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Sample records for manufacturing process final

  1. Integrated manufacturing and processing predoctoral fellowships. Final performance report

    SciTech Connect

    Rozzell, Thomas

    1999-10-01

    The first and fourth cohorts of U.S. Department of Energy Integrated Manufacturing and Processing Predoctoral Fellows were supported under this grant for up to three years of study leading to a PhD degree in a field related to integrated manufacturing and processing.

  2. Environmental assessment of advanced thin film manufacturing process. Final report

    SciTech Connect

    Cunningham, D.W.; Mopas, E.; Skinner, D.; McGuire, L.; Strehlow, M.

    1998-09-01

    This report describes work performed by BP Solar, Inc., to provide an extensive preproduction analysis of waste-stream abatement at its plant in Fairfield, California. During the study, numerous technologies were thoroughly evaluated, which allowed BP Solar to select systems that outperformed the stringent federal and state regulations. The main issues were originally perceived to be controlling cadmium compound releases to both air and wastewater to acceptable levels and adopting technologies for air and water waste streams in an efficient, cost-effective manner. BP Solar proposed high-efficiency, reliable control equipment that would reduce air-contaminant emission levels below levels of concern. Cadmium telluride dust is successfully controlled with high-efficiency (>99.9%) bag-in/bag-out filters. For air abatement, carbon canisters provide efficient VOC reduction, and wastewater pretreatment is required per federal pretreatment standards. BP Solar installed a cadmium-scavenging ion exchange system and electrowinning system capable of removing cadmium to <10 ppb (local publicly-owned-treatment-works limits for cadmium is 30 ppb). BP Solar plans to maximize potential reuse of rinse waters by phasing in additional wastewater treatment technologies. Finally, the work to date has identified the areas that need to be revisited as production scales up to ensure that all health, safety, and environmental goals are met.

  3. U.S. Department of Energy integrated manufacturing & processing predoctoral fellowships. Final Report

    SciTech Connect

    Petrochenkov, Margaret

    2003-03-31

    The objective of this program was threefold: to create a pool of PhDs trained in the integrated approach to manufacturing and processing, to promote academic interest in the field, and to attract talented professionals to this challenging area of engineering. It was anticipated that the program would result in the creation of new manufacturing methods that would contribute to improved energy efficiency, to better utilization of scarce resources, and to less degradation of the environment. Emphasis in the competition was on integrated systems of manufacturing and the integration of product design with manufacturing processes. Research addressed such related areas as aspects of unit operations, tooling and equipment, intelligent sensors, and manufacturing systems as they related to product design. This is the final report to close out the contract.

  4. United States Department of Energy Integrated Manufacturing & Processing Predoctoral Fellowships. Final Report

    SciTech Connect

    Petrochenkov, M.

    2003-03-31

    The objective of the program was threefold: to create a pool of PhDs trained in the integrated approach to manufacturing and processing, to promote academic interest in the field, and to attract talented professionals to this challenging area of engineering. It was anticipated that the program would result in the creation of new manufacturing methods that would contribute to improved energy efficiency, to better utilization of scarce resources, and to less degradation of the environment. Emphasis in the competition was on integrated systems of manufacturing and the integration of product design with manufacturing processes. Research addressed such related areas as aspects of unit operations, tooling and equipment, intelligent sensors, and manufacturing systems as they related to product design.

  5. Compatibility of manufacturing process fluids with R-134a and polyolester lubricant. Final report

    SciTech Connect

    Cavestri, R.C.; Schooley, D.L.

    1996-07-01

    This report includes a broad list of processing fluids that are known to be used to manufacture air conditioning and refrigeration products. Sixty-four process fluids from this list were selected for compatibility studies with R-134a and ICI EMKARATE RL32H (32 ISO) polyolester lubricant. Solutions or suspensions of the process fluid residues in polyolester lubricant were heated for 14 days at 175{degrees}C (347{degrees}F) in evacuated sealed glass tubes containing only valve steel coupons. Miscibility tests were performed at 90 wt.% R-134a, 10 wt.% polyolester lubricant with process fluid residue contaminate and were scanned in 10{degrees}C (18{degrees}F) increments over a temperature range of ambient to -40{degrees}C (-40{degrees}F). Any sign of turbidity, haze formation or oil separation was considered the immiscibility point.

