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All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

NASA Game Changing Development Program Manufacturing Innovation Project

This presentation examines the new NASA Manufacturing Innovation Project. The project is a part of the Game Changing Development Program which is one element of the Space Technology Programs Managed by Office of the Chief Technologist. The project includes innovative technologies in model-based manufacturing, digital additive manufacturing, and other next generation manufacturing tools. The project is also coupled with the larger federal initiatives in this area including the National Digital Engineering and Manufacturing Initiative and the Advanced Manufacturing Partnership. In addition to NASA, other interagency partners include the Department of Defense, Department of Commerce, NIST, Department of Energy, and the National Science Foundation. The development of game-changing manufacturing technologies are critical for NASA s mission of exploration, strengthening America s manufacturing competitiveness, and are highly related to current challenges in defense manufacturing activities. There is strong consensus across industry, academia, and government that the future competitiveness of U.S. industry will be determined, in large part, by a technologically advanced manufacturing sector. This presentation highlights the prospectus of next generation manufacturing technologies to the challenges faced NASA and by the Department of Defense. The project focuses on maturing innovative/high payoff model-based manufacturing technologies that may lead to entirely new approaches for a broad array of future NASA missions and solutions to significant national needs. Digital manufacturing and computer-integrated manufacturing "virtually" guarantee advantages in quality, speed, and cost and offer many long-term benefits across the entire product lifecycle. This paper addresses key enablers and emerging strategies in areas such as: Current government initiatives, Model-based manufacturing, and Additive manufacturing.

Tolbert, Carol↗
NASA NTRS2017

The Role of Advanced Manufacturing in Our Journey to Mars

The National Additive Manufacturing Innovation Institute was launched in August 2012 as a result of President Obama's proposed need for a whole-of-government advanced manufacturing effort. Mission: To accelerate the adoption of additive manufacturing technologies to increase domestic manufacturing competitiveness. Funding: Five federal agencies - the Departments of Defense, Energy, and Commerce, the National Science Foundation, and NASA - jointly committed to invest $45 million.

Advanced Manufacturing Innovation↗
NASA NTRS1993

Gaining the Competitive Edge: Design for Manufacturing

The successful design of a commercial aircraft which is intended to be in direct competition with existing aircraft requires a market analysis to establish design requirements, the development of a concept to achieve those goals. and the ability to economically manufacture the aircraft. It is often the case that an engineer designs system components with only the perspective of a particular discipline. The relationship of that component to the entire system is often a minor consideration. In an effort to highlight the interaction that is necessary during the design process, the students were organized into design/build teams and required to integrate aspects of market analysis, engineering design, production and economics into their concepts. In order to facilitate this process a hypothetical "Aeroworld" was established. Having been furnished relevant demographic and economic data for "Aeroworld". students were given the task of designing and building an aircraft for a specific market while achieving an economically competitive design. Involvement of the team in the evolution of the design from market definition to technical development to manufacturing allowed the students to identify critical issues in the design process and to encounter many of the conflicting requirements which arise in an aerospace systems design.

Batill, Stephen M.↗
NASA NTRS1998

Advanced Subsonic Combustion Rig

Researchers from the NASA Lewis Research Center have obtained the first combustion/emissions data under extreme future engine operating conditions. In Lewis' new world-class 60-atm combustor research facility--the Advanced Subsonic Combustion Rig (ASCR)--a flametube was used to conduct combustion experiments in environments as extreme as 900 psia and 3400 F. The greatest challenge for combustion researchers is the uncertainty of the effects of pressure on the formation of nitrogen oxides (NOx). Consequently, U.S. engine manufacturers are using these data to guide their future combustor designs. The flametube's metal housing has an inside diameter of 12 in. and a length of 10.5 in. The flametube can be used with a variety of different flow paths. Each flow path is lined with a high-temperature, castable refractory material (alumina) to minimize heat loss. Upstream of the flametube is the injector section, which has an inside diameter of 13 in. and a length of 0.5-in. It was designed to provide for quick changeovers. This flametube is being used to provide all U.S. engine manufacturers early assessments of advanced combustion concepts at full power conditions prior to engine production. To date, seven concepts from engine manufacturers have been evaluated and improved. This collaborated development can potentially give U.S. engine manufacturers the competitive advantage of being first in the market with advanced low-emission technologies.

