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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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Different companies involving a wide range of products and manufacturing processes were studied to define the requirements for industrial robots. A survey of all such automatic units offered on the world market was made to establish a data base. Principal applications include coating, spot welding, and loading and unloading operations.
Tests for studying the basic material are considered and quality control investigations involving preimpregnated materials (prepreg) are discussed. Attention is given to the prepreg area weight, the fiber area weight of prepregs, the resin content, volatile components, the effective thickness, resin flow, the resistance to bending strain, tensile strength, and shear strength. A description of tests conducted during the manufacturing process is also presented, taking into account X-ray methods, approaches of neutron radiography, ultrasonic procedures, resonance methods and impedance studies.
The solar array manufacturing industry costing standards model is designed to compare the cost of producing solar arrays using alternative manufacturing processes. Constructive criticism of the methodology used is intended to enhance its implementation as a practical design tool. Three main elements of the procedure include workbook format and presentation, theoretical model validity and standard financial parameters.
The manufacture and properties of a grating intended for extrasolar X-ray studies are described. The manufacturing process uses a split laser beam exposing an interference pattern on the photoresist-coated glass plated with a nickel parting layer. The grating, supporting structure, and mounting frame are electrodeposited on the nickel parting layer, and the final product is lifted from the glass substrate by selective etching of the nickel. A model was derived which relates the number of counts received in a given order m as a function of photon wavenumber. A 4-deg beam line was used to measure the efficiencies of gold transmission gratings for diffraction of X-rays in the range of 45 to 275 eV. The experimental results are in good agreement with model calculations.
Major rotor design criteria are discussed with particular emphasis on those aspects of rotor design that ensure long life component integrity. Dynamic considerations, that necessitate tuning of bladed disk and seal assemblies to avoid excessive vibratory stress at both design and off-design conditions are reviewed as well as low cycle fatigue considerations, which have resulted in detailed analysis procedures to establish part temperature and stress variation throughout an operating cycle and extensive specimen and component fatigue testing to establish safe cyclic operating limits. The frequency, size, and behavior of intrinsic material defects were investigated. Manufacturing process improvements, including the application of increasingly sophisticated inspection techniques and quality control procedures are reviewed in light of their impact on component durability.
The nickel-cadmium battery design developed for the Synchronous Meteorological Satellite (SMS) and Geostationary Operational Environmental Satellite (GOES) provided background and guidelines for future development, manufacture, and application of spacecraft batteries. SMS/GOES battery design, development, qualification testing, acceptance testing, and life testing/mission performance characteristics were evaluated for correlation with battery cell manufacturing process variables.
A cost effective design and manufacturing process which would produce solar cell modules capable of meeting qualification test criteria was developed. Emphasis was placed on the development of an aluminum paste back contact process.
SAMIS is a continuing activity of the Project Analysis and Integration Task of the Low-cost Silicon Solar Array Project (LSSA). It provides a standardized procedure for producing reliable estimates of the cost of manufacturing solar arrays or their components. These estimates are based on descriptions of the manufacturing processes which are being studied and developed by LSSA subcontractors and will be used to assess the commercial viability of those processes and to set research priorities.
As part of an effort to develop reliable, cost effective spacecraft thermal control heat pipes, Lewis Research Center of NASA is conducting life tests on 30 commercially-available heat pipes in 10 groups of different design and material combinations. Materials are aluminum and stainless steel, and working fluids are methanol and ammonia. The formation of noncondensible gas is observed for times exceeding 11,000 hours. The heat transport capacities of the pipes are also determined. Considerable gas is found in two groups of methanol pipes; one group shows no gas. One group of ammonia pipes has no observable gas. Another group has much gas. Manufacturers' processing schedules are examined for differences explaining the presence of gas. Heat transport capacity is found to be severely reduced in some pipes containing gas.
The means of ensuring total rigidity of lattice domes, using comparison with solid shells of 1-3 layers are discussed. Irregularities of manufacture, processing, and other factors are considered, as they relate to diminution of rigidity. The discussion uses the concepts of upper and lower critical loads on the structure in question.
The subject program was conducted for the purpose of generating cost information on ramjet engines and developing a methodology that could be employed to accurately predict production costs ramjet engines. The methodology addresses many different ramjet types, sizes and production quantities. The methodology determines the cost of individual modules of ramjet assemblies based on similarity of the modules to baseline components that are identified in a cost handbook. (There are typically around 20 basic components of a given ramjet to be costed.) The total cost of the engine is a summation of all the appropriate cost elements. A significant accomplishment of the program was the development of a large cost data base on many different configurations, materials of construction and variations in manufacturing processes. This data base should provide a good foundation on which to build other cost data as it becomes available.
A manufacturing process suitable for the large-scale production of silicon solar array modules at a cost of less than $500/peak kW is described. Factors which control the efficiency of ion implanted silicon solar cells, screen-printed thick film metallization, spray-on antireflection coating process, and panel assembly are discussed. Conclusions regarding technological readiness or cost effectiveness of individual process steps are presented.
Cost-driving parameters of space industrialization are discussed, specifically cost of transportation from earth to low earth orbit and productivity of labor in space. A design procedure for a space manufacturing facility (SMF) is outlined, and the design of a reference SMF is described. This SMF receives lunar materials and converts them to components of space structures such as solar power satellites. The effect of machine reliability is discussed. The SMF appears versatile and productive, and the space environment has some beneficial characteristics which may simplify manufacturing processes. Technology demonstration programs are needed, but prototypes of SMF equipment can be small devices.
Circuit smooths stepped waveform from analog-to-digital converter without appreciable phase shift between stepped input signal and smoothed output signal and without any effect from stepping rate. Waveform produced is suitable for driving controls used in manufacturing processes, aerospace systems, and automobiles.
Two clamps hold rod in fixed extension from cylinder even when power is off, converting actuator into stiff structural member. Locked actuator is useful as mechanical support or linkage or as fail-safe device in case of loss of hydraulic pressure. Potential applications include manufacturing processes and specialized handling and holding devices.
A complete OMNIUM-G System 7500 was cost analyzed for annual production quantities ranging from 25 to 10,000 units per year. Parts and components were subjected to in-depth scrutiny to determine optimum manufacturing processes, coupled with make or buy decisions on materials and small parts. When production quantities increase both labor and material costs reduce substantially. A redesign of the system that was analyzed could result in lower costs when annual production runs approach 100,000 units/year. Material and labor costs for producing 25, 100, 25,000 and 100,00 units are given for 17 subassembly units.
The paper describes a 'test case' manufacturing process sequence for solar photovoltaic modules which will cost 50 cents/watt in 1986. The process, which starts with the purification of silicon grown into 75-mm-wide thin ribbons, is discussed, and the plant layout is depicted; each department is sized to produce 250 MW of modules/per year. The cost of this process sequence is compared to present technology at various companies showing considerable spread for each process; data are tabulated in a composite state-of-the-art cell processing cost summary for these processes.
The tests are to insure that all cells put into the life cycle program are of high quality by the screening of cells found to have electrolyte leakage, internal shorts, low capacity, or inability of any cell to recover its open-circuit voltage above 1.150 volts during the internal short test. Test limits specify those values at which a cell is to be terminated from charge or discharge. Requirements are referenced to normally expected values based on past performance of aerospace nickel-cadmium cells with demonstrated life characteristics. Recommendations for the improvement of the manufacturing processes are presented.