travelled. EM-2 will also be a historic mission for Europe, as the ESM-2 will be the first European spacecraft to be part of a human transportation system carrying humans beyond low Earth orbit. ESM-2 is mainly a recurring production following ESM-1. Nevertheless, there are a number of important changes being implemented, for example, to incorporate upgrades to further enhance safety and reliability. The challenging delivery schedule for ESM-2 has driven the need to commence manufacturing prior to completion of the qualification on ESM-1. In addition, some requirement deviations and non-compliances approved for ESM-1 have resulted in modifications for ESM-2. In order to manage the competing constraints effectively, the ESM-2 Team has put in place a number of novel approaches to manage schedule, risk, and technical changes. Airbus has set up multi-functional teams according to an approach known as "Major Spacecraft Deliveries" consisting of quality assurance, engineering and procurement. The risk of starting manufacturing prior to qualification is managed through a special risk share agreement. This agreement necessitates rigorous risk reviews across the board for all manufacturing, assembly, integration and test milestones. The ESM-2 changes are managed by Configuration Management, but Airbus has also introduced the Technical Baseline Matrix to provide a transparent top-level overview of the changes from ESM-1 to ESM-2. The tool provides the basis for ESM-2 design and development needs, decisions, as well as the input for the Orion EM-2 Critical Design Review (CDR). The main technical evolutions, status of the production and the novel management approaches for ESM-2 are presented and discussed in the paper.

Orion European Service Module Programme↗
NASA NTRS2017

Forward Contamination of Ocean Worlds: A Stakeholder Conversation

A fundamental requirement for space missions designed to touch “potential habitats” is the single number 10−4, the allowable probability of a single Earth organism contaminating the potential habitat. Many aspects of a mission that affect its complexity and cost – hardware design and manufacture, assembly and test, and mission operations – are driven by this value, so it is important, on the threshold of an era of exploring ocean worlds, to have confidence in it. Yet despite its long pedigree and occasional reviews, we find that the current requirement lacks programmatically defensible justification. At issue are three weaknesses: 1) microbial biology, in particular the science of extremophiles, is a rapidly changing field; 2) forward contamination is both a scientific and an ethical issue, yet no ethics-based conversation is apparent within policy-setting circles; 3) because of these two factors, policy-setting cannot be static. We review the history of the requirement; how the evolving understanding of biology could drive it up or down; how the forward-contamination hazard relates to risk-management practice and to the ethics profession; and how a contemporary stakeholder conversation could adapt lessons already learned by other fields.

Waltemathe, Michael↗
NASA NTRSDate not supplied

LISA EDU Status

LISA will be the first space-based gravitational wave observatory, enabling orders of magnitude greater sensitivity than the state-of-the-art LIGO facility. L3Harris is developing an engineering development unit (EDU) telescope in support of NASA, ESA and the LISA Consortium. The LISA EDU telescope validates a flight-like telescope design and reduces risks associated with stability, materials, assembly, integration, and testing. Mission requirements are unlike any other and require picometer-level stability across the entire telescope’s beam path, even in the presence of temperature variation and jitter. As a result, an all-glass telescope design was developed. The brittle structure represents a new state of the art for stable telescopes, but also introduces challenges with managing assembly, manufacturability, and survivability. From 2019-2024, the LISA EDU project has increased manufacturing readiness and technology readiness for the optical telescope element.

Brian VanRensselaer↗
DOE OSTI2022

Cost Update: Commercial and Advanced Heliostat Collectors

The research team performed a detailed bottom-up manufacturing cost estimate for 2 heliostat designs: i) a commercially available design, the Stellio; and ii) an advanced heliostat design, the Drop-C. The Drop-C is designed and developed by Solar Dynamics (SD) of the United States, whilst the Stellio has been developed primarily by Schlaich Bergermann Und Partner, Sonne Gmbh (sbp) of Germany. The Stellio heliostat has been deployed at commercial scale and is being used at the Hami CSP 50-megawatt electric (MW e ) power tower plant in China. For each design, this includes all components for manufacturing and assembly in a manufacturing facility (e.g., struts and frame) using Design for Manufacturing and Assembly (DFMA), and the purchased parts (e.g., mirrors, control systems, and drives). The field-assembly and construction activities are also considered to determine the installed cost of the modelled solar fields.

14 SOLAR ENERGY↗
DOE OSTI2021

Self-assembly assisted additive manufacturing of thermosets

The present invention relates to formulations including a self-assembly monomer. In particular embodiments, the self-assembly monomer provides a thermoset having beneficial viscoelastic properties for printing methodologies. Methods of making and using such formulations are also provided.

