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NASA NTRS1995

Library reuse in a rapid development environment

The Aeroscience and Flight Mechanics Division (AFMD) established a Rapid Development Laboratory (RDL) to investigate and improve new 'rapid development' software production processes and refine the use of commercial, off-the-shelf (COTS) tools. These tools and processes take an avionics design project from initial inception through high fidelity, real-time, hardware-in-the-loop (HIL) testing. One central theme of a rapid development process is the use and integration of a variety of COTS tools: This paper discusses the RDL MATRIX(sub x)(R) libraries, as well as the techniques for managing and documenting these libraries. This paper also shows the methods used for building simulations with the Advanced Simulation Development System (ASDS) libraries, and provides metrics to illustrate the amount of reuse for five complete simulations. Combining ASDS libraries with MATRIX(sub x)(R) libraries is discussed.

Uhde, JO↗

NASA NTRSDate not supplied

Influence of Thermophysical Property Variability on Thermal Predictions of Ti-6Al-4V

The additive manufacturing (AM) industry has experienced rapid growth in recent decades as industrial interest in the process has grown. Because of this, there are many groups interested in simulations of the AM process. However, the influence of thermophysical property variability on the melt pool geometry during processing of various AM alloys is unclear. The goal of my work at NASA Langley Research Center (LaRC) was to characterize this influence on Ti-6Al-4V during AM processing alongside developing a tool to enable equivalent studies on other AM materials. To facilitate this process, a database tool was developed to contain and organize thermophysical data previously reported by primary sources. The specific thermophysical properties of interest for this study were density, specific heat capacity, and conductivity. Thermal diffusivity was calculated using the other three properties. This data was then fit with a Gaussian distribution and then randomly sampled from using Monte Carlo random value sampling. Using the Rosenthal equation, this sample data was used to simulate the temperature field during additive manufacturing and extract the melt pool geometry. Specifically, the melt pool’s length, width, and depth. This process was repeated an arbitrary number of times, with the default being 1000. Once this information was obtained, histograms were made showing the distributions of the sizes of the melt pool’s length, width, and depth. Representative statistical metrics of the distributions were calculated (mean, standard deviation, and coefficient of variance). This work found that at the simulated processing values, the melt pool’s width and depth had a 5.7% variation while the length had a 3.2% variation. Additionally, a tool was constructed to graph a thermal color map representation of the melt pool for specific, arbitrary values of density, specific heat, and conductivity. This tool allowed for more efficient plotting of individual queries of the thermophysical properties. The results that were observed in the research were that values reported in literature vary and this variance can have a significant impact on the simulation. Predictions of the melt pool’s dimensions show that length has a standard deviation of approximately 6 μm, width has a standard deviation of approximately 5 μm, and depth can vary by approximately 3 μm. Considering the mean sizes of length, width, and depth are 185 μm, 88 μm, and 44 μm respectively, such a deviation is significant. This shows that depth, for example, could be more than 10% larger or smaller than expected. This demonstrates that variability in the reported thermophysical properties are not negligible and should be expected to have an influence on the results of the laser powder bed fusion additive manufacturing process. When simulating this process in the future, measures should be taken to account for this discrepancy and the uncertainty involved

Justin Martin↗

NASA NTRS1978

Process air quality data

Air quality sampling was conducted. Data for air quality parameters, recorded on written forms, punched cards or magnetic tape, are available for 1972 through 1975. Computer software was developed to (1) calculate several daily statistical measures of location, (2) plot time histories of data or the calculated daily statistics, (3) calculate simple correlation coefficients, and (4) plot scatter diagrams. Computer software was developed for processing air quality data to include time series analysis and goodness of fit tests. Computer software was developed to (1) calculate a larger number of daily statistical measures of location, and a number of daily monthly and yearly measures of location, dispersion, skewness and kurtosis, (2) decompose the extended time series model and (3) perform some goodness of fit tests. The computer program is described, documented and illustrated by examples. Recommendations are made for continuation of the development of research on processing air quality data.

Butler, C. M.↗

NASA NTRSDate not supplied

Additive Manufacturing (AM) for Propulsion Component and System Applications

NASA MSFC is developing several areas of additive manufacturing (AM) for propulsion component and system applications. These developments include new AM process and material development, large-scale AM pathfinder component fabrication and hot-fire testing, AM-centric design methodology, modeling and simulation, post-processing advancements, and new design applications of AM in aerospace. Some specific areas NASA has focused is the development and commercial infusion of AM supply chain for materials such as copper-alloy GRCop (Cu-Cr-Nb), Hydrogen-resistant alloys (NASA HR-1, JBK-75), refractory-based alloys (C-103, W, Mo, new formulations), and bimetallic and multi-metallic AM processes. Additional efforts have been focused on large scale AM demonstrating complex thin-wall structures up to 60” diameter using directed energy deposition. Material characterization, properties and component hot-fire testing has been completed using many of these newly developed AM alloys/processes. NASA has also focused on improvements to post-processing including powder removal, surface enhancements, and support removal to further realize cost and schedule benefits to the overall supply chain. These developments are part of the NASA Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), Low Cost Upper Stage Propulsion (LCUSP) and Long Life Additive Manufacturing (LLAMA) projects, in addition to internal IRAD, and external collaborations.

