Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “machining processes”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,171 records · Page 65
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

High quality optically polished aluminum mirror and process for producing

A new technical advancement in the field of precision aluminum optics permits high quality optical polishing of aluminum monolith, which, in the field of optics, offers numerous benefits because of its machinability, lightweight, and low cost. This invention combines diamond turning and conventional polishing along with india ink, a newly adopted material, for the polishing to accomplish a significant improvement in surface precision of aluminum monolith for optical purposes. This invention guarantees the precise optical polishing of typical bare aluminum monolith to surface roughness of less than about 30 angstroms rms and preferably about 5 angstroms rms while maintaining a surface figure accuracy in terms of surface figure error of not more than one-fifteenth of wave peak-to-valley.

Lyons, III, James J.↗
NASA NTRS2007

Materials Development for Auxiliary Components for Large Compact Mo/Au TES Arrays

We describe our current fabrication process for arrays of superconducting transition edge sensor microcalorimeters, which incorporates superconducting Mo/Au bilayers and micromachined silicon structures. We focus on materials and integration methods for array heatsinking with our bilayer and micromachining processes. The thin superconducting molybdenum bottom layer strongly influences the superconducting behavior and overall film characteristics of our molybdenum/gold transition-edge sensors (TES). Concurrent with our successful TES microcalorimeter array development, we have started to investigate the thin film properties of molybdenum monolayers within a given phase space of several important process parameters. The monolayers are sputtered or electron-beam deposited exclusively on LPCVD silicon nitride coated silicon wafers. In our current bilayer process, molybdenum is electron-beam deposited at high wafer temperatures in excess of 500 degrees C. Identifying process parameters that yield high quality bilayers at a significantly lower temperature will increase options for incorporating process-sensitive auxiliary array components (AAC) such as array heat sinking and electrical interconnects into our overall device process. We are currently developing two competing technical approaches for heat sinking large compact TES microcalorimeter arrays. Our efforts to improve array heat sinking and mitigate thermal cross-talk between pixels include copper backside deposition on completed device chips and copper-filled micro-trenches surface-machined into wafers. In addition, we fabricated prototypes of copper through-wafer microvias as a potential way to read out the arrays. We present an overview on the results of our molybdenum monolayer study and its implications concerning our device fabrication. We discuss the design, fabrication process, and recent test results of our AAC development.

Finkbeiner, F. m.↗
NASA NTRS1973

Gear materials for high-production light-deputy service

The selection of a material for high volume, low cost gears requires careful consideration of all the requirements and the processes used to manufacture the gears. The wrong choice in material selection could very well mean the difference between success and failure. A summary of the cost that might be expected for different materials and processes is presented; it can be seen that the cost can span nearly three order of magnitudes from the molded plastic gear to the machined gear with stamped and powder metal gears falling in between these extremes.

Townsend, D. P.↗
NASA NTRS1978

Technology of welding aluminum alloys-II

Step-by-step procedures were developed for high integrity manual and machine welding of aluminum alloys. Detailed instructions are given for each step with tables and graphs to specify materials and dimensions. Throughout work sequence, processing procedure designates manufacturing verification points and inspection points.

Source record↗
NASA NTRS1987

Space Station - An innovative approach to manufacturing development

The development of the common modules for the planned dual-keel Space Station, which is a figure-eight configuration that requires the use of four common modules linked by six docking nodes in the center of the Station, is examined. The fabrication of the proposed common module designs, which are a four-barrel common module structure built using excess external tank barrel panels (Martin Marietta Michoud Aerospace), and a three-barrel design consisting of 2219 Al skins with a waffle-grid pattern machined on the outer surface (Boeing Aerospace Corporation) is described. The assistance provided by the NASA-Marshall Space Flight Center's Materials and Processes Laboratory, in particular the variable polarity plasma arc welding process, in the development of the common modules is discussed.

Sullivan, Kenneth W.↗
NASA NTRS1988

Space telerobots and planetary rovers

Space telerobots and planetary rovers are advanced forms of space automation that are being studied for missions beginning in the 1990s. This paper describes telerobots and planetary rovers, points out that pure autonomy is far beyond the state of the art, and goes on to discuss how useful, realizable telerobots and rovers can be developed in the context of human-machine systems. Telerobot and rover computational and architectural requirements are also briefly examined, and examples of current work, including the development of dedicated analog processing chips based upon neural networks are described. The paper closes with some speculations on the terrestrial implications of space robotics and some general conclusions.