Manning, Kylie↗
NASA NTRS2016

Cryogenic Fiber Optic Assemblies for Spaceflight Environments: Design, Manufacturing, Testing, and Integration

Fiber optic assemblies have been used on spaceflight missions for many years as an enabling technology for routing, transmitting, and detecting optical signals. Due to the overwhelming success of NASA in implementing fiber optic assemblies on spaceflight science-based instruments, system scientists increasingly request fibers that perform in extreme environments while still maintaining very high optical transmission, stability, and reliability. Many new applications require fiber optic assemblies that will operate down to cryogenic temperatures as low as 20 Kelvin. In order for the fiber assemblies to operate with little loss in optical throughput at these extreme temperatures requires a system level approach all the way from how the fiber assembly is manufactured to how it is held, routed, and integrated. The NASA Goddard Code 562 Photonics Group has been designing, manufacturing, testing, and integrating fiber optics for spaceflight and other high reliability applications for nearly 20 years. Design techniques and lessons learned over the years are consistently applied to developing new fiber optic assemblies that meet these demanding environments. System level trades, fiber assembly design methods, manufacturing, testing, and integration will be discussed. Specific recent examples of ground support equipment for the James Webb Space Telescope (JWST); the Ice, Cloud and Land Elevation Satellite-2 (ICESat-2); and others will be included.

Fiber Optic↗
DOE OSTI2025

Mesoscale fractal whey protein particles derived from microscale linear-shaped protein assemblies (Part 1): Manufacturing method and particle characteristics

Whey protein isolates (WPI) are widely used in processed foods for their versatile functional properties. Modifying the structural properties of proteins by assembling them into mesoscale or microscale particles may improve their functionality and broaden their applications. This study aims to manufacture and characterize mesoscale whey protein particles (WPP) derived from WPI. Two types of WPP, WPP1 (0.05 mL/min) and WPP2 (0.25 mL/min), were prepared through a multistep approach involving liquid antisolvent (LAS) precipitation, heat treatment, and microfluidization. Liquid antisolvent precipitation was performed by injecting a 20% (wt/vol) WPI dispersion (pH 7) into an ethanol-glycerol mixture (75:25, vol/vol) under laminar flow, followed by heat treatment at 80°C for 20 min as a particle hardening step. This process produced stable fiber- and ribbon-shaped whey protein assemblies (WPA), which served as precursors to WPP. Subsequent microfluidization (150 MPa, 6 passages) reduced the size of WPA, yielding mesoscale WPP with irregular morphologies and a more uniform size distribution, as revealed by microscopy and dynamic light scattering. ζ-Potential and fluorescence labeling indicated higher surface charge and surface hydrophobicity of WPP compared with untreated WPI. The WPP showed internal mass fractal and surface fractal structures at larger length scales, analyzed using small-angle X-ray scattering. Fourier transform infrared spectroscopy demonstrated an increased fraction of intermolecular β-sheets in WPP, suggesting that hydrogen bonding contributed to their formation. Gel electrophoresis confirmed that disulfide bonds served as the primary cross-links stabilizing the WPP structure. Furthermore, turbidity measurements showed that WPP exhibited superior colloidal phase stability compared with untreated WPI and maintained high colloidal stability under both acidic and neutral pH conditions.

Antisolvent precipitation↗
NASA NTRSDate not supplied

OSAM-2: Plans and Progress for the First Demonstration of Structural Manufacturing in Space

OSAM-2 began as a NASA Space Technology Mission Directorate Tipping Point project in 2016 in which an investment made in ground development and demonstration and/or flight demonstration will result in: Significant advancement of technology’s maturation High likelihood for utilization of technology in commercially fielded space application Significant improvement in ability to successfully bring space technology to market Topic area was “Robotic In-Space Manufacturing and Assembly of Spacecraft and Space Structures” Made In Space, Inc. (now Redwire) proposed Archinaut One, an in-space robotic precision manufacturing and assembly system for larger-than-deployable structures Manufacturing / assembly in the operational environment allows manufactured parts to be designed for that environment (and not for launch loads and need to deploy) In 2020 NASA budget language, NASA began using On-orbit Servicing, Assembly, and Manufacturing Mission 2 (OSAM-2) for Archinaut One Restore-L + SPIDER (SPace Infrastructure DExterous Robot) became OSAM-1 Note: Slide 7 contains video animation, best viewed in presentation mode, run time 2 mins 25 secs.