  6. Industrial process profiles for environmental use: Chapter 30. The electronic component manufacturing industry. Final report

    SciTech Connect

    Not Available

    1983-04-01

    This report is one of a series constituting the catalog of Industrial Process Profiles for Environmental Use. Each industry sector is addressed as a separate chapter of the study. The catalog was developed for the purpose of compiling relevant information concerning air, water, and solid waste emissions from industries which employ similar technologies, have common types of environmental impacts, and supply their products for further processing or consumption to the same general population of customers. This report addresses the following segments of the electronic component manufacturing industry: semiconductors, SIC 3674; capacitors, SIC 3675; resistors, SIC 3676; transformer and inductors, SIC 3677; printed circuit boards, SIC 3679052; electron tubes, SIC 36711, 36713; and cathode ray tubes, SIC 36712, 3671385.

  7. The mechanics of manufacturing processes

    SciTech Connect

    Wright, P.; Stori, J.; King, C.

    1996-10-01

    Economic pressures, particularly related to the quality of manufactured goods and `time-to-market` are forcing designers to think not only in terms of product design but also in terms of integrated product and process design, and finally in terms of deterministic manufacturing planning and control. As a result of these three high level needs, there is now an even greater need for comprehensive simulations that predict material behavior during a manufacturing process, the stresses and/or temperatures on associated tooling, and the final-product integrity. The phrase `manufacturing processes` of course covers a broad scope; it includes semiconductor manufacturing, injection molding of polymers, metal machining and precision lapping, wood and textile production, and the final assembly of piece-parts into a consumer product. It can be seen from this partial listing that the fields of fluid mechanics, solid mechanics, dynamics and tribology can all play a role. The introduction to the paper will contain a review of manufacturing processes and describe where simulations have been successfully applied, and where simulations are still lacking. The best of the simulations are those where the models accurately fit the physical phenomena, where accurate constitutive equations are available, and where boundary conditions are realistic. Thus, the body of the paper will focus on the results from one of these more successful simulations. It has been used to predict the deflections of tooling and the most appropriate operating conditions for the manufacturing process under study. A new method for manufacturing planning is described. In this method, closed form, somewhat simplified, analytical models are used to determine manufacturing planning parameters and then the results from these simpler models are refined by the fuller simulations. A case study in machining parameter selection for peripheral finish milling operations is developed.

  8. Freeze-casting as a Novel Manufacturing Process for Fast Reactor Fuels. Final Report

    SciTech Connect

    Wegst, Ulrike G.K.; Allen, Todd; Sridharan, Kumar

    2014-04-07

    Advanced burner reactors are designed to reduce the amount of long-lived radioactive isotopes that need to be disposed of as waste. The input feedstock for creating advanced fuel forms comes from either recycle of used light water reactor fuel or recycle of fuel from a fast burner reactor. Fuel for burner reactors requires novel fuel types based on new materials and designs that can achieve higher performance requirements (higher burn up, higher power, and greater margins to fuel melting) then yet achieved. One promising strategy to improved fuel performance is the manufacture of metal or ceramic scaffolds which are designed to allow for a well-defined placement of the fuel into the host, and this in a manner that permits greater control than that possible in the production of typical CERMET fuels.