Ruoff, Carl F.↗
NASA NTRS1990

Hybrid vision activities at NASA Johnson Space Center

NASA's Johnson Space Center in Houston, Texas, is active in several aspects of hybrid image processing. (The term hybrid image processing refers to a system that combines digital and photonic processing). The major thrusts are autonomous space operations such as planetary landing, servicing, and rendezvous and docking. By processing images in non-Cartesian geometries to achieve shift invariance to canonical distortions, researchers use certain aspects of the human visual system for machine vision. That technology flow is bidirectional; researchers are investigating the possible utility of video-rate coordinate transformations for human low-vision patients. Man-in-the-loop teleoperations are also supported by the use of video-rate image-coordinate transformations, as researchers plan to use bandwidth compression tailored to the varying spatial acuity of the human operator. Technological elements being developed in the program include upgraded spatial light modulators, real-time coordinate transformations in video imagery, synthetic filters that robustly allow estimation of object pose parameters, convolutionally blurred filters that have continuously selectable invariance to such image changes as magnification and rotation, and optimization of optical correlation done with spatial light modulators that have limited range and couple both phase and amplitude in their response.

Juday, Richard D.↗
NASA NTRS1991

A biconjugate gradient type algorithm on massively parallel architectures

The biconjugate gradient (BCG) method is the natural generalization of the classical conjugate gradient algorithm for Hermitian positive definite matrices to general non-Hermitian linear systems. Unfortunately, the original BCG algorithm is susceptible to possible breakdowns and numerical instabilities. Recently, Freund and Nachtigal have proposed a novel BCG type approach, the quasi-minimal residual method (QMR), which overcomes the problems of BCG. Here, an implementation is presented of QMR based on an s-step version of the nonsymmetric look-ahead Lanczos algorithm. The main feature of the s-step Lanczos algorithm is that, in general, all inner products, except for one, can be computed in parallel at the end of each block; this is unlike the other standard Lanczos process where inner products are generated sequentially. The resulting implementation of QMR is particularly attractive on massively parallel SIMD architectures, such as the Connection Machine.

Freund, Roland W.↗
NASA NTRS1993

Electromechanical Apparatus Measures Residual Stress

Nondestructive test exploits relationship between stress and eddy-current-probe resistance. Yields data on residual stress or strain in metal tension/compression specimen (stress or strain remaining in specimen when no stress applied from without). Apparatus is assembly of commercial equipment: tension-or-compression testing machine, eddy-current probe, impedance gain-and-phase analyzer measuring impedance of probe coil, and desktop computer, which controls other equipment and processes data received from impedance gain-and-phase analyzer.

Chern, Engmin J.↗
NASA NTRS2008

Effect of Weld Tool Geometry on Friction Stir Welded Ti-6Al-4V

In this study, flat 0.250" thick Ti-6Al-4V panels were friction stir welded (FSWed) using weld tools with tapered pins. The five different pin geometries of the weld tools included: 0 degree (straight cylinder), 15 degree, 30 degree, 45 degree, and 60 degree angles on the frustum. All weld tools had a smooth 7 degree concave shoulder and were made from microwave sintered tungsten carbide. For each weld tool geometry, the FSW process parameters were optimized to eliminate internal defects. All the welds were produced in position control with a 2.5 degree lead angle using a butt joint configuration for the panels. The process parameters of spindle rpm and travel speed were varied, altering the hot working conditions imparted to the workpiece. Load cells on the FSWing machine allowed for the torque, the plunge force, and the plow force to be recorded during welding. Resulting mechanical properties were evaluated from tensile tests results of the FSWjoints. Variations in the material flow were investigated by use of microstructural analysis including optical microscopy (OM), scanning electron microscopy (SEM), and orientation image mapping (aIM).