In-Space Manufacturing↗
NASA NTRS1975

Information and control issues of adaptable-programmable assembly systems for manufacturing and teleoperator applications

The real requirements of a task or task environment must be considered in developing a program for mechanical or electrical manipulators. Manipulation tasks must be analyzed, the information and control needed to accomplish them must be determined, and sensors, movers, controllers, and displays must be designed. Operations research in developing a computer controlled man-supervised multi-moded manipulator for an assembly system is described.

Nevins, J. L.↗
NASA NTRS2000

CSP Manufacturing Challenges and Assembly Reliability

Although the expression of CSP is widely used by industry from suppliers to users, its implied definition had evolved as the technology has matured. There are "expert definition"- package that is up to 1.5 time die- or "interim definition". CSPs are miniature new packages that industry is starting to implement and there are many unresolved technical issues associated with their implementation. For example, in early 1997, packages with 1 mm pitch and lower were the dominant CSPs, whereas in early 1998 packages with 0.8 mm and lower became the norm for CSPs. Other changes included the use of flip chip die rather than wire bond in CSP. Nonetheless the emerging CSPs are competing with bare die assemblies and are becoming the package of choice for size reduction applications. These packages provide the benefits of small size and performance of the bare die or flip chip, with the advantage of standard die packages. The JPL-led MicrotypeBGA Consortium of enterprises representing government agencies and private companies have jointed together to pool in-kind resources for developing the quality and reliability of chip scale packages (CSPs) for a variety of projects. This talk will cover specifically the experience of our consortium on technology implementation challenges, including design and build of both standard and microvia boards, assembly of two types of test vehicles, and the most current environmental thermal cycling test results.

Ghaffarian, Reza↗
NASA NTRS2019

Additive Manufacturing for Human Space Exploration

NASA’s In Space Manufacturing Initiative (ISM): The Case for ISM - Why; ISM Path to Exploration; In Space Robotic Manufacturing and Assembly (IRMA). Additive Manufacturing (AM) Development For Liquid Rocket Engine Space Flight Hardware. MSFC (Marshall Space Flight Center) Standard and Specification For Additively Manufactured Space Flight Hardware.

Additive Manufacturing Exploration↗
NASA NTRS2014

America's Next Great Ship: Space Launch System Core Stage Transitioning from Design to Manufacturing

The Space Launch System (SLS) Program is essential to achieving the Nation's and NASA's goal of human exploration and scientific investigation of the solar system. As a multi-element program with emphasis on safety, affordability, and sustainability, SLS is becoming America's next great ship of exploration. The SLS Core Stage includes avionics, main propulsion system, pressure vessels, thrust vector control, and structures. Boeing manufactures and assembles the SLS core stage at the Michoud Assembly Facility (MAF) in New Orleans, LA, a historical production center for Saturn V and Space Shuttle programs. As the transition from design to manufacturing progresses, the importance of a well-executed manufacturing, assembly, and operation (MA&O) plan is crucial to meeting performance objectives. Boeing employs classic techniques such as critical path analysis and facility requirements definition as well as innovative approaches such as Constraint Based Scheduling (CBS) and Cirtical Chain Project Management (CCPM) theory to provide a comprehensive suite of project management tools to manage the health of the baseline plan on both a macro (overall project) and micro level (factory areas). These tools coordinate data from multiple business systems and provide a robust network to support Material & Capacity Requirements Planning (MRP/CRP) and priorities. Coupled with these tools and a highly skilled workforce, Boeing is orchestrating the parallel buildup of five major sub assemblies throughout the factory. Boeing and NASA are transforming MAF to host state of the art processes, equipment and tooling, the most prominent of which is the Vertical Assembly Center (VAC), the largest weld tool in the world. In concert, a global supply chain is delivering a range of structural elements and component parts necessary to enable an on-time delivery of the integrated Core Stage. SLS is on plan to launch humanity into the next phase of space exploration.