  9. Final Technical Report - Autothermal Styrene Manufacturing Process with Net Export of Energy

    SciTech Connect

    Trubac, Robert , E.; Lin, Feng; Ghosh, Ruma: Greene, Marvin

    2011-11-29

    The overall objectives of the project were to: (a) develop an economically competitive processing technology for styrene monomer (SM) that would reduce process energy requirements by a minimum 25% relative to those of conventional technology while achieving a minimum 10% ROI; and (b) advance the technology towards commercial readiness. This technology is referred to as OMT (Oxymethylation of Toluene). The unique energy savings feature of the OMT technology would be replacement of the conventional benzene and ethylene feedstocks with toluene, methane in natural gas and air or oxygen, the latter of which have much lower specific energy of production values. As an oxidative technology, OMT is a net energy exporter rather than a net energy consumer like the conventional ethylbenzene/styrene (EB/SM) process. OMT plants would ultimately reduce the cost of styrene monomer which in turn will decrease the costs of polystyrene making it perhaps more cost competitive with competing polymers such as polypropylene.

  10. Beryllium Manufacturing Processes

    SciTech Connect

    Goldberg, A

    2006-06-30

    This report is one of a number of reports that will be combined into a handbook on beryllium. Each report covers a specific topic. To-date, the following reports have been published: (1) Consolidation and Grades of Beryllium; (2) Mechanical Properties of Beryllium and the Factors Affecting these Properties; (3) Corrosion and Corrosion Protection of Beryllium; (4) Joining of Beryllium; (5) Atomic, Crystal, Elastic, Thermal, Nuclear, and other Properties of Beryllium; and (6) Beryllium Coating (Deposition) Processes and the Influence of Processing Parameters on Properties and Microstructure. The conventional method of using ingot-cast material is unsuitable for manufacturing a beryllium product. Beryllium is a highly reactive metal with a high melting point, making it susceptible to react with mold-wall materials forming beryllium compounds (BeO, etc.) that become entrapped in the solidified metal. In addition, the grain size is excessively large, being 50 to 100 {micro}m in diameter, while grain sizes of 15 {micro}m or less are required to meet acceptable strength and ductility requirements. Attempts at refining the as-cast-grain size have been unsuccessful. Because of the large grain size and limited slip systems, the casting will invariably crack during a hot-working step, which is an important step in the microstructural-refining process. The high reactivity of beryllium together with its high viscosity (even with substantial superheat) also makes it an unsuitable candidate for precision casting. In order to overcome these problems, alternative methods have been developed for the manufacturing of beryllium. The vast majority of these methods involve the use of beryllium powders. The powders are consolidated under pressure in vacuum at an elevated temperature to produce vacuum hot-pressed (VHP) blocks and vacuum hot-isostatic-pressed (HIP) forms and billets. The blocks (typically cylindrical), which are produced over a wide range of sizes (up to 183 cm dia. by 61

  11. MEGARA optical manufacturing process

    NASA Astrophysics Data System (ADS)

    Carrasco, E.; Páez, G.; Granados, F.; Percino, E.; Castillo-Domínguez, E.; Avilés, J. L.; García-Vargas, M. L.; Gil de Paz, A.; Gallego, J.; Iglesias-Páramo, J.; Cedazo, R.

    2014-07-01

    MEGARA is the future visible integral-field and multi-object spectrograph for the GTC 10.4-m telescope located in La Palma. INAOE is a member of the MEGARA Consortium and it is in charge of the Optics Manufacturing work package. MEGARA passed the Optics Detailed Design Review in May 2013, and the blanks of the main optics have been already ordered and their manufacturing is in progress. Except for the optical fibers and microlenses, the complete MEGARA optical system will be manufactured in Mexico, shared between the workshops of INAOE and CIO. This includes a field lens, a 5-lenses collimator, a 7-lenses camera and a complete set of volume phase holographic gratings with 36 flat windows and 24 prisms, being all these elements very large and complex. Additionally, the optical tests and the complete assembly of the camera and collimator subsystems will be carried out in Mexico. Here we describe the current status of the optics manufacturing process.