Querin, Joseph A.↗
NASA NTRS2008

Mars Reconnaissance Orbiter Uplink Analysis Tool

This software analyzes Mars Reconnaissance Orbiter (MRO) orbital geometry with respect to Mars Exploration Rover (MER) contact windows, and is the first tool of its kind designed specifically to support MRO-MER interface coordination. Prior to this automated tool, this analysis was done manually with Excel and the UNIX command line. In total, the process would take approximately 30 minutes for each analysis. The current automated analysis takes less than 30 seconds. This tool resides on the flight machine and uses a PHP interface that does the entire analysis of the input files and takes into account one-way light time from another input file. Input flies are copied over to the proper directories and are dynamically read into the tool s interface. The user can then choose the corresponding input files based on the time frame desired for analysis. After submission of the Web form, the tool merges the two files into a single, time-ordered listing of events for both spacecraft. The times are converted to the same reference time (Earth Transmit Time) by reading in a light time file and performing the calculations necessary to shift the time formats. The program also has the ability to vary the size of the keep-out window on the main page of the analysis tool by inputting a custom time for padding each MRO event time. The parameters on the form are read in and passed to the second page for analysis. Everything is fully coded in PHP and can be accessed by anyone with access to the machine via Web page. This uplink tool will continue to be used for the duration of the MER mission's needs for X-band uplinks. Future missions also can use the tools to check overflight times as well as potential site observation times. Adaptation of the input files to the proper format, and the window keep-out times, would allow for other analyses. Any operations task that uses the idea of keep-out windows will have a use for this program.

Khanampompan, Teerapat↗
NASA NTRS2007

Creep Forming of Carbon-Reinforced Ceramic-Matrix Composites

A set of lecture slides describes an investigation of creep forming as a means of imparting desired curvatures to initially flat stock plates of carbon-reinforced ceramic-matrix composite (C-CMC) materials. The investigation is apparently part of a continuing effort to develop improved means of applying small CCMC repair patches to reinforced carbon-carbon leading edges of aerospace vehicles (e.g., space shuttles) prior to re-entry into the atmosphere of the Earth. According to one of the slides, creep forming would be an intermediate step in a process that would yield a fully densified, finished C-CMC part having a desired size and shape (the other steps would include preliminary machining, finish machining, densification by chemical vapor infiltration, and final coating). The investigation included experiments in which C-CMC disks were creep-formed by heating them to unspecified high temperatures for time intervals of the order of 1 hour while they were clamped into single- and double-curvature graphite molds. The creep-formed disks were coated with an oxidation- protection material, then subjected to arc-jet tests, in which the disks exhibited no deterioration after exposure to high-temperature test conditions lasting 490 seconds.

Vaughn, Wallace L.↗
NASA NTRS2010

Observing System Simulation Experiment (OSSE) for the HyspIRI Spectrometer Mission

The OSSE software provides an integrated end-to-end environment to simulate an Earth observing system by iteratively running a distributed modeling workflow based on the HyspIRI Mission, including atmospheric radiative transfer, surface albedo effects, detection, and retrieval for agile exploration of the mission design space. The software enables an Observing System Simulation Experiment (OSSE) and can be used for design trade space exploration of science return for proposed instruments by modeling the whole ground truth, sensing, and retrieval chain and to assess retrieval accuracy for a particular instrument and algorithm design. The OSSE in fra struc ture is extensible to future National Research Council (NRC) Decadal Survey concept missions where integrated modeling can improve the fidelity of coupled science and engineering analyses for systematic analysis and science return studies. This software has a distributed architecture that gives it a distinct advantage over other similar efforts. The workflow modeling components are typically legacy computer programs implemented in a variety of programming languages, including MATLAB, Excel, and FORTRAN. Integration of these diverse components is difficult and time-consuming. In order to hide this complexity, each modeling component is wrapped as a Web Service, and each component is able to pass analysis parameterizations, such as reflectance or radiance spectra, on to the next component downstream in the service workflow chain. In this way, the interface to each modeling component becomes uniform and the entire end-to-end workflow can be run using any existing or custom workflow processing engine. The architecture lets users extend workflows as new modeling components become available, chain together the components using any existing or custom workflow processing engine, and distribute them across any Internet-accessible Web Service endpoints. The workflow components can be hosted on any Internet-accessible machine. This has the advantages that the computations can be distributed to make best use of the available computing resources, and each workflow component can be hosted and maintained by their respective domain experts.

