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NASA NTRS2008

Metrology - Beyond the Calibration Lab

We rely on data from measurements every day; a gas-pump, a speedometer, and a supermarket weight scale are just three examples of measurements we use to make decisions. We generally accept the data from these measurements as "valid." One reason we can accept the data is the "legal metrology" requirements established and regulated by the government in matters of commerce. The measurement data used by NASA, other government agencies, and industry can be critical to decisions which affect everything from economic viability, to mission success, to the security of the nation. Measurement data can even affect life and death decisions. Metrology requirements must adequately provide for risks associated with these decisions. To do this, metrology must be integrated into all aspects of an industry including research, design, testing, and product acceptance. Metrology, the science of measurement, has traditionally focused on the calibration of instruments, and although instrument calibration is vital, it is only a part of the process that assures quality in measurement data. For example, measurements made in research can influence the fundamental premises that establish the design parameters, which then flow down to the manufacturing processes, and eventually impact the final product. Because a breakdown can occur anywhere within this cycle, measurement quality assurance has to be integrated into every part of the life-cycle process starting with the basic research and ending with the final product inspection process. The purpose of this paper is to discuss the role of metrology in the various phases of a product's life-cycle. For simplicity, the cycle will be divided in four broad phases, with discussions centering on metrology within NASA. .

Mimbs, Scott M.↗

NASA NTRS1996

Cost Effective Prototyping

This laboratory exercise seeks to develop a cost effective prototype development. The exercise has the potential of linking part design, CAD, mold development, quality control, metrology, mold flow, materials testing, fixture design, automation, limited parts production and other issues as related to plastics manufacturing.

Wickman, Jerry L.↗

NASA NTRS1980

Development and demonstration of manufacturing processes for fabricating graphite/LARC-160 polyimide structural elements, part 4, paragraph B

A quality assurance program was developed which included specifications for celion/LARC-160 polyimide materials and quality control of materials and processes. The effects of monomers and/or polymer variables and prepeg variables on the processibility of celion/LARC prepeg were included. Processes for fabricating laminates, honeycomb core panels, and chopped fiber moldings were developed. Specimens and conduct tests were fabricated to qualify the processes for fabrication of demonstration components.

Source record↗

NASA NTRSDate not supplied

Quantifying Burned Area and Smoke from Prescribed and Smaller Fires: West Palm Beach, Florida

In the Central and Southeastern U.S. (C&SE), small, short-lived fires are often underestimated by satellites due to their size, timing, cloud cover, and rapid regrowth or plowing after burns. Satellite data are essential for the National Emissions Inventory, as ground-based inventories are historically incomplete and geographically inconsistent. Agricultural burning, a widespread annual practice in many U.S. regions, significantly impacts air quality on local to regional scales. As part of NASA’s Health and Air Quality Applied Sciences (HAQAST) team, we develop a burned area inventory to account for these ‘missing’ small fires. Our study focuses on West Palm Beach, FL, near Lake Okeechobee, where agriculture fields are burned annually fall-spring for crop management and harvest. This region poses challenges for satellite detection due to frequent rain, flooding, and cloud cover.

Emily Gargulinski↗

NASA NTRS1988

Quality measures and assurance for AI (Artificial Intelligence) software

This report is concerned with the application of software quality and evaluation measures to AI software and, more broadly, with the question of quality assurance for AI software. Considered are not only the metrics that attempt to measure some aspect of software quality, but also the methodologies and techniques (such as systematic testing) that attempt to improve some dimension of quality, without necessarily quantifying the extent of the improvement. The report is divided into three parts Part 1 reviews existing software quality measures, i.e., those that have been developed for, and applied to, conventional software. Part 2 considers the characteristics of AI software, the applicability and potential utility of measures and techniques identified in the first part, and reviews those few methods developed specifically for AI software. Part 3 presents an assessment and recommendations for the further exploration of this important area.

Rushby, John↗

NASA NTRS1995

An Overview of the Quality Function Deployment (QFD) Technique

QFD is a product planning tool and a process methodology that enables all organizations, departments, and individuals in a business or a project to systematically focus on the critical performance, functions, and/or characteristics of a product that are the most important to the customer. It is part of the Total Quality Management (TQM) concept.. This presentation describes the objectives of QFD, the process for implementing the technique, the benefits derived from proper implementation, the kinds of systems where QFD is best utilized, what the success factors are, how QFD works, some guidelines for selection of a QFD team, and the functional roles of key team members.

