SEARCH · Engineering Papers

Results for “Additively Manufacturing”

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.

SourceResearch connectionFrom yearThrough year

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

At least 1,207 records · Page 67

All sources NASA NTRS DOE OSTI

NASA NTRSDate not supplied

NASA - DLA Land And Maritime Survey of Qualified Product List Manufacturers to Understand Barometric Pressure Testing Electrical Biasing Conditions

NASA Marshall Space Flight Center (MSFC) in collaboration with DLA Land and Maritime-VAC support is conducting a survey to obtain feedback on the device electrical bias procedures specified in method 1001 of MIL-STD-750-1, Barometric Pressure (reduced)’. The purpose of this survey is to obtain input from the DLA Land and Maritime qualified manufacturer community to determine whether additional bias details or information should be specified within the test method. The survey results will be used to improve any test method deficiencies and result in consistent test results.

barometric pressure testing of electronic componen↗

NASA NTRSDate not supplied

New Development Activities at NASA Ames in Reusable TPS Materials

Over the last few years, new activities in rapid, low-cost access to low-earth orbit (LEO) and hypersonic flight have refreshed interest in reusable thermal protection systems (RTPS) that have not had broad application since the Space Shuttle era. Development of novel systems having a greater consideration of full cycle cost (lower cost raw materials, manufacturing, integration, and refurbishment) in addition to improved performance are needed to enable this new generation of space flight. NASA Ames has a long history of RTPS development including invention of flexible blankets such as Advanced Flexible Reusable Surface Insulation (AFRSI), rigid ceramic tiles like Fibrous Refractory Composite Insulation (FRCI) and Alumina Enhanced Thermal Barrier (AETB), and multi-component systems like Toughened Uni-piece Fibrous Reinforced Oxidation-resistant Composite (TUFROC). In much more recent times, NASA Ames is supporting the growing commercial space field through internal research and development efforts for high-risk low TRL materials and collaboration with commercial partners including technology transfer. This talk will discuss the current development efforts that span broadly from updating legacy insulating systems with modern raw materials and processes to totally novel designs for heat pipes with various low-TRL activities in between. It will also discuss Ames’ recent re-investment in experimental capabilities to enable characterization and material testing.

Reusable thermal protection materials↗

NASA NTRSDate not supplied

New Development Activities at NASA Ames in Reusable TPS Materials

Reusable thermal protection materials↗

NASA NTRSDate not supplied

Reusable TPS Materials Development Activities at NASA Ames

Recent developments in low-cost access to low-earth orbit (LEO) and hypersonic flight are driving renewed demand in reusable thermal protection systems (RTPS) that have not had broad application since the Space Shuttle era. Modern systems will need to consider full cycle cost (lower cost raw materials, manufacturing, integration, and refurbishment) in addition to improved performance to enable this new generation of space flight. NASA Ames Research Center (ARC) has a long history of RTPS development including modern state-of-the-art materials like Alumina Enhanced Thermal Barrier (AETB), and multi-component systems like Toughened Uni-piece Fibrous Reinforced Oxidation-resistant Composite (TUFROC). Now, ARC is supporting the growing commercial space field through internal research and development efforts for high-risk low TRL materials and collaboration with commercial partners including technology transfer. This talk will discuss the current development efforts at ARC that span updating legacy insulating systems with modern raw materials and processes to totally novel designs for heat pipes with various low-TRL activities in between. It will also discuss Ames’ recent re-investment in experimental capabilities to enable characterization and material testing.

Adam Caldwell↗

NASA NTRS2018

Thermal Protection Systems Technology Transfer from Apollo and Space Shuttle to the Orion Program

