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At least 1,747 records · Page 97

The Use of a Satellite Communications System for Command and Control of the National Aeronautics and Space Administration Surrogate Unmanned Aerial System Research Aircraft

The NASA Langley Research Center has transformed a Cirrus Design SR22 general aviation (GA) aircraft into an Unmanned Aerial Systems (UAS) Surrogate research aircraft which has served for several years as a platform for unmanned systems research and development. The aircraft is manned with a Safety Pilot and a Research Systems Operator (RSO) that allows for flight operations almost any-where in the national airspace system (NAS) without the need for a Federal Aviation Administration (FAA) Certificate of Authorization (COA). The UAS Surrogate can be remotely controlled from a modular, transportable ground control station (GCS) like a true UAS. Ground control of the aircraft is accomplished by the use of data links that allow the two-way passage of the required data to control the aircraft and provide the GCS with situational awareness. The original UAS Surrogate data-link system was composed of redundant very high frequency (VHF) data radio modems with a maximum range of approximately 40 nautical miles. A new requirement was developed to extend this range beyond visual range (BVR). This new requirement led to the development of a satellite communications system that provided the means to command and control the UAS Surrogate at ranges beyond the limits of the VHF data links. The system makes use of the Globalstar low earth orbit (LEO) satellite communications system. This paper will provide details of the development, implementation, and flight testing of the satellite data communications system on the UAS Surrogate research aircraft.

Howell, Charles T.↗

Automatic Waveform Quality Control for Surface Waves Using Machine Learning

Surface-wave seismograms are widely used by researchers to study Earth’s interior and earthquakes. To extract information reliably and robustly from a suite of surface waveforms, the signals require quality control screening to reduce artifacts from signal complexity and noise. This process has usually been completed by human experts labeling each waveform visually, which is time consuming and tedious for large data sets. We explore automated approaches to improve the efficiency of waveform quality control processing by investigating logistic regression, support vector machines, K-nearest neighbors, random forests (RF), and artificial neural networks (ANN) algorithms. To speed up signal quality assessment, we trained these five machine learning (ML) methods using nearly 400,000 human-labeled waveforms. The ANN and RF models outperformed other algorithms and achieved a test accuracy of 92%. We evaluated these two best-performing models using seismic events from geographic regions not used for training. The results show that the two trained models agree with labels from human analysts but required only 0.4% of the time. Although the original (human) quality assignments assessed general waveform signal-to-noise, the ANN or RF labels can help facilitate detailed waveform analysis. Our investigations demonstrate the capability of the automated processing using these two ML models to reduce outliers in surface-wave-related measurements without human quality control screening.

58 GEOSCIENCES↗

NGEE Arctic CO2, CH4 and Energy Eddy-Covariance (EC) Flux Tower Auxiliary Measurements, Council Road Mile Marker 71, Seward Peninsula, Alaska, 2017 - 2019

Measurements began in July 2017 and are made year-round (2017 seasonal only) on the tussock tundra with discontinuous permafrost at the Council Road Site on the Seward Peninsula. CO2, CH4 and energy fluxes using the Eddy Covariance (EC) technique (Baldocchi 2003) and meteorological measurements are reported as 30-minute averages. The tower site is registered with AmeriFlux as US-NGC. See http://ameriflux.lbl.gov/sites/siteinfo/US-NGC for more information. Reported data include: (1) additional/extra meteorological and eddy covariance CO2, CH4 and energy flux data, (2) binned spectra for the three wind components, the sonic temperature and gas densities together with the binned cospectra for covariances of w (vertical wind component) and gas densities, (3) binned ogives (cumulative (co)spectra) for the three wind components, the sonic temperature and gas densities, and (4) tower site footprint matrices. The majority of the files are *.csv with paired visualization footprint files as *.jpg. Meteorological and eddy covariance CO2, CH4 and energy flux data (AmeriFlux BASE data product) are available from AmeriFlux BASE US-NGC NGEE Arctic Council (Torn, 2020) https://doi.org/10.17190/AMF/1634883. The Next-Generation Ecosystem Experiments: Arctic (NGEE Arctic), was a research effort to reduce uncertainty in Earth System Models by developing a predictive understanding of carbon-rich Arctic ecosystems and feedbacks to climate. NGEE Arctic was supported by the Department of Energy's Office of Biological and Environmental Research. The NGEE Arctic project had two field research sites: 1) located within the Arctic polygonal tundra coastal region on the Barrow Environmental Observatory (BEO) near Utqiagvik (Barrow), Alaska and 2) multiple areas in the discontinuous permafrost region of the Seward Peninsula north of Nome, Alaska. Through observations, experiments, and synthesis with existing datasets, NGEE Arctic provided an enhanced knowledge base for multi-scale modeling and contributed to improved process representation at global pan-Arctic scales within the Department of Energy's Earth system Model (the Energy Exascale Earth System Model, or E3SM), and specifically within the E3SM Land Model component (ELM).

