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Manufacturing process makes CxSiyNz fibers. Precursor fibers spun from extruding machine charged with polycarbosilazane resin. When pyrolyzed, resin converted to cross-linked mixture of silicon carbide and silicon nitride, still in fiber form. CxSiyNz fibers promising substitutes for carbon fibers in high-strength, low-weight composites where high electrical conductivity unwanted.
In July of 1984, Hughes and JPL initiated a contract for Hughes to design, fabricate and test 10 thin film Amorphous Silicon (a-Si) photovoltaic power modules. These modules were to be 1 ft x 4 ft in size. They were to be preceded by the delivery of 10 a-Si 4 in. square test devices. This effort is very timely since thin film PV development has progressed to the point where intermediate load power applications are on the horizon. It is important to know if current a-Si submodule design and manufacturing processes yield a product that is compatible with the packaging needed to meet a 20 to 30 year life span expectancy. The term submodule is assigned to an interconnected assembly of 28 a-Si cells deposited on a 1 foot square glass superstrate. These assemblies are equipped with electrical terminations, i.e., copper tabs at the four corners of the inverted submodules. It is these submodules that are to be interconnected and packaged into power modules, as opposed to the interconnected individual crystalline cells packaged into todays PV modules. A discussion of the fabrication methods and results follows.
NASA Lewis Research Center is currently involved in advanced cell component development for nickel-hydrogen cells and batteries. Long life, high energy density, improved performance and reliability are required for energy storage systems in future space missions. Commercially available as well as experimental hydrogen electrodes were assessed and copared to the state-of-the-art hydrogen electrode that is currently being used in nickel-hydrogen batteries. These electrodes were evaluated by scanning electron microscopy and standard electrochemical polarization measurements. Production variables such as Teflon content and platinum catalyst loading were considered in order to assess various hydrogen electrods with regard to the different electrode manufacturing processes.
A systems approach was adopted to study the pocketing phenomena on a solid rocket nozzle liner. The classical thermoelastic analysis was used to identify marginally strained regions on the composite liner erosion surface and at a depth coincident with the peak value of the across ply coefficient of thermal expansion. A failure criterion was introduced which included a thermal term and permitted failure assessment over the charred liner. The method was verified by satisfactory application to a reported related experiment. Liner pocketing mechanism was attributed to very localized material degradation caused during manufacturing process either by reduction of fiber strength and/or by concentration of resin volume fraction. Pocketing scenario over the degraged material was constructed with supporting formulation to predict size of fissures with respect to degraded material size and location in the liner and with burn time. Sensitivities of liner material parameters were determined to influence test programs designed to update mechanical data base of carbon cloth phenolic over the char temperature range.
The expert systems required for automating key functions of the Manned Space Station (MSS) are explored. It is necessary that the expert systems developed be flexible, degrade gracefully in the case of a failure, and be able to work with incomplete data. The AI systems will have to perform interpretation and diagnosis, design, prediction and induction, and monitoring and control functions. Both quantitative and qualitative reasoning capabilities need improvements, as do automatic verification techniques, explanation and learning capabilities, and the use of metaknowledge, i. e., knowledge about the knowledge contained in the knowledge base. Information retrieval, fault isolation and manufacturing process control demonstrations are needed to validate expert systems for the MSS.
Starting with the NASA-sponsored STAEBL program, optimization methods based primarily upon the versatile program COPES/CONMIN were introduced over the past few years to a broad spectrum of engineering problems in structural optimization, engine design, engine test, and more recently, manufacturing processes. By automating design and testing processes, many repetitive and costly trade-off studies have been replaced by optimization procedures. Rather than taking engineers and designers out of the loop, optimization has, in fact, put them more in control by providing sophisticated search techniques. The ultimate decision whether to accept or reject an optimal feasible design still rests with the analyst. Feedback obtained from this decision process has been invaluable since it can be incorporated into the optimization procedure to make it more intelligent. On several occasions, optimization procedures have produced novel designs, such as the nonsymmetric placement of rotor case stiffener rings, not anticipated by engineering designers. In another case, a particularly difficult resonance contraint could not be satisfied using hand iterations for a compressor blade, when the STAEBL program was applied to the problem, a feasible solution was obtained in just two iterations.