This paper describes how the Orion program is utilizing the Thermal Protection System (TPS) experience from the Apollo and Space Shuttle programs to reduce program risk and improve affordability to meet NASA's future manned exploration missions. The Orion program successfully completed the Exploration Flight Test (EFT-1) mission in 2014 and is currently assembling, integrating, and testing the next spacecraft for the Exploration Mission (EM-1) to meet the flight test objectives of an unmanned orbital mission to the moon and return to earth in 2019. The Orion spacecraft production operations are located in the Neil Armstrong Operations and Checkout (O&C) facility at the Kennedy Space Center (KSC) providing an affordable and seamless delivery approach of vehicles directly to the launch site eliminating spacecraft transportation and additional checkout testing. Innovative vehicle design, manufacturing and test operations approaches are maturing and evolving with each Orion vehicle build to support the challenging NASA exploration mission requirements beyond Low Earth Orbit (LEO) while reducing program cost and schedule impacts. An example of Orion's evolution is the incorporation of an improved heat shield design, assembly and testing approach to meet the higher re-entry velocities for a lunar return for the EM-1 mission. The EFT- 1 heat shield was based on the Apollo heat shield manufacturing processes and was assembled at a supplier location and then transported to KSC for final integration. The EM-1 heat shield is now manufactured, assembled, tested, and installed into the spacecraft at the O&C facility reducing program cost and production schedules. The transition of the Space Shuttle TPS capabilities has enabled Orion to provide a human rated capsule design using proven materials and processes established over years of orbiter re-entry missions. The Orion Crew Module (CM) TPS configuration is derived from the Apollo CM approach utilizing improved materials and processes developed from the Space Shuttle program. The Orion EFT-1 heat shield utilized the Avcoat ablative material from Apollo which was injected into a honeycomb substrate and has been updated for EM-1 incorporating a block configuration bonded to a composite shell structure. This approach utilizes the proven Avcoat material for the heat shield ablator and is utilizing derived bonding and inspection methods and techniques from the Space Shuttle tile experience. The Orion back shell TPS configuration is based on Space Shuttle tile designs using proven tile materials and coatings. The Orion forward bay cover utilizes the high temperature tiles similar to the back shell tiles and low temperature blankets derived from the Space Shuttle program reducing weight impacts. Space Shuttle Multi-Layer Insulation (MLI) is installed in the Orion capsule to control the interior temperature environment providing a light weight design. These TPS design approaches have performed successfully on the Orion first flight test on EFT-1 and are incorporated in the configuration for the next flight test for EM-1. Completion of these two flight tests will certify the TPS for the Orion program for human rated exploration missions and has reduced the development cost to the Orion program. In addition to transitioning the Space Shuttle TPS design configurations to Orion, the supporting manufacturing infrastructure, manufacturing processes, and inspection methods are also incorporated into the Orion assembly operations at KSC. This has avoided significant startup schedule and costs impacts of new capabilities and development of support operations necessary to fabricate, install, inspect, and validate the TPS installations for the Orion spacecraft. The Thermal Protection System Facility (TPSF) which supported the Space Shuttle program provides the heat shield Avcoat blocks and the back shell AETB-8 tiles for Orion program. Extending the existing Space Shuttle TPS operations at KSC provides onsite support to the Orion spacecraft assembly operations. A significant benefit to the Orion program is the transition of the Space Shuttle technician work force at KSC. This highly skilled workforce was able to transition to the Orion program and immediately support the TPS installation operations. They brought with them the human rated manufacturing and assembly operations culture that was critical to the Space Shuttle success avoiding the retraining cost and schedule impacts of a new workforce to Orion. The technician skills certification program from the Space Shuttle was found to be compatible with the Lockheed Martin technician certification programs enabling a seamless training process utilizing process similarity avoiding the cost of retraining the work force to Orion standards. The existing workforce is certificated for multiple processes enabling reassignment of technicians to other tasks in the Orion AI&P operations reducing the overall touch labor manpower requirements. Additional benefits of using the Space Shuttle workforce is the incorporation of the lessons learned from Space Shuttle processes to improve the Orion TPS processes. This has resulted in a continuous evolution of TPS processes to improve the producibility and reduce the program cost for the TPS for the Orion program. Transitioning the Apollo and Space Shuttle TPS designs, processes, and technician workforce has been instrumental in enabling Orion to successfully meet the program challenges for NASA's exploration missions of the future.

Stewart, Michael↗

NASA NTRS2019

Labor Estimation and Trending in an Operations Environment

Accurate cost estimation for future work is important for ensuring that organizations have the personnel and resources needed to complete a task successfully. Operations support in particular provides additional challenges for estimating cost. Unlike manufacturing-based work, it may be difficult to derive a "cost per product," and projects that appear to be similar may have drastically different underlying assumptions. In addition, for critical operations, a certain level of adaptability to changing circumstances is expected. Responding to contingencies or anomalies requires additional support and troubleshooting, and could result in increases to project cost. Labor estimation is one of the most important inputs for estimating the cost of an operations-based project, especially in a pre-established facility. Various methods are needed to develop reliable estimates. These methods include a bottom-up summarization of known or expected work items, and a top-down estimate generated by trending and scaling actual labor from past analogous operations support.