  12. Manufacturing Curriculum Grant. Final Report.

    ERIC Educational Resources Information Center

    Scarborough, Jule Dee

    A manufacturing curriculum for secondary vocational programs was designed to bridge the gap between grades 9-10 level courses and the community college-level curriculum of the Illinois Plan for Industrial Education. During the project, a literature review of manufacturing curriculum materials was conducted, a manufacturing conceptual framework was…

  13. Large forging manufacturing process

    DOEpatents

    Thamboo, Samuel V.; Yang, Ling

    2002-01-01

    A process for forging large components of Alloy 718 material so that the components do not exhibit abnormal grain growth includes the steps of: a) providing a billet with an average grain size between ASTM 0 and ASTM 3; b) heating the billet to a temperature of between 1750.degree. F. and 1800.degree. F.; c) upsetting the billet to obtain a component part with a minimum strain of 0.125 in at least selected areas of the part; d) reheating the component part to a temperature between 1750.degree. F. and 1800.degree. F.; e) upsetting the component part to a final configuration such that said selected areas receive no strains between 0.01 and 0.125; f) solution treating the component part at a temperature of between 1725.degree. F. and 1750.degree. F.; and g) aging the component part over predetermined times at different temperatures. A modified process achieves abnormal grain growth in selected areas of a component where desirable.

  14. Photovoltaic Manufacturing Technology, Phase 1, Final report

    SciTech Connect

    Easoz, J.R.; Herlocher, R.H. )

    1991-12-01

    This report examines the cost-effective manufacture of dendritic-web-based photovoltaic modules. It explains how process changes can increase production and reduce manufacturing costs. Long-range benefits of these improved processes are also discussed. Problems are identified that could impede increasing production and reducing costs; approaches to solve these problems are presented. These approaches involve web growth throughput, cell efficiency, process yield, silicon use, process control, automation, and module efficiency. Also discussed are the benefits of bifacial module design, unique to the dendritic web process.

  15. Blade Manufacturing Improvement Project: Final Report

    SciTech Connect

    SHERWOOD, KENT

    2002-10-01

    The Blade Manufacturing Improvement Project explores new, unique and improved materials integrated with innovative manufacturing techniques that promise substantial economic enhancements for the fabrication of wind turbine blades. The primary objectives promote the development of advanced wind turbine blade manufacturing in ways that lower blade costs, cut rotor weight, reduce turbine maintenance costs, improve overall turbine quality and increase ongoing production reliability. Foam Matrix (FMI) has developed a wind turbine blade with an engineered foam core, incorporating advanced composite materials and using Resin Transfer Molding (RTM) processes to form a monolithic blade structure incorporating a single molding tool. Patented techniques are employed to increase blade load bearing capability and insure the uniform quality of the manufactured blade. In production quantities, FMI manufacturing innovations may return a sizable per blade cost reduction when compared to the cost of producing comparable blades with conventional methods.

  16. Manufacturing process applications team (MATeam)

    NASA Technical Reports Server (NTRS)

    Bangs, E. R.; Meyer, J. D.

    1978-01-01

    Activities of the manufacturing applications team (MATeam) in effecting widespread transfer of NASA technology to aid in the solution of manufacturing problems in the industrial sector are described. During the program's first year of operation, 450 companies, industry associations, and government agencies were contacted, 150 manufacturing problems were documented, and 20 potential technology transfers were identified. Although none of the technology transfers has been commercialized and put in use, several are in the applications engineering phase, and others are in the early stages of implementation. The technology transfer process is described and guidelines used for the preparation of problems statements are included.

  17. Advanced Blade Manufacturing Project - Final Report

    SciTech Connect

    POORE, ROBERT Z.

    1999-08-01

    The original scope of the project was to research improvements to the processes and materials used in the manufacture of wood-epoxy blades, conduct tests to qualify any new material or processes for use in blade design and subsequently build and test six blades using the improved processes and materials. In particular, ABM was interested in reducing blade cost and improving quality. In addition, ABM needed to find a replacement material for the mature Douglas fir used in the manufacturing process. The use of mature Douglas fir is commercially unacceptable because of its limited supply and environmental concerns associated with the use of mature timber. Unfortunately, the bankruptcy of FloWind in June 1997 and a dramatic reduction in AWT sales made it impossible for ABM to complete the full scope of work. However, sufficient research and testing were completed to identify several promising changes in the blade manufacturing process and develop a preliminary design incorporating these changes.