Quality Function Deployment QFD customer focus cus↗

NASA NTRS1992

Design of fabric preforms for double diaphragm forming

Resin Transfer Molding (RTM) has the potential of becoming one of the most cost effective ways of producing composite structures since the raw materials used, resin and dry fabric, are less costly than prepregs. Unfortunately these low material costs are offset by the high labor costs incurred to layup the dry fabric into 3D shapes. To reduce the layup costs, double diaphragm forming is being investigated as a potential technique for creating a complex 3D preform from a simple flat layup. As part of our effort to develop double diaphragm forming into a production capable process, we have undertaken a series of experiments to investigate the interactions between process parameters, mold geometry, fabric weave, tow size, and the quality of the formed part. The results of these tests will be used to determine the forming geometry limitations of double diaphragm forming and to characterize the formability of fabric configurations. An important part of this work was the development of methods to measure and analyze fiber orientations, deformation angles, tow spreading, and shape conformation of the formed parts. This paper will describe the methods used to mark plies, the double diaphragm forming process, the techniques used to measure the formed parts, and the calculation of the parameters of interest. The results can be displayed as 3D contour plots. These experimental results have also been used to verify and improve a computer model which simulates the draping of fabrics over 3D mold shapes.

Luby, Steven↗

NASA NTRS1993

Improved ceramic slip casting technique

A primary concern in modern fluid dynamics research is the experimental verification of computational aerothermodynamic codes. This research requires high precision and detail in the test model employed. Ceramic materials are used for these models because of their low heat conductivity and their survivability at high temperatures. To fabricate such models, slip casting techniques were developed to provide net-form, precision casting capability for high-purity ceramic materials in aqueous solutions. In previous slip casting techniques, block, or flask molds made of plaster-of-paris were used to draw liquid from the slip material. Upon setting, parts were removed from the flask mold and cured in a kiln at high temperatures. Casting detail was usually limited with this technique -- detailed parts were frequently damaged upon separation from the flask mold, as the molded parts are extremely delicate in the uncured state, and the flask mold is inflexible. Ceramic surfaces were also marred by 'parting lines' caused by mold separation. This adversely affected the aerodynamic surface quality of the model as well. (Parting lines are invariably necessary on or near the leading edges of wings, nosetips, and fins for mold separation. These areas are also critical for flow boundary layer control.) Parting agents used in the casting process also affected surface quality. These agents eventually soaked into the mold, the model, or flaked off when releasing the case model. Different materials were tried, such as oils, paraffin, and even an algae. The algae released best, but some of it remained on the model and imparted an uneven texture and discoloration on the model surface when cured. According to the present invention, a wax pattern for a shell mold is provided, and an aqueous mixture of a calcium sulfate-bonded investment material is applied as a coating to the wax pattern. The coated wax pattern is then dried, followed by curing to vaporize the wax pattern and leave a shell mold of the calcium sulfate-bonded investment material. The shell mold is cooled to room temperature, and a ceramic slip is poured therein. After a ceramic shell of desired thickness has set up in the shell mold, excess ceramic slip is poured out. While still wet, the shell mold is peeled from the ceramic shell to expose any delicate or detailed parts, after which the ceramic shell is cured to provide a complete, detailed, precision ceramic article without parting lines.

Buck, Gregory M.↗

NASA NTRS2006

Control of Technology Transfer at JPL

Controlled Technology: 1) Design: preliminary or critical design data, schematics, technical flow charts, SNV code/diagnostics, logic flow diagrams, wirelist, ICDs, detailed specifications or requirements. 2) Development: constraints, computations, configurations, technical analyses, acceptance criteria, anomaly resolution, detailed test plans, detailed technical proposals. 3) Production: process or how-to: assemble, operated, repair, maintain, modify. 4) Manufacturing: technical instructions, specific parts, specific materials, specific qualities, specific processes, specific flow. 5) Operations: how-to operate, contingency or standard operating plans, Ops handbooks. 6) Repair: repair instructions, troubleshooting schemes, detailed schematics. 7) Test: specific procedures, data, analysis, detailed test plan and retest plans, detailed anomaly resolutions, detailed failure causes and corrective actions, troubleshooting, trended test data, flight readiness data. 8) Maintenance: maintenance schedules and plans, methods for regular upkeep, overhaul instructions. 9) Modification: modification instructions, upgrades kit parts, including software

