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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.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Design, Manufacturing, Assembly, and Lessons Learned of the Pre-production 325 MHz Couplers for the PIP-II Project at Fermilab

Five 325 MHz high-power couplers will be integrated into the pre-production Single Spoke Resonator Type-II (ppSSR2) cryomodule for the PIP-II project at Fermilab. Couplers were procured by both Fermilab and IJCLAB for this effort. The design of the coupler is described, including design optimizations from the previous generation. This paper then describes the coupler life cycle, including design, manufacturing, and assembly, along with the lessons learned at each stage.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Design, Manufacturing, Assembly, Testing, and Lessons Learned of the Prototype 650 MHz Couplers

Six 650 MHz high-power couplers will be integrated into the prototype High Beta 650 MHz (HB650) cryomodule for the PIP-II project at Fermilab. The design of the coupler is described, including design optimizations from the previous generation. This paper then describes the coupler life-cycle, including manufacturing, assembly, testing, conditioning and the lessons learned at each stage.

43 PARTICLE ACCELERATORS↗
NASA NTRS2016

Cryogenic Fiber Optic Assemblies for Spaceflight Environments: Design, Manufacturing, Testing, and Integration

Fiber optic assemblies have been used on spaceflight missions for many years as an enabling technology for routing, transmitting, and detecting optical signals. Due to the overwhelming success of NASA in implementing fiber optic assemblies on spaceflight science-based instruments, system scientists increasingly request fibers that perform in extreme environments while still maintaining very high optical transmission, stability, and reliability. Many new applications require fiber optic assemblies that will operate down to cryogenic temperatures as low as 20 Kelvin. In order for the fiber assemblies to operate with little loss in optical throughput at these extreme temperatures requires a system level approach all the way from how the fiber assembly is manufactured to how it is held, routed, and integrated. The NASA Goddard Code 562 Photonics Group has been designing, manufacturing, testing, and integrating fiber optics for spaceflight and other high reliability applications for nearly 20 years. Design techniques and lessons learned over the years are consistently applied to developing new fiber optic assemblies that meet these demanding environments. System level trades, fiber assembly design methods, manufacturing, testing, and integration will be discussed. Specific recent examples of ground support equipment for the James Webb Space Telescope (JWST); the Ice, Cloud and Land Elevation Satellite-2 (ICESat-2); and others will be included.

Fiber Optic↗
NASA NTRS2000

Design and Flight Testing of an Inflatable Sunshield for the NGST

The Next Generation Space Telescope (NGST) mission is scheduled to launch in 2007 and be stationed at L2 for a mission life of ten years. The large aperture mirror and optical detectors aboard NGST require shielding from the constant solar energy seen at this orbit. The government reference NGST design, called the Yardstick, baselined a sunshield using an inflation deployment system. During the formulation phase, NGST is spending approximately 25% of the overall budget to foster the development of new technology. The goal is to develop and demonstrate enabling or enhancing technology and provide innovative solutions for the design of the NGST observatory. Inflatable technology falls in the category of enhancing technology due to its advantages in weight, stowed volume and cost. The Inflatable Sunshield in Space (ISIS) flight experiment will provide a realistic space flight demonstration of an inflatable sunshield. The supporting technology development program will provide an information base for the design, manufacture, assembly and testing of large thin membranes and inflatable structural elements for space structures. The ISIS experiment will demonstrate the feasibility of using inflatable technology to passively cool optical systems for NGST and provide correlation between analytical predictions and on orbit results. The experiment will be performed on a Hitchhiker/Space Shuttle mission in late 2001. The ISIS mission is an effort to address several major technical challenges of the NGST inflatable sunshield, namely controlled inflation deployment, plenarity and separation of large stretched membranes, space rigidization of inflatable booms, and dynamic modeling and simulation. This paper will describe the design of the flight experiment and the testing to be performed on-orbit.

Adams, Michael L.↗
NASA NTRS1979

Preliminary QCGAT program test results

The paper presents the NASA Lewis program to demonstrate that large engine technology can be applied to general aviation engines to reduce noise, emissions, and fuel consumption. After a Phase I study, two contractors, Garrett AiResearch and AVCO-Lycoming, were selected to design, manufacture, assemble, test, and deliver their Quiet, Clean, General Aviation Turbofan (QCGAT) engines to NASA. Noise, emission, and performance goals and how well they were met are discussed. Noise goals involve take off noise 3.5 n. mi. from runway threshold, sideline noise at .25 n mi. and approach noise 1 n mi. from the runway at an altitude of 370 ft. The AiResearch engines power a stretched Learjet 35 and the Lycoming a specially conceived Beech executive jet, resulting in differing power goals. Thus the thrust goal for the Lycoming was 1622 lb. while the AiResearch goal was 3937 lb. Cruise thrust goals were 485 lb. at Mach 0.6 at 25,000 ft. and 903 lb. at Mach 0.8 at 40,000 ft. respectively. The design of both engines, based on existing cores, is studied, noting such special QCGAT features as new reduction gears, combustor and power turbine. Test results are given, indicating that while the goals for noise and thrust were met those for emissions were only partially met.