  18. Environmentally conscious manufacturing integrated demonstration. Final report

    SciTech Connect

    Gentry, D.E.

    1993-07-01

    The objective of the Environmentally Conscious Manufacturing Integrated Demonstration was to show that several of the individually developed materials and processes to reduce hazardous materials and waste could be successfully used on a single assembly. A methodology was developed that could be used on any product to plan the approach to eliminating hazardous materials. Sample units of an existing design electronic unit were fabricated applying this methodology and substituting nonhazardous materials and processes. The results of this project show that total waste can be drastically reduced by at least an order of magnitude and hazardous material and waste can be essentially eliminated in the manufacture of this type of electronic devices.

  19. Photovoltaic industry manufacturing technology. Final report

    SciTech Connect

    Vanecek, D.; Diver, M.; Fernandez, R.

    1998-08-01

    This report contains the results of the Photovoltaic (PV) Industry Manufacturing Technology Assessment performed by the Automation and Robotics Research Institute (ARRI) of the University of Texas at Arlington for the National Renewable Energy laboratory. ARRI surveyed eleven companies to determine their state-of-manufacturing in the areas of engineering design, operations management, manufacturing technology, equipment maintenance, quality management, and plant conditions. Interviews with company personnel and plant tours at each of the facilities were conducted and the information compiled. The report is divided into two main segments. The first part of the report presents how the industry as a whole conforms to ``World Class`` manufacturing practices. Conclusions are drawn from the results of a survey as to the areas that the PV industry can improve on to become more competitive in the industry and World Class. Appendix A contains the questions asked in the survey, a brief description of the benefits to performing this task and the aggregate response to the questions. Each company participating in the assessment process received the results of their own facility to compare against the industry as a whole. The second part of the report outlines opportunities that exist on the shop floor for improving Process Equipment and Automation Strategies. Appendix B contains the survey that was used to assess each of the manufacturing processes.

  20. Modeling and simulation of CVD processes for manufacturing ceramic composites. Final report, 30 September 1994-25 June 1995

    SciTech Connect

    Adjerid, S.; Flaherty, J.E.; Hudson, J.B.; Shephard, M.S.; Webster, B.E.

    1995-06-29

    A chemical vapor deposition (CVD) process used to coat crystal sapphire fibers with B-Al2O3 has been mathematically modelled and numerically simulated using adaptive finite element software. This software system is applicable for solving transient and steady partial differential equations and is capable of automatic mesh generation, mesh-order variation, and/or mesh refinement.

  1. New Skills in Process Manufacturing.

    ERIC Educational Resources Information Center

    Dumbrell, Tom; de Montfort, Rowena; Finnegan, Wendy

    Recent changes in the nature of work in Australia's process manufacturing industry and their impact on operative-level workers and vocational education and training (VET) were examined. Structured interviews were conducted with training or human resource managers in 16 firms representing a cross-section of small, medium, and large enterprises…

  2. Process for manufacturing multilayer capacitors

    DOEpatents

    Lauf, R.J.; Holcombe, C.E.; Dykes, N.L.

    1996-01-02

    The invention is directed to a method of manufacture of multilayer electrical components, especially capacitors, and components made by such a method. High capacitance dielectric materials and low cost metallizations layered with such dielectrics may be fabricated as multilayer electrical components by sintering the metallizations and the dielectrics during the fabrication process by application of microwave radiation. 4 figs.

  3. Process for manufacturing multilayer capacitors

    DOEpatents

    Lauf, Robert J.; Holcombe, Cressie E.; Dykes, Norman L.

    1996-01-01

    The invention is directed to a method of manufacture of multilayer electrical components, especially capacitors, and components made by such a method. High capacitance dielectric materials and low cost metallizations layered with such dielectrics may be fabricated as multilayer electrical components by sintering the metallizations and the dielectrics during the fabrication process by application of microwave radiation.