54 ENVIRONMENTAL SCIENCES↗

Skylab-4 visual observations project: Geological features of southwestern North America

Visual observations conducted by Skylab-4 crewmen on seven designated geological target areas and other targets of opportunity in parts of southwestern United States and northwestern Mexico were described. The experiments were designed to learn how effectively geologic features could be observed from orbit and what research information could be obtained from the observations when supported by ground studies. For the limited preparation they received, the crewmen demonstrated exceptional observational ability and produced outstanding photographic studies. They also formulated cogent opinions on how to improve future observational and photo-documentation techniques. From the photographs and other observations, it was possible to obtain significant research contributions to on-going field investigations. These contributions were integrated into other aspects of the ground investigations to the following topics: major faults, regional stratigraphy, occurrence of Precambrian crystalline rocks, mapping of Mesozoic volcanic rocks, regional geology.

Silver, L. T.↗

Space technology putting it in the educational perspective

One of the precepts of the company was to provide educators with practical, innovative, and manageable audio-visual teaching aids in a wide spectrum of educational fields, but primarily geography, geology and social science. A pilot slide set was prepared, demonstrating primary areas along the entire length of the San Andreas Fault Zone in California and Mexico. This set utilized several NASA infrared research aircraft photos, to more clearly delineate fault traces. A decision was made to mount a massive program of repackaging NASA generated infrared aircraft imagery into topical teaching sets.

Hankins, D. B.↗

In-flight total forces, moments and static aeroelastic characteristics of an oblique-wing research airplane

A low-speed flight investigation has provided total force and moment coefficients and aeroelastic effects for the AD-1 oblique-wing research airplane. The results were interpreted and compared with predictions that were based on wind tunnel data. An assessment has been made of the aeroelastic wing bending design criteria. Lateral-directional trim requirements caused by asymmetry were determined. At angles of attack near stall, flow visualization indicated viscous flow separation and spanwise vortex flow. These effects were also apparent in the force and moment data.

Curry, R. E.↗

Engineering Data Compendium. Human Perception and Performance, Volume 1

The concept underlying the Engineering Data Compendium was the product an R and D program (Integrated Perceptual Information for Designers project) aimed at facilitating the application of basic research findings in human performance to the design of military crew systems. The principal objective was to develop a workable strategy for: (1) identifying and distilling information of potential value to system design from existing research literature, and (2) presenting this technical information in a way that would aid its accessibility, interpretability, and applicability by system designers. The present four volumes of the Engineering Data Compendium represent the first implementation of this strategy. This is Volume 1, which contains sections on Visual Acquisition of Information, Auditory Acquisition of Information, and Acquisition of Information by Other Senses.