Failure of Stirling Space Power Demonstrator Engine (SPDE) regenerator screens was investigated. After several hours of operation the SPDE was shut down for inspection and on removing the regenerator screens, debris of unknown origin was discovered along with considerable cracking of the screens in localized areas. Metallurgical analysis of the debris determined it to be cracked-off-deformed pieces of the 41 micron thickness Type 304 stainless steel wire screen. Scanning electron microscopy of the cracked screens revealed failures occurring at wire crossovers and fatigue striations on the fracture surface of the wires. Thus, the screen failure can be characterized as a fatigue failure of the wires. The crossovers were determined to contain a 30 percent reduction in wire thickness and a highly worked microstructure occurring from the manufacturing process of the wire screens. Later it was found that reduction in wire thickness occurred because the screen fabricator had subjected it to a light cold-roll process after weaving. Installation of this screen left a clearance in the regenerator allowing the screens to move. The combined effects of the reduction in wire thickness, stress concentration (caused by screen movement), and highly worked microstructure at the wire crossovers led to the fatigue failure of the screens.
The low gravity environment of the space station is suitable for experiments or manufacturing processes which require near zero gravity. An experiment was fabricated to test the validity of the active control process and to verify the flow and control parameters identified in a theoretical model. Zero gravity is approximated in the horizontal plane using a low friction air bearing table. An analog control system was designed to activate calibrated air jets when displacement of the test mass is sensed. The experiment demonstrates that an air jet control system introduces an effective damping factor to control oscillatory response. The amount of damping as well as the flow parameters, such as pressure drop across the valve and flow rate of air, are verified by the analytical model.
The research program of Semiconductor Research Corp. is managed as three overlapping areas: Manufacturing Sciences, Design Sciences and Microstructure Sciences. A total of 40 universities are participating in the performance of over 200 research tasks. The goals and direction of Manufacturing Sciences research became more clearly focused through the efforts of the Manufacturing Sciences Committee of the SRC Technical Advisory Board (TAB). The mission of the SRC Manufacturing Research is the quantification, control, and understanding of semiconductor manufacturing process necessary to achieve a predictable and profitable product output in the competitive environment of the next decade. The 1994 integrated circuit factory must demonstrate a three level hierarchy of control: (1) operation control, (2) process control, and (3) process design. These levels of control are briefly discussed.
Fiber reinforcements are being explored as a means to increasing the performance of superalloys past 980 C. Fiber-reinforced superalloys (FRS), particularly tungsten FRS (TFRS) are candidate materials for rocket-engine turbopump blades for advanced Shuttle engines and in airbreathing and other rocket engines. Refractory metal wires are the reinforcement of choice due to tolerance to fiber/matrix interactions. W alloy fibers have a maximum tensile strength of 2165 MPa at 1095 C and a 100 hr creep rupture strength at stresses up to 1400 MPa. A TFRS has the potential of a service temperature 110 C over the strongest superalloy. Manufacturing processes being evaluated to realize the FRS components are summarized, together with design features which will be introduced in turbine blades to take advantage of the FRS materials and to extend their surface life.
An extensive experimental test program was conducted to define the dynamic characteristics of the newly installed fan blades of the NASA Ames 40- by 80-/80- by 120-Foot Wind Tunnel. The tests were intended to substantiate the blade design and manufacturing process, verify installation integrity, and guarantee safe fan-drive operation. The program included a shake test of each fan blade after installation and before operation as well as the monitoring of blade strain levels during initial operation. Structural characteristics, as determined by the shake test, include the modal frequency and damping values for elastic bending and torsion modes between 5 and 130 Hz. Operational testing defined the maximum and oscillatory blade-bending strains throughout the drive-system operational envelope. Results are presented for the shake test and initial operation of the 40- by 80-Foot Wind Tunnel circuit.
Addressing elements indirectly through shift register reduces number of test probes. With aid of new technique, complex test structure on silicon wafer tested with relatively small number of test probes. Conserves silicon area by reduction of area devoted to pads. Allows thorough evaluation of test structure characteristics and of manufacturing process parameters. Test structure consists of shift register and matrix of inverter/transmission-gate cells connected to two-by-ten array of probe pads. Entire pattern contained in square area having only 1.6-millimeter sides. Shift register is conventional static CMOS device using inverters and transmission gates in master/slave D flip-flop configuration.