Additive Manufacturing↗

NASA NTRS1992

Service tough composite structures using the Z-direction reinforcement process

Foster-Miller has developed a new process to provide through thickness reinforcement of composite structures. The process reinforces laminates locally or globally on-tool during standard autoclave processing cycles. Initial test results indicate that the method has the potential to significantly reduce delamination in carbon-epoxy. Laminates reinforced with the z-fiber process have demonstrated significant improvements in mode 1 fracture toughness and compression strength after impact. Unlike alternative methods, in-plane properties are not adversely affected.

Freitas, Glenn↗

NASA NTRSDate not supplied

Series Bosch Carbon Formation Reactor Trade Study and Down-Select

Human exploration missions to Mars and other destinations beyond low Earth orbit require highly robust, reliable, and maintainable life support systems that maximize the recovery of oxygen (O2). One process in development and under consideration is the Series-Bosch System (S-Bosch). This system is a two stage reactor process that reduces carbon dioxide (CO2) with hydrogen (H2) to produce water and solid carbon. Theoretically, the Bosch process can recover 100% of the O2 from CO2 in the form of water, making it an attractive option for long duration missions. The Series Bosch system includes a reverse water gas shift (RWGS) reactor, a carbon formation reactor (CFR), a H2 extraction membrane, and a CO2extraction membrane. To further the development of oxygen recovery systems, NASA awarded Phase I contracts to several entities under the Game Changing Development Program addressing Spacecraft Oxygen Recovery (SCOR). Two of the hardware deliverables were integrated into the Carbon Dioxide Reduction Test Stand (CORTS) as carbon formation reactors and performance evaluations were executed at Marshall Space Flight Center. A trade study was performed between these two reactors along with one developed at MSFC. This paper provided the necessary information for the Advanced Exploration Systems/Life Support Systems Project (AES/LSS) managers to select a CFR for further development and discusses the process of selection.

Bosch↗

NASA NTRS2008

Automated Translation of Safety Critical Application Software Specifications into PLC Ladder Logic

The numerous benefits of automatic application code generation are widely accepted within the software engineering community. A few of these benefits include raising the abstraction level of application programming, shorter product development time, lower maintenance costs, and increased code quality and consistency. Surprisingly, code generation concepts have not yet found wide acceptance and use in the field of programmable logic controller (PLC) software development. Software engineers at the NASA Kennedy Space Center (KSC) recognized the need for PLC code generation while developing their new ground checkout and launch processing system. They developed a process and a prototype software tool that automatically translates a high-level representation or specification of safety critical application software into ladder logic that executes on a PLC. This process and tool are expected to increase the reliability of the PLC code over that which is written manually, and may even lower life-cycle costs and shorten the development schedule of the new control system at KSC. This paper examines the problem domain and discusses the process and software tool that were prototyped by the KSC software engineers.

Leucht, Kurt W.↗

NASA NTRS1989

Explicit modeling and computational load distribution for concurrent processing simulation of the space station

Two important aspects of concurrent processing under development at TRW are discussed. These are: (1) the derivation of explicit mathematical models of multibody dynamic systems, and (2) a balanced computational load distribution (BCLD) among loosely coupled computational units (processors) of a concurrent processing system. The developed methodologies are demonstrated by way of an application to the Phase 1 of the Space Station - a task being performed by TRW under NASA/JSC contract NAS9-17778. The mathematical model of the Space Station consists of three interconnected flexible bodies capable of undergoing large, rigid-body motion with respect to each other. Body 1 is the main central body and contains the pressurized modules inboard of the two Alpha gimbals. Bodies 2 and 3 are the starboard and port bodies connected to Body 1 at the Alpha gimbals and include all components on the transverse booms outboard of the Alpha gimbals (including the solar arrays). The control systems in the model maintain Body 1 in a prescribed 3-axis attitude control mode, while producing large-angle rotations of the flexible solar arrays to position them normal to the sun-line.