Jet Propulsion Laboratory (JPL)↗

NASA NTRS2011

Pre-Finishing of SiC for Optical Applications

13 Manufacturing & Prototyping A method is based on two unique processing steps that are both based on deterministic machining processes using a single-point diamond turning (SPDT) machine. In the first step, a high-MRR (material removal rate) process is used to machine the part within several microns of the final geometry. In the second step, a low-MRR process is used to machine the part to near optical quality using a novel ductile regime machining (DRM) process. DRM is a deterministic machining process associated with conditions under high hydrostatic pressures and very small depths of cut. Under such conditions, using high negative-rake angle cutting tools, the high-pressure region near the tool corresponds to a plastic zone, where even a brittle material will behave in a ductile manner. In the high-MRR processing step, the objective is to remove material with a sufficiently high rate such that the process is economical, without inducing large-scale subsurface damage. A laser-assisted machining approach was evaluated whereby a CO2 laser was focused in advance of the cutting tool. While CVD (chemical vapor deposition) SiC was successfully machined with this approach, the cutting forces were substantially higher than cuts at room temperature under the same machining conditions. During the experiments, the expansion of the part and the tool due to the heating was carefully accounted for. The higher cutting forces are most likely due to a small reduction in the shear strength of the material compared with a larger increase in friction forces due to the thermal softening effect. The key advantage is that the hybrid machine approach has the potential to achieve optical quality without the need for a separate optical finishing step. Also, this method is scalable, so one can easily progress from machining 50-mm-diameter samples to the 250-mm-diameter mirror that NASA desires.

Rozzi, Jay↗

NASA NTRS2008

Improving the Optical Quality Factor of the WGM Resonator

Resonators usually are characterized with two partially dependent values: finesse (F) and quality factor (Q). The finesse of an empty Fabry-Perot (FP) resonator is defined solely by the quality of its mirrors and is calculated as F=piR(exp 1/2)/(1-R). The maximum up-to-date value of reflectivity R approximately equal to 1 - 1.6 x 10(exp -6) is achieved with dielectric mirrors. An FP resonator made with the mirrors has finesse F=1.9 x 10(exp 6). Further practical increase of the finesse of FP resonators is problematic because of the absorption and the scattering of light in the mirror material through fundamental limit on the reflection losses given by the internal material losses and by thermodynamic density fluctuations on the order of parts in 109. The quality factor of a resonator depends on both its finesse and its geometrical size. A one-dimensional FP resonator has Q=2 F L/lambda, where L is the distance between the mirrors and lambda is the wavelength. It is easy to see that the quality factor of the resonator is unlimited because L is unlimited. F and Q are equally important. In some cases, finesse is technically more valuable than the quality factor. For instance, buildup of the optical power inside the resonator, as well as the Purcell factor, is proportional to finesse. Sometimes, however, the quality factor is more valuable. For example, inverse threshold power of intracavity hyperparametric oscillation is proportional to Q(exp 2) and efficiency of parametric frequency mixing is proportional to Q(exp 3). Therefore, it is important to know both the maximally achievable finesse and quality factor values of a resonator. Whispering gallery mode (WGM) resonators are capable of achieving larger finesse compared to FP resonators. For instance, fused silica resonators with finesse 2.3 x 10(exp 6) and 2.8 x 10(exp 6) have been demonstrated. Crystalline WGM resonators reveal even larger finesse values, F=6.3 x 10(exp 6), because of low attenuation of light in the transparent optical crystals. The larger values of F and Q result in the enhancement of various nonlinear processes. Low-threshold Raman lasing, optomechanical oscillations, frequency doubling, and hyperparametric oscillations based on these resonators have been recently demonstrated. Theory predicts a possibility of nearly 10(exp 14) room-temperature optical Q-factors of optical crystalline WGM resonators, which correspond to finesse levels higher than 10(exp 9). Experiments have shown numbers a thousand times lower than that. The difference occurs due to media imperfections. To substantially reduce the optical losses caused by the imperfections, a specific, multi-step, asymptotic processing of the resonator is implemented. The technique has been initially developed to reduce microwave absorption in dielectric resonators. One step of the process consists of mechanical polishing performed after high temperature annealing. Several steps repeat one after another to lead to significant reduction in optical attenuation and, as a result, to the increase of Q-factor as well as finesse of the resonator which demonstrates a CaF2 WGM resonator with F greater than 10(exp 7) and Q greater than 10(exp 11).

Savchenkov, Anatoliy↗

NASA NTRSDate not supplied

Hot Structure Concepts and Materials for Space Exploration Project

Hot structures are multifunctional material systems that integrate the functions of thermal protection systems (TPS) and primary structure to increase mass efficiency in aerospace vehicles. The goal of this project was to improve our capabilities for developing lightweight, reusable, and reliable hot structures concepts to enable advanced space exploration missions. Specifically, current hot structure carbon/carbon (C/C) composite material systems have low interlaminar strength, which can lead to material failures at low load levels, and large material property variability in as-fabricated parts. Two parallel paths were followed to address these shortcomings. First, analysis models were developed to identify the conditions under which excessive interlaminar stresses occur and to evaluate the potential of stitching the C/C laminae to improve the interlaminar thermal-structural response. This effort included the development of high-fidelity, fracture-based thermal-structural finite element analysis models to evaluate critical features needed to produce efficient hot structure concepts. The second path focused on developing atomistic and mesoscale simulation tools to model the fabrication process in an effort to reduce the time and cost of production while improving the quality of the resulting parts. Aspects of the process currently being investigated include the infusion of the matrix precursor into the fiber preform, the cure of the precursor molecules into their polymeric form, and the carbonization and graphitization of the polymer to form the carbon matrix material. Results of the 6-month study are presented herein.