Boff, Kenneth R.↗

Utilization of Space Station Freedom for technology research

Space Station Freedom presents a unique opportunity for technology developers to conduct research in the space environment. Research can be conducted in the pressurized volume of the Space Station's laboratories or attached to the Space Station truss in the vacuum of space. Technology developers, represented by the Office of Aeronautics and Space Technology (OAST), will have 12 percent of the available Space Station resources (volume, power, data, crew, etc.) to use for their research. Most technologies can benefit from research on Space Station Freedom and all these technologies are represented in the OAST proposed traffic model. This traffic model consists of experiments that have been proposed by technology developers but not necessarily selected for flight. Experiments to be flown in space will be selected through an Announcement of Opportunity (A.O.) process. The A.O. is expected to be released in August, 1992. Experiments will generally fall into one of the 3 following categories: (1) Individual technology experiments; (2) Instrumented Space Station; and (3) Guest investigator program. The individual technology experiments are those that do not instrument the Space Station nor directly relate to the development of technologies for evolution of Space Station or development of advanced space platforms. The Instrumented Space Station category is similar to the Orbiter Experiments Program and allows the technology developer to instrument subsystems on the Station or develop instrumentation packages that measure products or processes of the Space Station for the advancement of space platform technologies. The guest investigator program allows the user to request data from Space Station or other experiments for independent research. When developing an experiment, a developer should consider all the resources and infrastructure that Space Station Freedom can provide and take advantage of these to the maximum extent possible. Things like environment, accommodations, carriers, and integration should all be taken into account. In developing experiments at Langley Research Center, an iterative approach is proving useful. This approach uses Space Station utilization and subsystem experts to advise and critique experiment designs to take advantage of everything the Space Station has to offer. Also, solid object modeling and animation computer tools are used to fully visualize the experiment and its processes. This process is very useful for attached payloads and allows problems to be detected early in the experiment design phase.

Avery, Don E.↗

Unsteady aerodynamic behavior of an airfoil with and without a slat

Unsteady flow behavior and load characteristics of a 2D VR-7 airfoil with and without a leading-edge slat were studied in the water tunnel of the Aeroflightdynamics Directorate, NASA Ames Research Center. Both airfoils were oscillated sinusoidally between 5 and 25 deg at Re = 200,000 to obtain the unsteady lift, drag, and pitching moment data. A fluorescent dye was released from an orifice located at the leading edge of the airfoil for the purpose of visualizing the boundary layer and wake flow. The flowfield and load predictions of an incompressible Navier-Stokes code based on a velocity-vorticity formulation were compared with the test data. The test and predictions both confirm that the slatted VR-7 airfoil delays both static and dynamic stall as compared to the VR-7 airfoil alone.

Tung, Chee↗

Development of a Prototype Simulation Executive with Zooming in the Numerical Propulsion System Simulation

A major difficulty in designing aeropropulsion systems is that of identifying and understanding the interactions between the separate engine components and disciplines (e.g., fluid mechanics, structural mechanics, heat transfer, material properties, etc.). The traditional analysis approach is to decompose the system into separate components with the interaction between components being evaluated by the application of each of the single disciplines in a sequential manner. Here, one discipline uses information from the calculation of another discipline to determine the effects of component coupling. This approach, however, may not properly identify the consequences of these effects during the design phase, leaving the interactions to be discovered and evaluated during engine testing. This contributes to the time and cost of developing new propulsion systems as, typically, several design-build-test cycles are needed to fully identify multidisciplinary effects and reach the desired system performance. The alternative to sequential isolated component analysis is to use multidisciplinary coupling at a more fundamental level. This approach has been made more plausible due to recent advancements in computation simulation along with application of concurrent engineering concepts. Computer simulation systems designed to provide an environment which is capable of integrating the various disciplines into a single simulation system have been proposed and are currently being developed. One such system is being developed by the Numerical Propulsion System Simulation (NPSS) project. The NPSS project, being developed at the Interdisciplinary Technology Office at the NASA Lewis Research Center is a 'numerical test cell' designed to provide for comprehensive computational design and analysis of aerospace propulsion systems. It will provide multi-disciplinary analyses on a variety of computational platforms, and a user-interface consisting of expert systems, data base management and visualization tools, to allow the designer to investigate the complex interactions inherent in these systems. An interactive programming software system, known as the Application Visualization System (AVS), was utilized for the development of the propulsion system simulation. The modularity of this system provides the ability to couple propulsion system components, as well as disciplines, and provides for the ability to integrate existing, well established analysis codes into the overall system simulation. This feature allows the user to customize the simulation model by inserting desired analysis codes. The prototypical simulation environment for multidisciplinary analysis, called Turbofan Engine System Simulation (TESS), which incorporates many of the characteristics of the simulation environment proposed herein, is detailed.