  4. 24 CFR 3285.6 - Final leveling of manufactured home.

    Code of Federal Regulations, 2011 CFR

    2011-04-01

    ... 24 Housing and Urban Development 5 2011-04-01 2011-04-01 false Final leveling of manufactured home... HOUSING AND URBAN DEVELOPMENT MODEL MANUFACTURED HOME INSTALLATION STANDARDS General § 3285.6 Final leveling of manufactured home. The manufactured home must be adequately leveled prior to completion of...

  5. 24 CFR 3285.6 - Final leveling of manufactured home.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... 24 Housing and Urban Development 5 2010-04-01 2010-04-01 false Final leveling of manufactured home... HOUSING AND URBAN DEVELOPMENT MODEL MANUFACTURED HOME INSTALLATION STANDARDS General § 3285.6 Final leveling of manufactured home. The manufactured home must be adequately leveled prior to completion of...

  6. 24 CFR 3285.6 - Final leveling of manufactured home.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... 24 Housing and Urban Development 5 2014-04-01 2014-04-01 false Final leveling of manufactured home... HOUSING AND URBAN DEVELOPMENT MODEL MANUFACTURED HOME INSTALLATION STANDARDS General § 3285.6 Final leveling of manufactured home. The manufactured home must be adequately leveled prior to completion of...

  7. 24 CFR 3285.6 - Final leveling of manufactured home.

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... 24 Housing and Urban Development 5 2012-04-01 2012-04-01 false Final leveling of manufactured home... HOUSING AND URBAN DEVELOPMENT MODEL MANUFACTURED HOME INSTALLATION STANDARDS General § 3285.6 Final leveling of manufactured home. The manufactured home must be adequately leveled prior to completion of...

  8. 24 CFR 3285.6 - Final leveling of manufactured home.

    Code of Federal Regulations, 2013 CFR

    2013-04-01

    ... 24 Housing and Urban Development 5 2013-04-01 2013-04-01 false Final leveling of manufactured home... HOUSING AND URBAN DEVELOPMENT MODEL MANUFACTURED HOME INSTALLATION STANDARDS General § 3285.6 Final leveling of manufactured home. The manufactured home must be adequately leveled prior to completion of...

  9. Laser Material Processing in Manufacturing

    NASA Astrophysics Data System (ADS)

    Jones, Marshall

    2014-03-01

    This presentation will address some of the past, present, and potential uses of lasers for material processing in manufacturing. Laser processing includes welding, drilling, cutting, cladding, etc. The U.S. was the hot bed for initial uses of lasers for material processing in the past with Europe, especially Germany, presently leading the way. The future laser processing leader may still be Germany. Selected uses, past and present, of lasers within GE will also be highlighted as seen in such business units as Aviation, Lighting, Power and Water, Healthcare, and Transportation.

  10. Manufacturing Process Applications Team (MATeam)

    NASA Technical Reports Server (NTRS)

    1978-01-01

    The activities of the Manufacturing Process Applications Team concerning the promotion of joint Industry/Federal Agency/NASA funded research and technology operating plan (RTOP) programs are reported. Direct transfers occurred in cutting tools, laser wire stripping, soldering, and portable X-ray unit technology. TROP program funding approval was obtained for the further development of the cutting tool Sialon and development of an automated nondestructive fracture toughness testing system.

  11. Development of a High Volume Capable Process to Manufacture High Performance Photovoltaic Cells: Cooperative Research and Development Final Report, CRADA Number CRD-08-322

    SciTech Connect

    Geisz, J. F.

    2012-11-01

    The intent of the work is for RFMD and NREL to cooperate in the development of a commercially viable and high volume capable process to manufacture high performance photovoltaic cells, based on inverted metamorphic (IMM) GaAs technology. The successful execution of the agreement will result in the production of a PV cell using technology that is capable of conversion efficiency at par with the market at the time of release (reference 2009: 37-38%), using RFMD's production facilities. The CRADA work has been divided into three phases: (1) a foundation phase where the teams will demonstrate the manufacturing of a basic PV cell at RFMD's production facilities; (2) a technology demonstration phase where the teams will demonstrate the manufacturing of prototype PV cells using IMM technology at RFMD's production facilities, and; (3) a production readiness phase where the teams will demonstrate the capability to manufacture PV cells using IMM technology with high yields, high reliability, high reproducibility and low cost.