Koenig, R. W.↗
DOE OSTI2022

CEA Contribution to the PIP-II Linear Accelerator

The Proton Improvement Plan II (PIP-II) that will be installed at Fermilab is the first U.S. accelerator project that will have significant contributions from international partners. CEA joined the international collaboration in 2018, and will deliver 10 low-beta cryomodules as In-Kind Contribution to the PIP-II project, with cavities supplied by LASA-INFN and power couplers and tuning systems supplied by Fermilab. This paper presents the CEA scope of work that includes the design, manufacturing, assembly and tests of the cryomodules and the upgrade of the existing infrastructures to the PIP-II requirements.

43 PARTICLE ACCELERATORS↗
NASA NTRS1989

Unified Engineering Software System

Collection of computer programs performs diverse functions in prototype engineering. NEXUS, NASA Engineering Extendible Unified Software system, is research set of computer programs designed to support full sequence of activities encountered in NASA engineering projects. Sequence spans preliminary design, design analysis, detailed design, manufacturing, assembly, and testing. Primarily addresses process of prototype engineering, task of getting single or small number of copies of product to work. Written in FORTRAN 77 and PROLOG.

Purves, L. R.↗
NASA NTRS2003

Capabilities of the Materials Contamination Team at Marshall Space Flight Center

The Materials Contamination Team of the Environmental Effects Group, Materials, Processes, and Manufacturing Department, has been recognized for its contribution to space flight, including space transportation, space science and flight projects, such as the reusable solid rocket motor, Chandra X-Ray Observatory, and the International Space Station. The Materials Contamination Team s realm of responsibility encompasses all phases of hardware development including design, manufacturing, assembly, test, transportation, launch-site processing, on-orbit exposure, return, and refurbishment if required. Contamination is a concern in the Space Shuttle with sensitivity bondlines and reactive fluid (liquid oxygen) compatibility as well as for sensitive optics, particularly spacecraft such as Hubble Space Telescope and Chandra X-Ray Observatory. The Materials Contamination Team has a variety of facilities and instrumentation capable of contaminant detection identification, and monitoring. The team addresses material applications dealing with environments, including production facilities, clean rooms, and on-orbit exposure. The team of engineers and technicians also develop and evaluates new surface cleanliness inspection technologies. Databases are maintained by the team for proces! materials as well as outgassing and optical compatibility test results for specific environments.

Burns, H. D.↗
NASA NTRS2003

Capabilities of the Materials Contamination Team at Marshall Space Flight Center

The Materials Contamination Team at the Marshall Space Flight Center (MSFC) has been recognized for its contributions supporting the National Aeronautics and Space Administration (NASA) spacecraft development programs. These programs include the Reusable Solid Rocket Motor (RSRM), Chandra X-Ray Observatory, and the International Space Station (ISS). The Environmental Effects Group, with the Materials Contamination Team and the Space Environmental Effects Team has been an integral part of NASA's success by the testing, evaluation, and qualification of materials, hardware, and processes. This paper focuses on the capabilities of the Materials Contamination Team. The Materials Contamination Team's realm of responsibility includes establishing contamination control during all phases of hardware development, including design, manufacturing, assembly, test, transportation, launch site processing, on-orbit exposure, return, and refurbishment. The team continues its mission of reducing the risk of equipment failure due to molecular or particulate contamination. Contamination is a concern in the Space Shuttle with sensitive bond-lines and reactive fluid (liquid oxygen) compatibility as well as for spacecraft with sensitive optics, such as Hubble Space Telescope and Chandra X-ray Observatory. The Materials Contamination Team has a variety of facilities and instrumentation capable of contaminant detection, identification, and monitoring. The team addresses material applications dealing with environments, including production facilities, clean rooms, and on-orbit exposure. The optically stimulated electron emission (OSEE) system, the Ultraviolet (UV) fluorescence (UVF) surface contamination detection, and the Surface Optics Corporation 400 (SOC 400) portable hand-held Fourier Transform Infrared (FTIR) spectrometer are state-of-the-art tools for in-process molecular contamination detection. The team of engineers and technicians also develop contamination calibration standards and evaluate new surface cleanliness inspection technologies. The team utilizes facilities for on-orbit simulation testing of materials for outgassing and molecular film deposition characteristics in the presence of space environmental effects, such as Atomic Oxygen (AO) and UV radiation exposure. The Materials Contamination Team maintains databases for process materials as well as outgassing and optical compatibility test results for specific environments.