thermal↗

NASA NTRS1979

Quality assurance and control in the production and static tests of the solid rocket boosters for the Space Shuttle

The paper surveys the various aspects of design and overhaul of the solid rocket boosters. It is noted that quality control is an integral part of the design specifications. Attention is given to the production process which is optimized towards highest quality. Also discussed is the role of the DCA (Defense Contract Administration) in inspecting the products of subcontractors, noting that the USAF performs this role for prime contractors. Fabrication and construction of the booster is detailed with attention given to the lining of the booster cylinder and the mixing of the propellant and the subsequent X-ray inspection.

Cerny, O. F.↗

NASA NTRS2005

Improvements to the Total Temperature Calibration of the NASA Glenn Icing Research Tunnel

The ability to accurately set repeatable total temperature conditions is critical for collecting quality icing condition data, particularly near freezing conditions. As part of efforts to continually improve data quality in the NASA Glenn Icing Research Tunnel (IRT), new facility instrumentation and new calibration hardware for total temperature measurement were installed and new operational techniques were developed and implemented. This paper focuses on the improvements made in the calibration of total temperature in the IRT.

Arrington, E. Allen↗

NASA NTRS1977

Scientist/AMPS equipment interface study

The principal objective was to determine for each experiment how the operating procedures and modes of equipment onboard shuttle can be managed in real-time or near-real-time to enhance the quality of results. As part of this determination the data and display devices that a man will need for real-time management are defined. The secondary objectives, as listed in the RFQ and technical proposal, were to: (1) determine what quantities are to be measured (2) determine permissible background levels (3) decide in what portions of space measurements are to be made (4) estimate bit rates (5) establish time-lines for operating the experiments on a mission or set of missions and (6) determine the minimum set of hardware needed for real-time display. Experiment descriptions and requirements were written. The requirements of the various experiments are combined and a minimal set of joint requirements are defined.

Anderson, H. R.↗

NASA NTRS1981

Historical overview of V/STOL aircraft technology

The requirements for satisfactory characteristics in several key technology areas are discussed and a review is made of various V/STOL aircraft for the purpose of assessing the success or failure of each design in meeting design requirements. Special operating techniques were developed to help circumvent deficiencies. For the most part performance and handling qualities limitations restricted operational evaluations. Flight operations emphasized the need for good STOL performance, good handling qualities, and stability and control augmentation. The majority of aircraft suffered adverse ground effects.

Anderson, S. B.↗

NASA NTRS1986

Development of sensor augmented robotic weld systems for aerospace propulsion system fabrication

In order to meet stringent performance goals for power and reuseability, the Space Shuttle Main Engine was designed with many complex, difficult welded joints that provide maximum strength and minimum weight. To this end, the SSME requires 370 meters of welded joints. Automation of some welds has improved welding productivity significantly over manual welding. Application has previously been limited by accessibility constraints, requirements for complex process control, low production volumes, high part variability, and stringent quality requirements. Development of robots for welding in this application requires that a unique set of constraints be addressed. This paper shows how robotic welding can enhance production of aerospace components by addressing their specific requirements. A development program at the Marshall Space Flight Center combining industrial robots with state-of-the-art sensor systems and computer simulation is providing technology for the automation of welds in Space Shuttle Main Engine production.

Jones, C. S.↗

NASA NTRS1985

Studies of lightning data in conjunction with geostationary satellite data

Since January, work has been proceeding on the first phase of this project: the creation of an extensive real-time lightning data base accessible via the Space Science and Engineering Center McIdas system. The purpose of this endeavor is two-fold: to enhance the availability and ease of access to lightning data among the various networks, governmental and research agencies; and to test the feasiblity and desirability of such efforts in succeeding years. The final steps in the creation of the necessary communications links, hardware, and software are in the process of being completed. Operations ground rules for access among the various users have been discussed and are being refined. While the research planned for the last year of the project will rely for the most part on archived, quality-controlled data from the various networks, the real-time data will provide a valuable first-look at potentially interesting case studies. For this purpose, tools are being developed on McIdas for display and analysis of the data as they become available. In conjunction with concurrent GOES real-time imagery, strike locations can be plotted, gridded and contoured, or displayed in various statistical formats including frequency distributions, histograms, and scatter plots. The user may also perform these functions in relation to arbitrarily defined areas on the satellite image. By mid-May these preparations for the access and analysis of real-time lightning data are expected to be complete.

Auvine, B.↗