In experimental manufacturing process, numerically-controlled machine tool temporarily converts into inspection machine by installing electronic touch probes and specially-developed numerical-control software. Software drives probes in paths to and on newly machined parts and collects data on dimensions of parts.
Failure of Stirling Space Power Demonstrator Engine (SPDE) regenerator screens was investigated. After several hours of operation the SPDE was shut down for inspection and on removing the regenator screens, debris of unknown origin was discovered along with considerable cracking of the screens in localized areas. Metallurgical analysis of the debris determined it to be cracked-off-deformed pieces of the 41 micron thickness Type 304 stainless steel wire screen. Scanning electron microscopy of the cracked screens revealed failures occurring at wire crossovers and fatigue striations on the fracture surface of the wires. Thus, the screen failure can be characterized as a fatigue failure of the wires. The crossovers were determined to contain 30 percent reduction in wire thickness and a highly worked microstructure occurring from the manufacturing process of the wire screens. Later it was found that reduction in wire thickness occurred because the screen fabricator had subjected it to a light cold-roll process after weaving. Installation of this screen left a clearance in the regenerator allowing the screens to move. The combined effects of the reduction in wire thickness, stress concentration (caused by screen movement), and highly worked microstructure at the wire crossovers led to the fatigue failure of the screens.
NASA Lewis Research Center is currently involved in advanced cell component development for nickel-hydrogen cells and batteries. Long life, high energy density, improved performance and reliability are required for energy storage systems in future space missions. Commercially available as well as experimental hydrogen electrodes were assessed and compared to the state-of-the-art hydrogen electrode that is currently being used in nickel-hydrogen batteries. These electrodes were evaluated by scanning electron microscopy and standard electrochemical polarization measurements. Production variables such as Teflon content and platinum catalyst loading were considered in order to assess various hydrogen electrodes with regard to the different electrode manufacturing processes.
The flight problems experienced with the reusable Space Shuttle Orbiter have decreased during subsequent flights of each vehicle. By comparison to first flights of previous vehicles, the problems encountered on the initial flight of each new vehicle entering the fleet decreased. This improvement in turn has reduced the turnaround time between flights significantly and thus greatly enhanced the increased Space Shuttle launch frequency. The reusable manned space vehicle concept necessitated the development of a flight problem recognition and resolution system which would enable a thorough and timely vehicle turnaround flow. Flight evaluation, testing, and repair of manned spacecraft to enhance reliability and to ensure mission success is a unique activity. Real-time recognition of the flight problem, prompt isolation of the cause, and timely implementation of the corrective action are the keys to maintaining an operational fleet. Examples of flight problems that have been encountered as well as the corrective actions implemented during the first 24 Space Shuttle missions are presented. The corrective actions taken to preclude problem recurrence include modifications of hardware designs, manufacturing processes, flight software, test methods, and operational procedures.
This paper is concerned with the implementation and assessment of joint motion management strategies for kinematically redundant robotic manipulators operating in the micro-gravity environment of Space Station. These robots must be capable of conducting experiments and manufacturing processes without disturbing the micro-gravity environment through base reactions/motions. The redundant degrees of freedom of the manipulator permit the inverse kinematic problem to be solved simultaneously with the minimization of a cost function. The cost function in this case is the weighted sum of the squares of the base forces and moments and is minimized over discrete time segments. The Generalized Inverse Method and Rayleigh Ritz technique are used to solve the combined optimization/inverse kinematics problem. Numerical examples include various robotic configurations and degrees of manipulator redundancy.
When tracking control systems are used in repetitive operations such as robots in various manufacturing processes, the controller will make the same errors repeatedly. Here consideration is given to learning controllers that look at the tracking errors in each repetition of the process and adjust the control to decrease these errors in the next repetition. A general formalism is developed for learning control of discrete-time (time-varying or time-invariant) linear multivariable systems. Methods of specifying a desired trajectory (such that the trajectory can actually be performed by the discrete system) are discussed, and learning controllers are developed. Stability criteria are obtained which are relatively easy to use to insure convergence of the learning process, and proper gain settings are discussed in light of measurement noise and system uncertainties.