Lee, Chi-Ming↗
NASA NTRS1995

Electronic manufacturing and packaging in Japan

This report summarizes the status of electronic manufacturing and packaging technology in Japan in comparison to that in the United States, and its impact on competition in electronic manufacturing in general. In addition to electronic manufacturing technologies, the report covers technology and manufacturing infrastructure, electronics manufacturing and assembly, quality assurance and reliability in the Japanese electronics industry, and successful product realization strategies. The panel found that Japan leads the United States in almost every electronics packaging technology. Japan clearly has achieved a strategic advantage in electronics production and process technologies. Panel members believe that Japanese competitors could be leading U.S. firms by as much as a decade in some electronics process technologies. Japan has established this marked competitive advantage in electronics as a consequence of developing low-cost, high-volume consumer products. Japan's infrastructure, and the remarkable cohesiveness of vision and purpose in government and industry, are key factors in the success of Japan's electronics industry. Although Japan will continue to dominate consumer electronics in the foreseeable future, opportunities exist for the United States and other industrial countries to capture an increasingly large part of the market. The JTEC panel has identified no insurmountable barriers that would prevent the United States from regaining a significant share of the consumer electronics market; in fact, there is ample evidence that the United States needs to aggressively pursue high-volume, low-cost electronic assembly, because it is a critical path leading to high-performance electronic systems.

Kelly, Michael J.↗
NASA NTRS1995

JTEC Panel report on electronic manufacturing and packaging in Japan

This report summarizes the status of electronic manufacturing and packaging technology in Japan in comparison to that in the United States, and its impact on competition in electronic manufacturing in general. In addition to electronic manufacturing technologies, the report covers technology and manufacturing infrastructure, electronics manufacturing and assembly, quality assurance and reliability in the Japanese electronics industry, and successful product realization strategies. The panel found that Japan leads the United States in almost every electronics packaging technology. Japan clearly has achieved a strategic advantage in electronics production and process technologies. Panel members believe that Japanese competitors could be leading U.S. firms by as much as a decade in some electronics process technologies.

Kelly, Michael J.↗
NASA NTRS1996

Hypercars: The next industrial revolution

The auto industry -- one-seventh of the GNP, and the highest expression of the Iron Age -- is about to trigger the biggest transformation in industrial structure since the microchip. Ultralight cars molded from net-shape advanced composites can be several-fold lighter than present steel cars, yet safer, sportier, and more comfortable, durable, and beautiful. Modern hybrid-electric drives boost efficiency approximately 1.3-1.5x in heavy steel cars, but approximately 5-20x in ultralight, very slippery plafforms. Synergistically combined into ultralight-hybrid 'hypercars,' these elements can yield state-of-the-shelf family cars that average 150-300+ mi/gal -- twice that with state-of-the-art technologies -- yet can also be superior in all other respects, probably including cost: carbon-fiber monocoques can actually be cheaper to mass-produce that steel unibodies. Designing cars more like aircraft and less like tanks requires not only an approximately 400-500 kg curb mass and very low air and road drag, but also an aerospace philosophy of engineering integration. Mass, cost, and complexity turn out to compound with heavy hybrids but to decompound with ultralight hybrids, owing partly to radical simplification. Excellent aerodynamics, preferable including advanced techniques for passive boundary-layer control, will be the key to successful design integration. Transforming automaking is a competitive and environmental imperative, could form the nucleus of a green industrial Renaissance, and would enhance national security by, among other things, saving as much oil as OPEC now extracts. However, this transformation faces serious cultural barriers. For example, hypercars will be more like computers with wheels than like cars with chips -- they'll have an order of magnitude more code than today's cars -- but Detroit is not a software culture. Just the transition from stamped and welded steel to integrated and adhesive-joined synthetics is difficult enough. Nonetheless, hypercars are rapidly heading to market in the late 1990s, because approximately 25 current and intending automakers are eager to capture their potentially decisive competitive advantages -- including order-of-magnitude reductions in product cycle time, tooling cost, assembly effort, and parts count. Hypercars will succeed, and may well sweep the market, not because of mandates or subsidies, but because of manufacturers' quest for competitive advantage and customers' desire for better, smarter cars.