Reed, John A.↗

Radiation Blocking Lenses

Biomedical Optical Company of America's (BOCA) suntiger lenses, similar in principle to natural filters in the eyes of hawks and eagles, bar 99 percent of potentially harmful wavelengths, while allowing visually useful colors of light (red, orange, green) to pass through. They also improve visual acuity, night vision and haze or fog visibility. The lenses evolved from work done by James B. Stephens and Dr. Charles G. Miller of the Jet Propulsion Laboratory. They developed a formula and produced a commercial welding curtain that absorbs, filters, and scatters light. This research led to protective glasses now used by dentists, workers in hazardous environments, CRT operators and skiers.

Source record↗

Aura Atmospheric Data Products and Their Availability from NASA Goddard Earth Sciences DAAC

NASA's EOS-Aura spacecraft was launched successfully on July 15, 2004. The four instruments onboard the spacecraft are the Microwave Limb Sounder (MLS), the Ozone Monitoring Instrument (OMI), the Tropospheric Emission Spectrometer (TES), and the High Resolution Dynamics Limb Sounder (HBDLS). The Aura instruments are designed to gather earth sciences measurements across the ultraviolet, visible, infra-red, thermal and microwave regions of the electromagnetic spectrum. Aura will provide over 70 distinct standard atmospheric data products for use in ozone layer and surface UV-B monitoring, air quality forecast, and atmospheric chemistry and climate change studies (http://eosaura.gsfc.nasa.gov/). These products include earth-atmosphere radiances and solar spectral irradiances; total column, tropospheric, and profiles of ozone and other trace gases, surface W-B flux; clouds and aerosol characteristics; and temperature, geopotential height, and water vapor profiles. The MLS, OMI, and HIRDLS data products will be archived at the NASA Goddard Earth Sciences (GES) Distributed Active Archive Center (DAAC), while data from TES will be archived at NASA Langley Research Center DAAC. Some of the standard products which have gone through quick preliminary checks are already archived at the GES DAAC (http://daac.nsfc.nasa.gov/) and are available to the Aura science team and data validation team members for data validation; and to the application and visualization software developers, for testing their application modules. Once data are corrected for obvious calibration problems and partially validated using in-situ observations, they would be made available to the broader user community. This presentation will provide details of the whole suite of Aura atmospheric data products, and the time line of the availability of the rest of the preliminary products and of the partially validated provisional products. Software and took available for data access, visualization, and data mining will also be discussed.

Ahmad, S.↗

Zero Boil-Off Tank (ZBOT) Experiment

The Zero-Boil-Off Tank (ZBOT) experiment has been developed as a small scale ISS experiment aimed at delineating important fluid flow, heat and mass transport, and phase change phenomena that affect cryogenic storage tank pressurization and pressure control in microgravity. The experiments use a simulant transparent low boiling point fluid (PnP) in a sealed transparent Dewar to study and quantify: (a) fluid flow and thermal stratification during pressurization; (b) mixing, thermal destratification, depressurization, and jet-ullage penetration during pressure control by jet mixing. The experiment will provide valuable microgravity empirical two-phase data associated with the above-mentioned physical phenomena through highly accurate local wall and fluid temperature and pressure measurements, full-field phase-distribution and flow visualization. Moreover, the experiments are performed under tightly controlled and definable heat transfer boundary conditions to provide reliable high-fidelity data and precise input as required for validation verification of state-of-the-art two-phase CFD models developed as part of this research and by other groups in the international scientific and cryogenic fluid management communities.