Turmon, Michael J.↗
NASA NTRS2023

Observational Constraints Reduce Model Spread but Not Uncertainty in Global Wetland Methane Emission Estimates

The recent rise in atmospheric methane (CH 4 ) concentrations accelerates climate change and offsets mitigation efforts. Although wetlands are the largest natural CH 4 source, estimates of global wetland CH 4 emissions vary widely among approaches taken by bottom-up (BU) process-based biogeochemical models and top-down (TD) atmospheric inversion methods. Here, we integrate in situ measurements, multi-model ensembles, and a machine learning upscaling product into the International Land Model Benchmarking system to examine the relationship between wetland CH 4 emission estimates and model performance. We find that using better-performing models identified by observational constraints reduces the spread of wetland CH 4 emission estimates by 62% and 39% for BU- and TD-based approaches, respectively. However, global BU and TD CH 4 emission estimate discrepancies increased by about 15% (from 31 to 36 TgCH 4 year −1 ) when the top 20% models were used, although we consider this result moderately uncertain given the unevenly distributed global observations. Our analyses demonstrate that model performance ranking is subject to benchmark selection due to large inter-site variability, highlighting the importance of expanding coverage of benchmark sites to diverse environmental conditions. We encourage future development of wetland CH 4 models to move beyond static benchmarking and focus on evaluating site-specific and ecosystem-specific variabilities inferred from observations.

Kuang-Yu Chang↗
NASA NTRS2021

Development of an Additive Manufacturing Ecosystem for Qualification of Additive Manufacturing Processes and Materials in Aviation

The major challenges associated with additive manufacturing (AM) are an ability to qualify parts and the costs associated with the technology. Our team will study and mature technologies as detailed below to develop an ecosystem for the qualification of AM machines, which in turn supports the certification of part production. Additive manufacturing offers unique opportunities for the aviation industry in the fabrication of original components and replacement parts. Aggressive use of metals AM has, for example, allowed the rapid development and production of new launch vehicle designs, at substantially reduced costs. Aviation has unique challenges, such as higher production volumes, but the potential value of integrating AM into aviation manufacturing is clear. To implement the ecosystem for AM qualification, the team will run a set of six multi-disciplinary projects. Each of these projects will address a current barrier to AM process qualification, and efficient production.

Koushik Datta↗
NASA NTRSDate not supplied

A Machine Learning Framework for Error Compensation in Radiative Transfer Calculations

Radiative heat transfer influences the amount of heat flux transferred to the surface of the hypersonic vehicle, which is essential to evaluate the performance of thermal protection systems. The radiative heat flux is found to be computationally prohibitive while accounting for the variation in spatial, angular, and spectral domains. A new methodology has been recently developed to alleviate the cost of computation in the spectral domain by constructing flow-agnostic reduced-order models (ROMs). The developed spectral ROM databases provide grouping strategies that account for non-equilibrium absorption and emission as well as interaction between disparate species due to spectral overlap in associated radiative processes. However, the developed ROMs need to be optimized for a specific combination of interacting gas species and would need to re-calibrated in case individual species are added/omitted. In this work, we use various machine learning (ML) techniques to approximate the radiative intensities determined by a ROM optimized for a specific gas mixture. The ML model relies on the ROM databases developed for a single species which ignores any spectral overlap. Thus, radiation evaluation starts with a simple summation of radiative intensities predicted using these non-calibrated ROMs for the contributing species. The ML framework then provides a correction to account for the interplay in the frequency, i.e., emission of photons by one species and absorption by another, and yields mixture-specific radiation fields. Once trained on the individual ROM databases, the ML framework offers instantaneous corrections that serves as a time/cost effective alternative to the optimization of ROMs for a specific gas mixture. The ML framework is trained on both the high fidelity and ROM evaluated line of sight (LOS) data from Orion, Stardust, and FIRE II cases to obtain a general purpose correction model for earth re-entry scenarios when radiation contributions from both atomic nitrogen and atomic oxygen are considered. A geometric length scale parameter is used in the training process to account for errors introduced in the ROM databases as a consequence of high optical thickness. The efficacy of the ML framework is underscored through extensive analysis of train and test errors with respect to all the re-entry scenarios. The applicability of such an ML framework was further corroborated by embedding it in a state-of-the-art US3D - NERO system for determining the radiative heat flux transferred to the hypersonic vehicle surface.

Radiation↗