Burns, Howard↗
NASA NTRS2012

James Webb Space Telescope Optical Telescope Element Mirror Development History and Results

In a little under a decade, the James Webb Space Telescope (JWST) program has designed, manufactured, assembled and tested 21 flight beryllium mirrors for the James Webb Space Telescope Optical Telescope Element. This paper will summarize the mirror development history starting with the selection of beryllium as the mirror material and ending with the final test results. It will provide an overview of the technological roadmap and schedules and the key challenges that were overcome. It will also provide a summary or the key tests that were performed and the results of these tests.

Feinber, Lee D.↗
NASA NTRS2002

Design and Manufacturing Processes of Long-Life Hollow Cathode Assemblies

The design and manufacturing processes for Hollow Cathode Assemblies (HCA's) that operate over a broad range of emission currents up to 30 Amperes, at low potentials, with lifetimes in excess of 17,500 hours. The processes include contamination control procedures which cover hollow cathode component cleaning procedures, gas feed system designs and specifications, and hollow cathode activation and operating procedures to thereby produce cathode assemblies that have demonstrated stable and repeatable operating conditions, for both the discharge current and voltage. The HCA of this invention provides lifetimes of greater than 10,000 hours, and expected lifetimes of greater than 17,500 hours, whereas the present state-of-the-art is less than 500 hours at emission currents in excess of 1 Ampere. Stable operation is provided over a large range of operating emission currents, up to a 6:1 ratio, and this HCA can emit electron currents of up to 30 Amperes in magnitude to an external anode that simulates the current drawn to a space plasma at voltages of less than 20 Volts.

Michael J Patterson↗
NASA NTRS1984

Parabolic Dish Stirling Module

The design, manufacture, and assembly of a commercially designed parabolic dish Stirling 25 kWe module is examined. The cost, expected performance, design uniquenesses, and future commercial potential of this module, which is regarded as the most technically advanced in the parabolic dish industry is discussed.

Washom, B.↗
NASA NTRS2000

Influence of Design Variations on Systems Performance

High-risk aerospace components have to meet very stringent quality, performance, and safety requirements. Any source of variation is a concern, as it may result in scrap or rework. poor performance, and potentially unsafe flying conditions. The sources of variation during product development, including design, manufacturing, and assembly, and during operation are shown. Sources of static and dynamic variation during development need to be detected accurately in order to prevent failure when the components are placed in operation. The Systems' Health and Safety (SHAS) research at the NASA Ames Research Center addresses the problem of detecting and evaluating the statistical variation in helicopter transmissions. In this work, we focus on the variations caused by design, manufacturing, and assembly of these components, prior to being placed in operation (DMV). In particular, we aim to understand and represent the failure and variation information, and their correlation to performance and safety and feed this information back into the development cycle at an early stage. The feedback of such critical information will assure the development of more reliable components with less rework and scrap. Variations during design and manufacturing are a common source of concern in the development and production of such components. Accounting for these variations, especially those that have the potential to affect performance, is accomplished in a variety ways, including Taguchi methods, FMEA, quality control, statistical process control, and variation risk management. In this work, we start with the assumption that any of these variations can be represented mathematically, and accounted for by using analytical tools incorporating these mathematical representations. In this paper, we concentrate on variations that are introduced during design. Variations introduced during manufacturing are investigated in parallel work.