ISS↗

Effectiveness of Redundant Communications Systems in Maintaining Operational Control of Small Unmanned Aircraft

NASA has been researching prototype technologies for an Unmanned Aircraft System (UAS) Traffic Management (UTM) system to facilitate enabling of safe and efficient civilian low-altitude airspace and UAS operations, in a series of Technical Capability Levels (TCL) activities that are increasingly complex. In TCL1, completed in 2015, visual line-of-sight operations such as agriculture, firefighting and infrastructure monitoring were addressed with a focus on geofencing and operations scheduling. Technologies and requirements needed for beyond visual line-of-sight (BVLOS) operations in sparsely populated areas were examined in TCL2 in 2016, and those for operations over moderately populated areas in TCL3 in 2017 and 2018. TCL4 will build on the earlier TCLs and focus on technologies and requirements for operations in higher-density urban areas for tasks such as news gathering, package delivery and for managing large-scale contingencies. This paper describes a communications test conducted in TCL3 and discusses insights gained from the test. In the test, operators were directed to equip UAS with redundant Command and Control (C2) communications systems, send a maneuver command to Unmanned Aircraft (UA) via the primary system, then verify execution of the sent command. This exercise was repeated with each redundant system. The test was designed to assess effectiveness of redundant C2 systems in maintaining operational control of UA. Several UAS were configured with varying arrangements to achieve redundancy, including two identical radio modems using the same frequency band, WiFi and Long-Term Evolution (LTE) cellular modems, etc. From the test, digital data such as time maneuver command sent, time maneuver verified, etc., were collected. Descriptions of methods to detect loss of C2 communications and contingency steps for such event were collected and assessed. The final paper will include a detailed analysis of the collected data leading to the following insights. First, effectiveness of redundant C2 systems depends on several factors, such as operational environment and communications service availability. For example, use of two identical point-to-point radio to connect operator and UA on the same frequency band can be effective in mitigating radio malfunction when operating in an environment where possibility of Radio Frequency (RF) interference is low, such as over open plains. However, the same arrangement may not be effective where high level of RF transmissions in broad spectrum ranges can be expected, such as over or near urban areas. For redundant systems that consist of external communications services, such as cellular and satellite communications network, redundancy is maintained only in the areas where more than one services are available. Therefore, UAS operators should have the means to plan for and monitor the performance of external communications services they are relying on to control UA. Second, communications performance needs, such as the minimum data transfer rate and the maximum tolerable latency, should be assessed to reflect the potential hazard that can come from loss of UA control. For example, UA operations over desolate area pose less hazard to people than operations over densely populated area and performance need for the former would be less than the latter.

Jung, Jaewoo↗

The Nasa Multiscale Analysis Tool: an Enabling Platform for Achieving Vision 2040

Vision 2040 is a community-driven consensus document, written in 2018, aimed at defining the potential 25-year future state required for performing integrated multiscale modeling of materials and systems for future aerospace and aeronautical applications. Nine Vision Key Elements (KEs) were defined along with associated technical gaps. This paper will address current NASA GRC research efforts utilizing the NASA Multiscale Analysis Tool (NASMAT). This paper will specifically focus on NASMAT’s ability to address gaps in three of the nine Vision 2040 KEs: 1) Models and Methods, 2) Multiscale Measurements and Characterization Tools and Methods, and 6) Data, Informatics, and Visualization. NASMAT is a versatile platform for performing computationally efficient multiscale analyses of heterogeneous materials. NASMAT offers the user flexibility to define an arbitrary number of length scales (levels) where a variety of micromechanics theories can be implemented at each level. Micromechanics theories can be selected to balance accuracy and computational efficiency and range from analytical (Mori-Tanaka) to several semi-analytical (method of cells) formulations. NASMAT can also be coupled with external software and used to perform multiscale analyses of more complex structures. The paper will include a recent application of NASMAT to model a complex, three-dimensional woven composite, with a particular emphasis placed on multiscale measurements utilized to enhance the quality of the multiscale analysis. Since typical NASMAT analyses can be completed in on the order of seconds to minutes, a second example will demonstrate NASMAT’s ability to generate large quantities of data useful for sensitivity analysis, uncertainty quantification, or machine learning applications. Current progress on developing multiscale data visualization tools will also be addressed along with the challenges associated with and proposed solutions for sifting through large amounts of data. These examples will demonstrate that NASMAT is an enabling platform for achieving the goals in Vision 2040.