Lovins, Amory B.↗
NASA NTRS1995

Ultrasonic Imaging Technology Helps American Manufacturer of Nondestructive Evaluation Equipment Become More Competitive in the Global Market

Sonix, Inc., of Springfield, Virginia, has implemented ultrasonic imaging methods developed at the NASA Lewis Research Center. These methods have heretofore been unavailable on commercial ultrasonic imaging systems and provide significantly more sensitive material characterization than conventional high-resolution ultrasonic c-scanning. The technology transfer is being implemented under a cooperative agreement between NASA and Sonix, and several invention disclosures have been submitted by Dr. Roth to protect Lewis interests. Sonix has developed ultrasonic imaging systems used worldwide for microelectronics, materials research, and commercial nondestructive evaluation (NDE). In 1993, Sonix won the U.S. Department of Commerce "Excellence in Exporting" award. Lewis chose to work with Sonix for two main reasons: (1) Sonix is an innovative leader in ultrasonic imaging systems, and (2) Sonix was willing to apply the improvements we developed with our in-house Sonix equipment. This symbiotic joint effort has produced mutual benefits. Sonix recognized the market potential of our new and highly sensitive methods for ultrasonic assessment of material quality. We, in turn, see the cooperative effort as an effective means for transferring our technology while helping to improve the product of a domestic firm.

Source record↗
NASA NTRSDate not supplied

The Competition of Failure Modes in an Additively Manufactured Disk Superalloy

Additive manufacturing of powder metallurgy disk superalloys can produce unique microstructures that are different from those usually encountered in traditional processing by consolidation, forging, and heat treatments. Unusual variations in grain size, major and minor phase precipitate sizes, and defects can occur. The associated failure modes of these unique microstructures are of high interest. The objective of this study was to compare the failure modes for a powder metallurgy disk superalloy LSHR produced by electron beam melting additive manufacturing. Specimens were subsequently given different solution heat treatments and a fixed aging heat treatment. Tensile, creep, and fatigue failure modes were screened in tests at elevated temperatures. Failure modes were considered with respect to these unique microstructures.

additive manufacturing↗
NASA NTRS2023

Competition of Failure Modes in an Additively Manufactured Disk Superalloy

Additive manufacturing of powder metallurgy (PM) disk superalloys can produce unique microstructures that differ from those usually encountered in traditional processing as the result of consolidation, forging, and heat treatments. Unusual variations in grain size, major and minor phase precipitate sizes, and defects can occur. The failure modes associated with these unique microstructures are of high interest. The objective of this study was to compare the failure modes for a low solvus, high refractory (LSHR) PM disk superalloy produced by electron-beam-melting additive manufacturing. Specimens were subsequently given different solution heat treatments and a fixed aging heat treatment. Tensile, creep, and fatigue failure modes were screened in tests at elevated temperatures. Failure modes were considered with respect to these unique microstructures.

additive manufacturing↗
NASA NTRS2000

Modular Low-Heater-Power Cathode/Electron Gun Assembly for Microwave and Millimeter Wave Traveling Wave Tubes

A low-cost, low-mass, electrically efficient, modular cathode/electron gun assembly has been developed by FDE Inc. of Beaverton, Oregon, under a Small Business Innovation Research (SBIR) contract with the NASA Glenn Research Center at Lewis Field. This new assembly offers significant improvements in the design and manufacture of microwave and millimeter wave traveling-wave tubes (TWT's) used for radar and communications. It incorporates a novel, low-heater-power, reduced size and mass, high-performance barium dispenser type thermionic cathode and provides for easy integration of the cathode into a large variety of conventional TWT circuits. Among the applications are TWT's for Earth-orbiting communication satellites and for deep space communications, where future missions will require smaller spacecraft, higher data transfer rates (higher frequencies and radiofrequency output power), and greater electrical efficiency. A particularly important TWT application is in the microwave power module (a hybrid microwave/millimeter wave amplifier consisting of a low-noise solid-state driver, a small TWT, and an electronic power conditioner integrated into a single compact package), where electrical efficiency and thermal loading are critical factors and lower cost is needed for successful commercialization. The design and fabrication are based on practices used in producing cathode ray tubes (CRT's), which is one of the most competitive and efficient manufacturing operations in the world today. The approach used in the design and manufacture of thermionic cathodes and electron guns for CRT's has been optimized for fully automated production, standardization of parts, and minimization of costs. It is applicable to the production of similar components for microwave tubes, with the additional benefits of low mass and significantly lower cathode heater power (less than half that of dispenser cathodes presently used in TWT s). Modular cathode/electron gun assembly. The modular cathode/electron gun assembly consists of four subassemblies the cathode, the focus electrode, the header (including the electrical feedthroughs), and the gun envelope (including the anode) a diagram of which is shown. The modular construction offers a number of significant advantages, including flexibility of design, interchangeability of parts, and a drop-in final assembly procedure for quick and accurate alignment. The gun can accommodate cathodes ranging in size from 0.050 to 0.250-in. in diameter and is applicable to TWT's over a broad range of sizes and operating parameters, requiring the substitution of only a few parts: that is, the cathode, focus electrode, and anode. The die-pressed cathode pellets can be made with either flat or concave (Pierce gun design) emitting surfaces. The gun can be either gridded (pulse operation) or ungridded (continuous operation). Important factors contributing to low cost are the greater use of CRT materials and parts, the standardization of processes (welding and mechanical capture), and tooling amenable to automated production. Examples are the use of simple shapes, drawn or stamped metal parts, and parts joined by welding or mechanical capture. Feasibility was successfully demonstrated in the retrofit and testing of a commercial Kaband (22-GHz) TWT. The modular cathode/electron gun assembly was computer modeled to replicate the performance of the original electron gun and fabricated largely from existing CRT parts. Significant test results included demonstration of low heater power (1.5-W, 1010 C brightness temperature for a 0.085-in.-diameter cathode), mechanical ruggedness (100g shock and vibration tests in accordance with military specifications (MIL specs)), and a very fast warmup. The results of these tests indicate that the low-cost CRT manufacturing approach can be used without sacrificing performance and reliability.