Laing, Jason↗

NASA NTRSDate not supplied

NASA's Exploration and In-Space Services (NExIS) Division OSAM-1 Propellant Transfer Subsystem Progress 2020

National Aeronautics and Space Administration (NASA)’s Exploration and In-Space Services (NExIS) Division of Goddard Space Flight Center has been developing technology for the On-orbit Servicing, Assembly and Manufacturing Mission 1 (OSAM-1) to robotically refuel heritage and new satellites on-orbit. OSAM-1, formerly known as Restore-L, successfully passed an important NASA milestone called Key Decision Point-C (KDP-C), receiving agency-level approval for its implementation. The decision point also establishes the mission’s official schedule and budget. The OSAM-1 spacecraft, Servicing Payload and the Space Infrastructure Dexterous Robot (SPIDER) payload will refuel a satellite in space, assemble a communications antenna and manufacture a beam. By demonstrating these capabilities, the mission is advancing never-before tested technologies for use in future missions (by NASA and other government organizations and private industry). The mission is funded by the Technology Demonstration Missions program within NASA’s Space Technology Mission Directorate. This paper covers a review of servicing extensibility and critical technologies that are being developed within NExIS with a focus on the fluid transfer refueling technology within the framework of the Propellant Transfer Subsystem (PTS). An overview of the planned initial technology demonstration servicing mission via the OSAM-1 Space Vehicle is provided as an extension of the technology development progress reported in 20181, and 20192. The general objectives, challenges, and key technologies are presented as an introduction to the context of the OSAM-1 mission, and a precursor to the OSAM-1 PTS specific development status. Development and progress of the Hose Management Assembly (HMA) and Propellant Transfer Assembly (PTA) are discussed. HMA risk reduction test results including those of thermal vacuum testing are presented. Important analytical results are discussed and progress of drawings and procedures developed for the fabrication and testing phase are shown. A summary of the PTS overall verification status and design activities prepared for the critical design peer review are presented. Procurement progress is shown with status on long, medium, and short term efforts to acquire the hardware required to support the mission objectives. Technology development, challenges, and testing status are discussed with particular regard to the OSAM-1 specific key assemblies including the PTA and HMA along with the overall integrated flight mockup of the spacecraft to client fluid transfer testing conducted in the servicing testbeds. The paper concludes with key milestones leading to the goal of on-orbit refueling to be demonstrated in 2024. The overall mission Launch Readiness Date (LRD) has been realigned to accommodate budget profiles and incorporation of additional on-orbit assembly and manufacturing demonstration efforts.

Propellant transfer, satellite servicing↗

NASA NTRS2001

Modeling Heat Flow In a Calorimeter Equipped With a Textured Solar Collector

Heat engines are being considered for generating electric power for minisatellite applications, particularly for those missions in high radiation threat orbits. To achieve this objective, solar energy must be collected and transported to the hot side of the heat engine. A solar collector is needed having the combined properties of high solar absorptance, low infrared emittance, and high thermal conductivity. To test candidate solar collector concepts, a simple calorimeter was designed, manufactured, and installed in a bench top vacuum chamber to measure heat flow. In addition, a finite element analysis model of the collector/calorimeter combination was made to model this heat flow. The model was tuned based on observations from the as-manufactured collector/calorimeter combination. In addition, the model was exercised to examine other collector concepts, properties, and scale up issues.

Jaworske, Donald A.↗

NASA NTRS2010

Shuttle Environmental Assurance: Brominated Flame Retardants - Concerns, Drivers, Potential Impacts and Mitigation Strategies

Brominated Flame Retardants (BFRs) are widely used in the manufacture of electrical and electronic components and as additives in formulations for foams, plastics and rubbers. The United States (US) and the European Union (EU)have increased regulation and monitoring of of targeted BFRs, such as Polybrominated Diphenyl Ethers (PBDEs) due to the bioaccumulative effects in humans and animals. In response, manufacturers and vendors of BFR-containing materials are changing flame-retardant additives, sometimes without notifying BFR users. In some instances, Deca-bromodiphenylether (Deca-BDE) and other families of flame retardants are being used as replacement flame retardants for penta-BDE and octa-BDE. The reformulation of the BFR-containing material typically results in the removal of the targeted PBDE and replacement with a non-PBDE chemical or non-targeted PBDE. Many users of PBDE -based materials are concerned that vendors will perform reformulation and not inform the end user. Materials performance such as flammability, adhesion , and tensile strength may be altered due to reformulation. The requalification of newly formulated materials may be required, or replacement materials may have to be identified and qualified. The Shuttle Enviornmental Assurance (SEA) team indentified a risk to the Space Shuttle Program associated with the possibility that targeted PBDEs may be replaced without notification. Resultant decreases in flame retardancy, Liquid Oxygen (LOX) compatibility, or material performance could have serious consequences.

Clark-Ingram, Marceia↗

NASA NTRS1972

The use of models in structural testing.