Birkenstock, Benjamin↗
NASA NTRS2017

Work Term Assignment Spring 2017

My tour in the Engineering Robotics directorate exceeded my expectations. I learned lessons about Creo, manufacturing and assembly, collaboration, and troubleshooting. During my first tour, last spring, I used Creo on a smaller project, but had limited experience with it before starting in the Dynamic Systems Test branch this spring. I gained valuable experience learning assembly design, sheet metal design and designing with intent for manufacturing and assembly. These skills came from working both on the hatch and the floor. I also learned to understand the intent of other designers on models I worked with. While redesigning the floor, I was modifying an existing part and worked to understand what the previous designer had done to make it fit with the new model. Through working with the machine shop and in the mock-up, I learned much more about manufacturing and assembly. I used a Dremel, rivet gun, belt sander, and countersink for the first time. Through taking multiple safety training for different machine shops, I learned new machine shop safety skills specific to each one. This semester also gave me new collaborative opportunities. I collaborated with engineers within my branch as well as with Human Factors and the building 10 machine shop. This experience helped me learn how to design for functionality and assembly, not only for what would be easiest in my designs. In addition to these experiences, I learned many lessons in troubleshooting. I was the first person in my office to use a Windows 10 computer. This caused unexpected issues with NASA services and programs, such as the Digital Data Management Server (DDMS). Because of this, I gained experience finding solutions to lockout and freeze issues as well as Creo specific settings. These will be useful skills to have in the future and will be implemented in future rotations. This co-op tour has motivated me more to finish my degree and pursue my academic goals. I intend to take a machining Career Gateway Elective in the Fall to improve my skills in building as well as designing with manufacturing intent. I am also inspired to take more mechatronics CGE courses before I graduate to learn more about the crossover between mechanical and electrical engineering. This semester, I worked on multiple projects and had the opportunity to learn from engineers of different disciplines. I became proficient in Creo 2.0, a program I had not used significantly before. I finished modifying the hatch for 3D print and made sizeable modifications to the nose floor support design. I also gained hands-on experience that will be useful in my engineering career in the future. I would consider all of these major achievements from this spring semester. Lastly, I learned to ask more questions and to search for the right people to find answers which I know will be a valuable skill in the future. This summer, I will be completing my last rotation in the Flight Operations Directorate at Ellington Air Field. After this last tour, I will be returning to school for the Fall, Spring and Summer. I will graduate in August of 2018. I am looking forward to learning more about the different jobs available to engineers. This division works directly with many different types of aircrafts and I am excited to learn more about this focus of engineering. The Aircraft Operations Division values team work greatly and I intend to improve my interpersonal skills by working with them this summer.

Sico, Mallory↗
NASA NTRS1974

Implications of multiplane-multispeed balancing for future turbine engine design and cost

This paper describes several alternative approaches, provided by multiplane-multispeed balancing, to traditional gas turbine engine manufacture and assembly procedures. These alternatives, which range from addition of trim-balancing at the end of the traditional assembly process to modular design of the rotating system for assembly and balancing external to the engine, require attention by the engine designer as an integral part of the design process. Since multiplane-multispeed balancing may be incorporated at one or more of several points during manufacture-assembly, its deliberate use is expected to provide significant cost and performance (reduced vibration) benefits. Moreover, its availability provides the designer with a firm base from which he may advance, with reasonable assurance of success, into the flexible rotor dynamic regime.

Badgley, R. H.↗
NASA NTRS1994

The use of interactive computer vision and robot hand controllers for enhancing manufacturing safety

Current available robotic systems provide limited support for CAD-based model-driven visualization, sensing algorithm development and integration, and automated graphical planning systems. This paper describes ongoing work which provides the functionality necessary to apply advanced robotics to automated manufacturing and assembly operations. An interface has been built which incorporates 6-DOF tactile manipulation, displays for three dimensional graphical models, and automated tracking functions which depend on automated machine vision. A set of tools for single and multiple focal plane sensor image processing and understanding has been demonstrated which utilizes object recognition models. The resulting tool will enable sensing and planning from computationally simple graphical objects. A synergistic interplay between human and operator vision is created from programmable feedback received from the controller. This approach can be used as the basis for implementing enhanced safety in automated robotics manufacturing, assembly, repair and inspection tasks in both ground and space applications. Thus, an interactive capability has been developed to match the modeled environment to the real task environment for safe and predictable task execution.

Marzwell, Neville I.↗
DOE OSTI2022

Standardization and First Lessons Learned of the Prototype HB650 Cryomodule for PIP-II at Fermilab

The prototype High Beta 650 MHz cryomodule (pHB650 CM) has been designed by an integrated design team, consisting of Fermilab (USA), CEA (France), STFC UKRI (UK), and RRCAT (India). The manufacturing and assembly of this prototype cryomodule is being done at Fermilab, whereas the production cryomodules will be manufactured and assembled by STFC-UKRI. As the first PIP-II cryomodule for which standardization was applied, the design, manufacturing and assembly of this cryomodule led to significant lessons being learnt and experiences gathered. These were incorporated into the design of the pre-production Single Spoke Resonator Type 2 cryomodule (ppSSR2 CM) and the pre-production Low Beta 650 MHz cryomodule (ppLB650 CM). This paper presents the pHB650 CM lessons learned and experiences gathered from the design to the lower coldmass assembly and how this cryomodule has a positive impact on all the next Proton Improvement Plan-II (PIP-II) cryomodules due to the standardization set up among SSR and 650 cryomodules.

43 PARTICLE ACCELERATORS↗