Gluck, R.↗

NASA NTRS1983

Parallel processing in a host plus multiple array processor system for radar

Host plus multiple array processor architecture is demonstrated to yield a modular, fast, and cost-effective system for radar processing. Software methodology for programming such a system is developed. Parallel processing with pipelined data flow among the host, array processors, and discs is implemented. Theoretical analysis of performance is made and experimentally verified. The broad class of problems to which the architecture and methodology can be applied is indicated.

Barkan, B. Z.↗

NASA NTRS1991

Fabrication of lightweight Si/SiC LIDAR mirrors

A new, chemical vapor deposition (CVD) process was developed for fabricating lightweight, polycrystalline silicon/silicon-carbide (Si/SiC) mirrors. The process involves three CVD steps: (1) to produce the mirror faceplate; (2) to form the lightweight backstructure, which is deposited integral to the faceplate; and (3) to deposit a layer of optical-grade material, e.g., Si, onto the front surface of the faceplate. The mirror figure and finish are fabricated into the faceplate.

Goela, Jitendra S.↗

NASA NTRS1991

A Process for Preparing 1,3-Diamino-5-Pentafluorosulfanylbenzene and Polymers Therefrom

Diamines have shown their utility in the formation of many polymers. Examples of these polymers include polyimides, polyamides, and epoxies. The properties of these polymers are often dependent on the diamine which is used to make the polymer. By the present invention, a process was developed to make a diamine containing pentafluorosulfanylbenzene moiety. This process involves two steps: the preparation of a dinitro precursor and the reduction of the dinitro compound to form the diamine. This diamine was then reacted with various dianhydrides, diacidchlorides, and epoxy resins to yield the corresponding polyimide, polyamide, and epoxy polymers. These polymers were then used to make films, a wire coating enamel, and a semi-permeable membrane. The novelty of this invention resides in the process to make the diamine. Traditionally, dinitro compounds are reduced with hydrazine or a catalyst such as palladium on charcoal. The catalyst which is used in this invention is platinum oxide. When this catalyst is used, it makes it possible to form a polymer-grade diamine.

St.clair, Anne K.↗

NASA NTRS1993

Textile composite processing science

A multi-dimensional model of the Resin Transfer Molding (RTM) process was developed for the prediction of the infiltration behavior of a resin into an anisotropic fiber preform. Frequency dependent electromagnetic sensing (FDEMS) was developed for in-situ monitoring of the RTM process. Flow visualization and mold filling experiments were conducted to verify sensor measurements and model predictions. Test results indicated good agreement between model predictions, sensor readings, and experimental data.

Loos, Alfred C.↗

NASA NTRS1999

X-33/RLV Program Aerospike Engines

Substantial progress was made during the past year in support of the X-33/RLV program. X-33 activity was directed towards completing the remaining design work and building hardware to support test activities. RLV work focused on the nozzle ramp and powerpack technology tasks and on supporting vehicle configuration studies. On X-33, the design activity was completed to the detail level and the remainder of the drawings were released. Component fabrication and engine assembly activity was initiated, and the first two powerpacks and the GSE and STE needed to support powerpack testing were completed. Components fabrication is on track to support the first engine assembly schedule. Testing activity included powerpack testing and component development tests consisting of thrust cell single cell testing, CWI system spider testing, and EMA valve flow and vibration testing. Work performed for RLV was divided between engine system and technology development tasks. Engine system activity focused on developing the engine system configuration and supporting vehicle configuration studies. Also, engine requirements were developed, and engine performance analyses were conducted. In addition, processes were developed for implementing reliability, mass properties, and cost controls during design. Technology development efforts were divided between powerpack and nozzle ramp technology tasks. Powerpack technology activities were directed towards the development of a prototype powerpack and a ceramic turbine technology demonstrator (CTTD) test article which will allow testing of ceramic turbines and a close-coupled gas generator design. Nozzle technology efforts were focused on the selection of a composite nozzle supplier and on the fabrication and test of composite nozzle coupons.

Source record↗

NASA NTRS2001

Automated Fiber Placement of PEEK/IM7 Composites with Film Interleaf Layers

The incorporation of thin discrete layers of resin between plies (interleafing) has been shown to improve fatigue and impact properties of structural composite materials. Furthermore, interleafing could be used to increase the barrier properties of composites used as structural materials for cryogenic propellant storage. In this work, robotic heated-head tape placement of PEEK/IM7 composites containing a PEEK polymer film interleaf was investigated. These experiments were carried out at the NASA Langley Research Center automated fiber placement facility. Using the robotic equipment, an optimal fabrication process was developed for the composite without the interleaf. Preliminary interleaf processing trials indicated that a two-stage process was necessary; the film had to be tacked to the partially-placed laminate then fully melted in a separate operation. Screening experiments determined the relative influence of the various robotic process variables on the peel strength of the film-composite interface. Optimization studies were performed in which peel specimens were fabricated at various compaction loads and roller temperatures at each of three film melt processing rates. The resulting data were fitted with quadratic response surfaces. Additional specimens were fabricated at placement parameters predicted by the response surface models to yield high peel strength in an attempt to gage the accuracy of the predicted response and assess the repeatability of the process. The overall results indicate that quality PEEK/lM7 laminates having film interleaves can be successfully and repeatability fabricated by heated head automated fiber placement.