Wintucky, Edwin G.↗
NASA NTRS1985

High-density digital recording

The problems associated with high-density digital recording (HDDR) are discussed. Five independent users of HDDR systems and their problems, solutions, and insights are provided as guidance for other users of HDDR systems. Various pulse code modulation coding techniques are reviewed. An introduction to error detection and correction head optimization theory and perpendicular recording are provided. Competitive tape recorder manufacturers apply all of the above theories and techniques and present their offerings. The methodology used by the HDDR Users Subcommittee of THIC to evaluate parallel HDDR systems is presented.

Kalil, F.↗
NASA NTRS1988

National plans for aircraft icing and improved aircraft icing forecasts and associated warning services

Recently, the United States has increased its activities related to aircraft icing in numerous fields: ice phobics, revised characterization of icing conditions, instrument development/evaluation, de-ice/anti-ice devices, simulated supercooled clouds, computer simulation and flight tests. The Federal Coordinator for Meteorology is involved in two efforts, one a National Plan on Aircraft Icing and the other a plan for Improved Aircraft Icing Forecasts and Associated Warning Services. These two plans will provide an approved structure for future U.S. activities related to aircraft icing. The recommended activities will significantly improve the position of government agencies to perform mandated activities and to enable U.S. manufacturers to be competitive in the world market.

Pass, Ralph P.↗
NASA NTRS1991

Continuous fiber-reinforced titanium aluminide composites

An account is given of the fabrication techniques, microstructural characteristics, and mechanical behavior of a lightweight, high service temperature SiC-reinforced alpha-2 Ti-14Al-21Nb intermetallic-matrix composite. Fabrication techniques under investigation to improve the low-temperature ductility and environmental resistance of this material system, while reducing manufacturing costs to competitive levels, encompass powder-cloth processing, foil-fiber-foil processing, and thermal-spray processing. Attention is given to composite microstructure problems associated with fiber distribution and fiber-matrix interfaces, as well as with mismatches of thermal-expansion coefficient; major improvements are noted to be required in tensile properties, thermal cycling effects, mechanical damage, creep, and environmental effects.

Mackay, R. A.↗
NASA NTRS1994

Intelligent robotics can boost America's economic growth

A case is made for strategic investment in intelligent robotics as a part of the solution to the problem of improved global competitiveness for U.S. manufacturing, a critical industrial sector. Similar cases are made for strategic investments in intelligent robotics for field applications, construction, and service industries such as health care. The scope of the country's problems and needs is beyond the capability of the private sector alone, government alone, or academia alone to solve independently of the others. National cooperative programs in intelligent robotics are needed with the private sector supplying leadership direction and aerospace and non-aerospace industries conducting the development. Some necessary elements of such programs are outlined. The National Aeronautics and Space Administration (NASA) and the Lyndon B. Johnson Space Center (JSC) can be key players in such national cooperative programs in intelligent robotics for several reasons: (1) human space exploration missions require supervised intelligent robotics as enabling tools and, hence must develop supervised intelligent robotic systems; (2) intelligent robotic technology is being developed for space applications at JSC (but has a strong crosscutting or generic flavor) that is advancing the state of the art and is producing both skilled personnel and adaptable developmental infrastructure such as integrated testbeds; and (3) a NASA JSC Technology Investment Program in Robotics has been proposed based on commercial partnerships and collaborations for precompetitive, dual-use developments.

Erickson, Jon D.↗