Vision 2040↗

Performance Evaluation of Augmented Teleoperation of Contact Manipulation Tasks

At Argonne National Laboratory, an enhanced telerobotic concept has been suggested by providing augmented virtual fixtures for precise and dexterous manipulation. The proposed technology incorporated a human-robot interface that can assist personnel on the processes of Deactivation and Decommissioning in sites of high radiation. It has been implemented on a dual-arm robot system, known as Baxter, by integrating the Robotic Operating System (ROS) with 3D sensors and visual-haptic operator interface. However, what remained before its practical utilization is the capability for precisely placing the virtual fixtures. To this end, the objectives involved camera calibration, which required hardware fabrication and setup, as well as modification and implementation of ROS. The goal of this Research and Development is to develop an augmented-reality- based operator interface for human-inclusive, intelligent, and autonomous robotic system for the Deactivation and Decommissioning (D and D) of radioactive sites. The objectives are to develop: Collaborative Robot; Multi-modal Mixed-Reality Human-Robot Interface; Intelligent and Autonomous Behaviors. In order to achieve this, Baxter's Head-Kinect camera and Left-Hand camera need to be calibrated to overlap the real environment with the simulated environment. Camera calibration, which is crucial for precisely placing the virtual fixtures, was successful after running the simulations. The real and simulated environments overlapped, permitting the utilization of augmented teleoperation and the dexterous manipulation of Baxter for D and D applications in nuclear sites. Future steps: Performance evaluation of augmented teleoperation of contact manipulation tasks: Multiple-Camera 3D Reconstruction and Automation. Oculus Interface: Augmented reality and machine learning for enhanced telerobotic operation (Augmented Tele-autonomy): Machine-learning techniques for complex and flexible autonomous robotic behaviors. Interactive remote operation of robotic systems. Mesh cutting with simulation and real robot.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Atomistic Method Applied to Computational Modeling of Surface Alloys