Hulcher, A. Bruce↗

NASA NTRS2007

Coating Carbon Fibers With Platinum

A process for coating carbon fibers with platinum has been developed. The process may also be adaptable to coating carbon fibers with other noble and refractory metals, including rhenium and iridium. The coated carbon fibers would be used as ingredients of matrix/fiber composite materials that would resist oxidation at high temperatures. The metal coats would contribute to oxidation resistance by keeping atmospheric oxygen away from fibers when cracks form in the matrices. Other processes that have been used to coat carbon fibers with metals have significant disadvantages: Metal-vapor deposition processes yield coats that are nonuniform along both the lengths and the circumferences of the fibers. The electrical resistivities of carbon fibers are too high to be compatible with electrolytic processes. Metal/organic vapor deposition entails the use of expensive starting materials, it may be necessary to use a furnace, and the starting materials and/or materials generated in the process may be hazardous. The present process does not have these disadvantages. It yields uniform, nonporous coats and is relatively inexpensive. The process can be summarized as one of pretreatment followed by electroless deposition. The process consists of the following steps: The surfaces of the fiber are activated by deposition of palladium crystallites from a solution. The surface-activated fibers are immersed in a solution that contains platinum. A reducing agent is used to supply electrons to effect a chemical reduction in situ. The chemical reduction displaces the platinum from the solution. The displaced platinum becomes deposited on the fibers. Each platinum atom that has been deposited acts as a catalytic site for the deposition of another platinum atom. Hence, the deposition process can also be characterized as autocatalytic. The thickness of the deposited metal can be tailored via the duration of immersion and the chemical activity of the solution.

Effinger, Michael R.↗

NASA NTRS2014

Fast Response Shape Memory Effect Titanium Nickel (TiNi) Foam Torque Tubes

Shape Change Technologies has developed a process to manufacture net-shaped TiNi foam torque tubes that demonstrate the shape memory effect. The torque tubes dramatically reduce response time by a factor of 10. This Phase II project matured the actuator technology by rigorously characterizing the process to optimize the quality of the TiNi and developing a set of metrics to provide ISO 9002 quality assurance. A laboratory virtual instrument engineering workbench (LabVIEW'TM')-based, real-time control of the torsional actuators was developed. These actuators were developed with The Boeing Company for aerospace applications.

Jardine, Peter↗

NASA NTRS2017

Designing Flightdeck Procedures: Literature Resources

This technical publication contains the titles, abstracts, summaries, descriptions, and/or annotations of available literature sources on procedure design and development, requirements, and guidance. It is designed to provide users with an easy access to available resources on the topic of procedure design, and with a sense of the contents of these sources. This repository of information is organized into the following publication sources: Research (e.g., journal articles, conference proceedings), Manufacturers' (e.g., operation manuals, newsletters), and Regulatory and/or Government (e.g., advisory circulars, reports). An additional section contains synopses of Accident/Incident Reports involving procedures. This work directly supports a comprehensive memorandum by Barshi, Mauro, Degani, & Loukopoulou (2016) that summarizes the results of a multi-year project, partially funded by the FAA, to develop technical reference materials that support guidance on the process of developing cockpit procedures (see "Designing Flightdeck Procedures" https://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/20160013263.pdf). An extensive treatment of this topic is presented in a forthcoming book by the same authors.

flightdeck↗

NASA NTRSDate not supplied

Data Science and the Knowledge Discovery Adventure

This talk will cover the important steps involved in the data science and knowledge discovery process: • Initial fact gathering (interview domain experts, review reports, articles, state-of-the-art) • Identify the problem (prediction, classification, statistical analysis, etc.) • Survey supporting data sources • Understand the data (numerical, categorical, text, sampling rate, data quality issues, etc.) • Selecting relevant features and sources • Acquire the data (set up agreements with the data stewards, APIs to download, etc.) • Merge data sources (temporal, spatial, common key, other ontologies...) • Feature Engineering (non linear domain knowledge or physics-based relationships) • Build data processing pipeline (may need to tap into data stream, develop parallel processing algorithm, federated learning etc.) • Build model and test (tune hyper-parameters, cross validation.) • Analyze/Validate results (do the results make sense. Does it answer the original question). • Deploy/Publish (Monitor and assess benefits)

Data science↗