The design, construction and instrumentation of plastic model shells used in elastic stability studies is discussed. The work demonstrates that specimens made of such materials are of great value in parametric studies because of their ease of manufacture and the simplicity of modification. Additionally, it is shown that they are most useful in the development of nondestructive test techniques. The paper indicates how deformation measurements made at low load levels can be used to accurately predict critical conditions.

Horton, W. H.↗

NASA NTRS1977

Analytical study of space processing of immiscible materials for superconductors and electrical contacts

The results of a study conducted to determine the role space processing or materials research in space plays in the superconductor and electrical contact industries are presented. Visits were made to manufacturers, users, and research organizations connected with these products to provide information about the potential benefits of the space environment and to exchange views on the utilization of space facilities for manufacture, process development, or research. In addition, space experiments were suggested which could result in improved terrestrial processes or products. Notable examples of these are, in the case of superconductors, the development of Nb-bronze alloys (Tsuei alloys) and, in the electrical contact field, the production of Ag-Ni or Ag-metal oxide alloys with controlled microstructure for research and development activities as well as for product development. A preliminary experimental effort to produce and evaluate rapidly cooled Pb-Zn and Cu-Nb-Sn alloys in order to understand the relationship between microstructure and superconducting properties and to simulate the fine structure potentially achievable by space processing was also described.

Gelles, S. H.↗

NASA NTRS1983

Integrated Technology Rotor/Flight Research Rotor (ITR/FRR) concept definition

A program was performed to identify and evaluate a variety of candidate rotor hub configurations for the ITR/FRR. Design criteria were established for the development of the hub concepts. Eight initial hub configurations were examined and two were selected for further refinement and evaluation. The selected concepts were bearingless designs with and without lead-lag dampers. The selected concepts were refined to the point that their physical properties relative to the Government's technical goals and manufacturing aspects could be assessed. In addition, variations that could be incorporated for the FRR were identified and compatibility for installation on the RSRA was addressed.

Harse, J. H.↗

NASA NTRS1990

A light-trapping solar cell coverglass

A novel method of reducing surface reflectivity which eliminates the need to texturize the surface of the cell is presented. A double light pass is achieved by using a light-trapping coverglass which redirects reflected light back to the cell surface by total internal reflection. This technique allows low-reflectance surfaces to be used on planar solar cells, including GaAs and InP, with the benefit of increasing the possible short-circuit current (and hence the efficiency) by 6 to 10 percent with no additional steps added to the cell manufacturing process. The coverglass design also has applications to reduction of grid shadowing and to light trapping within the cell.

Landis, Geoffrey A.↗

NASA NTRS1992

Single-Cycle Versus Multicycle Proof Testing

Report compares single-cycle with multiple-cycle mechanical-stress tests of parts under mechanical stresses. Objective of proof testing: to screen out gross manufacturing or material deficiencies and provide additional assurance of quality. Report concludes that changes in distribution of crack sizes during multicycle proof testing depend on initial distribution, number of cycles, relationship between resistance of material and elastic/plastic fracture-mechanics parameter, relationship between load control and displacement control, and magnitude of applied load or displacement. Whether single-cycle or multicycle testing used depends on shape, material, and technique of fabrication of components tested.

Hudak, S. J., Jr.↗

NASA NTRS2000

Effects of Imperfections on the Buckling Response of Compression-Loaded Composite Shells

The results of an experimental and numerical study of the effects of imperfections on the buckling response of unstiffened thin-walled composite cylindrical shells are presented. Results that identify the individual and combined effects of traditional initial geometric shell-wall imperfections and non-traditional shell-wall thickness variations, shell-end geometric imperfections and variations in loads applied to the ends of the shells on the shell buckling response are included. In addition, results illustrating the effects of manufacturing flaws in the form of gaps between adjacent pieces of graphite-epoxy tape in some of the laminate plies are presented in detail. The shells have been analyzed with a nonlinear finite-element analysis code that accurately accounts for these effects on the buckling and nonlinear responses of the shells. The numerical results indicate that traditional and nontraditional initial imperfections can cause a significant reduction in the buckling load of a compression-loaded composite shell. Furthermore, the results indicate that the imperfections couple in a nonlinear manner. The numerical results correlate well with the experimental results. The nonlinear analysis results are also compared to the results from a traditional linear bifurcation buckling analysis. The results suggest that the nonlinear analysis procedure can be used for determining accurate, high-fidelity design knockdown factors for shell buckling and collapse. The results can also be used to determine the effects of manufacturing tolerances on the buckling response of composite shells.