Tumer, Irem Y.↗
DOE OSTI2021

Development of Integrated Mechanical Pods

This presentation highlights early wins, updated progress, and upcoming developments on ‘national-scale shared development platform’ for rapid prototyping, testing and validation of various integrated Mechanical Pod solutions and form factors. Such pod solutions consist of a set of all-electric heat pump mechanical equipment that have integrated functionalities through built-in controls, with heating, cooling, hot water, ventilation (including energy recovery), electrical management, and battery storage within a single package. The presentation draws inspiration from the success of bathroom pods in the US modular construction industry, UK’s efforts with unitizing mechanical systems as ‘utility cupboards’, and VEIC’s early wins in design-build of all-electric Mechanical Pod solutions in Vermont. The presentation includes researchers and partners involved with NREL in Design for Manufacturing and Assembly (DfMA), Virtual Design and Construction (VDC), and digital twin based process optimization modeling of integrated Mechanical Pod solutions. The presentation aims to highlight early wins from such a platform and how various physical and virtual tools are currently being employed as part of NREL’s ongoing multi-year project funded by US DOE. Streamlined procurement, coordination, installation, and O&M of Mechanical Pods such that the majority of work is delegated to the off-site modular factory implies monetary savings. Such a seemingly basic shift in location of the construction process leads to great reduction in complexity, first cost, lead time, and waste, and greater opportunities for innovative compartmentalization and integration of mechanical systems appropriately sized for each apartment or hotel guest room. However, past studies on unitized combination systems show that high installation costs, maintenance issues, challenges with system integration, limitations in existing electrical infrastructure, and lack of architecturally appealing solutions are key barriers. NREL and partners aim to address key barriers through DfMA approach, rapid prototyping and testing, and digital twin process optimization modeling. The presentation is also a call for interested entities to partner with NREL as part of the national-scale development platform, help drive both product and process innovation, and encourage open source sharing of learnings. Learning objectives include (1) learn about the vision of national-scale shared development platform for process-product innovation on integrated mechanical pod solutions and how to get involved, (2) gain an understanding of the components of an all-electric, high performance home, design characteristics and equipment included in an all-electric mechanical pod, integration of mechanical systems within a modular factories’ assembly line, and the system’s commissioning, operation and maintenance. The pre-planning and coordination with the factory and sub-contractors are also highlighted, (3) gain an understanding of using process modeling tools to quantify resource-constrained performance of operations (such as integration of energy efficiency strategies) to manufacture modules of varying design, (4) gain insights on virtual design, rapid prototyping, and emulated testing of various form factors across different climatic conditions. The need for such preliminary testing with open source sharing of learnings will also be highlighted.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Robotics for Systems Integration in Buildings: Pilot Study of Viable Approaches to Install Hygrothermal and Rigid Electrical Systems

The Industrialized Construction Innovation (ICI) team at the National Renewable Energy Laboratory (NREL) has been exploring the use of robotics to integrate hygrothermal, mechanical, electrical, and plumbing systems in prefabricated building assemblies (off-site construction) and 3D-printed buildings (on-site construction). Such multisystem integration tasks often require specialized robots and custom end effectors to handle a range of rigid and nonrigid building components. This paper begins with a brief overview of the current state of robotics in construction, followed by a pilot study exploring the use of robotics to integrate a simple prototype multitrade wall assembly composed of structural studs, hygrothermal layer, wall finishing, and electrical fixtures. The study was funded by the US Department of Energy's (DOE's) Advanced Materials and Manufacturing Technologies Office (AMMTO). Insights about the implementation of design for manufacturing and assembly (DfMA) principles in designing the prototype wall for robotic assembly, and selection of appropriate robotic end-effector hardware to handle these components are included. Detailed comparison of computational toolpath simulations of the robotic assembly process and real-life demonstration of the same are presented. Finally, limitations and lessons learned from this study are included, along with future research recommendations for robotic assembly of more complex multitrade assemblies, including potential scenarios such as robotic outfitting of facilities in extraterrestrial environments.

advanced manufacturing↗
DOE OSTI2024

Robotics for Systems Integration in Buildings - Pilot Study of Viable Approaches to Install Hygrothermal and Rigid Electrical Systems: Preprint

The Industrialized Construction Innovation (ICI) team at the National Renewable Energy Laboratory (NREL) has been exploring the use of robotics to integrate hygrothermal, mechanical, electrical, and plumbing systems in prefabricated building assemblies (offsite construction) and 3D Printed buildings (onsite construction). Such multi-system integration tasks often require specialized robots and custom end-effectors for handling a range of rigid and non-rigid building components. This paper begins with a brief overview of the current state of robotics in construction, followed by a pilot study exploring the use of robotics to integrate a simple prototype multi-trade wall assembly composed of structural studs, hygrothermal layer, wall finishing, and electrical fixtures. The study was funded by the Department of Energy's (DOE) Advanced Materials and Manufacturing Technologies Office (AMMTO). Insights about the implementation of design for manufacturing and assembly (DfMA) principles in designing the prototype wall for robotic assembly, and selection of appropriate robotic end effector hardware for handling these components are included. Detailed comparison of computational toolpath simulations of the robotic assembly process and real-life demonstration of the same is presented. Finally, limitations and lessons learned from this study along with future research recommendations for robotic assembly of more complex multi-trade assemblies, including potential scenarios such as robotic outfitting of facilities in extra-terrestrial environments is included.

advanced manufacturing↗