The formation of surface alloys is a growing research field that, in terms of the surface structure of multicomponent systems, defines the frontier both for experimental and theoretical techniques. Because of the impact that the formation of surface alloys has on surface properties, researchers need reliable methods to predict new surface alloys and to help interpret unknown structures. The structure of surface alloys and when, and even if, they form are largely unpredictable from the known properties of the participating elements. No unified theory or model to date can infer surface alloy structures from the constituents properties or their bulk alloy characteristics. In spite of these severe limitations, a growing catalogue of such systems has been developed during the last decade, and only recently are global theories being advanced to fully understand the phenomenon. None of the methods used in other areas of surface science can properly model even the already known cases. Aware of these limitations, the Computational Materials Group at the NASA Glenn Research Center at Lewis Field has developed a useful, computationally economical, and physically sound methodology to enable the systematic study of surface alloy formation in metals. This tool has been tested successfully on several known systems for which hard experimental evidence exists and has been used to predict ternary surface alloy formation (results to be published: Garces, J.E.; Bozzolo, G.; and Mosca, H.: Atomistic Modeling of Pd/Cu(100) Surface Alloy Formation. Surf. Sci., 2000 (in press); Mosca, H.; Garces J.E.; and Bozzolo, G.: Surface Ternary Alloys of (Cu,Au)/Ni(110). (Accepted for publication in Surf. Sci., 2000.); and Garces, J.E.; Bozzolo, G.; Mosca, H.; and Abel, P.: A New Approach for Atomistic Modeling of Pd/Cu(110) Surface Alloy Formation. (Submitted to Appl. Surf. Sci.)). Ternary alloy formation is a field yet to be fully explored experimentally. The computational tool, which is based on the BFS (Bozzolo, Ferrante, and Smith) method for the calculation of the energetics, consists of a small number of simple PCbased computer codes that deal with the different aspects of surface alloy formation. Two analysis modes are available within this package. The first mode provides an atom-by-atom description of real and virtual stages 1. during the process of surface alloying, based on the construction of catalogues of configurations where each configuration describes one possible atomic distribution. BFS analysis of this catalogue provides information on accessible states, possible ordering patterns, and details of island formation or film growth. More importantly, it provides insight into the evolution of the system. Software developed by the Computational Materials Group allows for the study of an arbitrary number of elements forming surface alloys, including an arbitrary number of surface atomic layers. The second mode involves large-scale temperature-dependent computer 2. simulations that use the BFS method for the energetics and provide information on the dynamic processes during surface alloying. These simulations require the implementation of Monte-Carlo-based codes with high efficiency within current workstation environments. This methodology capitalizes on the advantages of the BFS method: there are no restrictions on the number or type of elements or on the type of crystallographic structure considered. This removes any restrictions in the definition of the configuration catalogues used in the analytical calculations, thus allowing for the study of arbitrary ordering patterns, ultimately leading to the actual surface alloy structure. Moreover, the Monte Carlo numerical technique used for the large-scale simulations allows for a detailed visualization of the simulated process, the main advantage of this type of analysis being the ability to understand the underlying features that drive these processes. Because of the simplicity of the BFS method for e energetics used in these calculations, a detailed atom-by-atom analysis can be performed at any point in the simulation, providing necessary insight on the details of the process. The main objective of this research program is to develop a tool to guide experimenters in understanding and interpreting often unexpected results in alloy formation experiments. By reducing the computational effort without losing physical accuracy, we expect that powerful simulation tools will be developed in the immediate future, which will allow material scientists to easily visualize and analyze processes at a level not achievable experimentally.

Bozzolo, Guillermo H.↗

Manufacturing Process Simulation of Large-Scale Cryotanks

NASA's Space Launch Initiative (SLI) is an effort to research and develop the technologies needed to build a second-generation reusable launch vehicle. It is required that this new launch vehicle be 100 times safer and 10 times cheaper to operate than current launch vehicles. Part of the SLI includes the development of reusable composite and metallic cryotanks. The size of these reusable tanks is far greater than anything ever developed and exceeds the design limits of current manufacturing tools. Several design and manufacturing approaches have been formulated, but many factors must be weighed during the selection process. Among these factors are tooling reachability, cycle times, feasibility, and facility impacts. The manufacturing process simulation capabilities available at NASA.s Marshall Space Flight Center have played a key role in down selecting between the various manufacturing approaches. By creating 3-D manufacturing process simulations, the varying approaches can be analyzed in a virtual world before any hardware or infrastructure is built. This analysis can detect and eliminate costly flaws in the various manufacturing approaches. The simulations check for collisions between devices, verify that design limits on joints are not exceeded, and provide cycle times which aide in the development of an optimized process flow. In addition, new ideas and concerns are often raised after seeing the visual representation of a manufacturing process flow. The output of the manufacturing process simulations allows for cost and safety comparisons to be performed between the various manufacturing approaches. This output helps determine which manufacturing process options reach the safety and cost goals of the SLI. As part of the SLI, The Boeing Company was awarded a basic period contract to research and propose options for both a metallic and a composite cryotank. Boeing then entered into a task agreement with the Marshall Space Flight Center to provide manufacturing simulation support. This paper highlights the accomplishments of this task agreement, while also introducing the capabilities of simulation software.

Babai, Majid↗