Hilburger, Mark W.↗

NASA NTRS2001

Mars Flyer Rocket Propulsion Risk Assessment: ARC Testing

This report describes the investigation of a 10-N, bipropellant thruster, operating at -40 C, with monomethy1hydrazine (MMH) and 25% nitric oxide in nitrogen tetroxide (MON-25). The thruster testing was conducted as part of a risk reduction activity for the Mars Flyer, a proposed mission to fly a miniature airplane in the Martian atmosphere. Testing was conducted using an existing thruster, designed for MMH and MON-3 propellants. MON-25 oxidizer was successfully manufactured from MON-3 by the addition of nitric oxide. The thruster was operated successfully over a range of propellant temperatures (-40 to 21 C and feed pressures (6.9 to 20.7 kPa). The thruster hardware was always equal or lower than the propellant temperature. Most tests were 30- and 60-second durations, with 600- and 1200-second duration and pulse testing also conducted. When operating at -40 C, the mixture ratio of the thruster shifted from the nominal value of 1.65 to about 1.85, probably caused by an increase in MMH viscosity, with a corresponding reduction in MMH flowrate. Specific impulse at - 40 C (at nominal feed pressures) was 267 sec, while performance was 277 sec at 21 C. This difference in performance was due, in part, to the mixture ratio shift.

Source record↗

NASA NTRS2003

The Evaluation of High Temperature Adhesive Bonding Processes for Rocket Engine Combustion Chamber Applications

NASA Glenn Research Center is currently evaluating the possibility of using high- temperature polymer matrix composites to reinforce the combustion chamber of a rocket engine. One potential design utilizes a honeycomb structure composed of a PMR-II- 50/M40J 4HS composite facesheet and titanium honeycomb core to reinforce a stainless steel shell. In order to properly fabricate this structure, adhesive bond PMR-II-50 composite. Proper prebond surface preparation is critical in order to obtain an acceptable adhesive bond. Improperly treated surfaces will exhibit decreased bond strength and durability, especially in metallic bonds where interface are susceptible to degradation due to heat and moisture. Most treatments for titanium and stainless steel alloys require the use of strong chemicals to etch and clean the surface. This processes are difficult to perform due to limited processing facilities as well as safety and environmental risks and they do not consistently yield optimum bond durability. Boeing Phantom Works previously developed sol-gel surface preparations for titanium alloys using a PETI-5 based polyimide adhesive. In support of part of NASA Glenn Research Center, UDRI and Boeing Phantom Works evaluated variations of this high temperature sol-gel surface preparation, primer type, and primer cure conditions on the adhesion performance of titanium and stainless steel using Cytec FM 680-1 polyimide adhesive. It was also found that a modified cure cycle of the FM 680-1 adhesive, i.e., 4 hrs at 370 F in vacuum + post cure, significantly increased the adhesion strength compared to the manufacturer's suggested cure cycle. In addition, the surface preparation of the PMR-II-50 composite was evaluated in terms of surface cleanness and roughness. This presentation will discuss the results of strength and durability testing conducted on titanium, stainless steel, and PMR-II-50 composite adherends to evaluate possible bonding processes.

McCray, Daniel↗

NASA NTRS1997

An Investigation to Improve Quality Evaluations of Primers and Propellant for 20mm Munitions

To reduce the frequency of electrically initiated, 20mm munition hangfires (delayed ignitions), a joint Army/NASA investigation was conducted to recommend quality evaluation improvements for acceptance of both primers and gun propellant. This effort focused only on evaluating ignition and combustion performance as potential causes of hangfires: poor electrical initiation of the primer, low output performance of the primer, low ignition sensitivity of the gun propellant, and the effects of cold temperature. The goal was to determine the "best" of the Army and NASA test methods to assess the functional performance of primers and gun propellants. The approach was to evaluate the performance of both high-quality and deliberately defective primers to challenge the sensitivity of test methods. In addition, the ignition sensitivity of different manufacturing batches of gun propellants was evaluated. The results of the investigation revealed that improvements can be made in functional evaluations that can assist in identifying and reducing ignition and performance variations. The "best" functional evaluation of primers and propellant is achieved through a combination of both Army and NASA test methods. Incorporating the recommendations offered in this report may provide for considerable savings in reducing the number of cartridge firings, while significantly lowering the rejection rate of primer, propellant and cartridge lots. The most probable causes for ignition and combustion-related hangfires were the lack of calcium silicide in the primer mix, a low output performance of primers, and finally, poor ignition sensitivity of gun propellant. Cold temperatures further reduce propellant ignition sensitivity, as well as reducing burn rate and chamber pressures.

Bement, L. J.↗