  12. Process for manufacturing tantalum capacitors

    DOEpatents

    Lauf, Robert J.; Holcombe, Cressie E.; Dykes, Norman L.

    1993-01-01

    A process for manufacturing tantalum capacitors in which microwave energy is used to sinter a tantalum powder compact in order to achieve higher surface area and improved dielectric strength. The process comprises cold pressing tantalum powder with organic binders and lubricants to form a porous compact. After removal of the organics, the tantalum compact is heated to 1300.degree. to 2000.degree. C. by applying microwave radiation. Said compact is then anodized to form a dielectric oxide layer and infiltrated with a conductive material such as MnO.sub.2. Wire leads are then attached to form a capacitor to said capacitor is hermetically packaged to form the finished product.

  13. Process for manufacturing tantalum capacitors

    DOEpatents

    Lauf, R.J.; Holcombe, C.E.; Dykes, N.L.

    1993-02-02

    A process for manufacturing tantalum capacitors in which microwave energy is used to sinter a tantalum powder compact in order to achieve higher surface area and improved dielectric strength. The process comprises cold pressing tantalum powder with organic binders and lubricants to form a porous compact. After removal of the organics, the tantalum compact is heated to 1,300 to 2,000 C by applying microwave radiation. Said compact is then anodized to form a dielectric oxide layer and infiltrated with a conductive material such as MnO[sub 2]. Wire leads are then attached to form a capacitor to said capacitor is hermetically packaged to form the finished product.

  14. Monitoring of an antigen manufacturing process.

    PubMed

    Zavatti, Vanessa; Budman, Hector; Legge, Raymond; Tamer, Melih

    2016-06-01

    Fluorescence spectroscopy in combination with multivariate statistical methods was employed as a tool for monitoring the manufacturing process of pertactin (PRN), one of the virulence factors of Bordetella pertussis utilized in whopping cough vaccines. Fluorophores such as amino acids and co-enzymes were detected throughout the process. The fluorescence data collected at different stages of the fermentation and purification process were treated employing principal component analysis (PCA). Through PCA, it was feasible to identify sources of variability in PRN production. Then, partial least square (PLS) was employed to correlate the fluorescence spectra obtained from pure PRN samples and the final protein content measured by a Kjeldahl test from these samples. In view that a statistically significant correlation was found between fluorescence and PRN levels, this approach could be further used as a method to predict the final protein content. PMID:26879644

  15. Wind Turbine Manufacturing Process Monitoring

    SciTech Connect

    Waseem Faidi; Chris Nafis; Shatil Sinha; Chandra Yerramalli; Anthony Waas; Suresh Advani; John Gangloff; Pavel Simacek

    2012-04-26

    To develop a practical inline inspection that could be used in combination with automated composite material placement equipment to economically manufacture high performance and reliable carbon composite wind turbine blade spar caps. The approach technical feasibility and cost benefit will be assessed to provide a solid basis for further development and implementation in the wind turbine industry. The program is focused on the following technology development: (1) Develop in-line monitoring methods, using optical metrology and ultrasound inspection, and perform a demonstration in the lab. This includes development of the approach and performing appropriate demonstration in the lab; (2) Develop methods to predict composite strength reduction due to defects; and (3) Develop process models to predict defects from leading indicators found in the uncured composites.

  16. Trajectory-Oriented and Fault-Tolerant-Based Intelligent Process Control for Flexible CIGS PV Module Manufacturing; Final Technical Report, 13 May 2002--30 May 2005

    SciTech Connect

    Simpson, L.; Britt, J.; Birkmire, R.; Vincent, T.

    2005-10-01

    ITN Energy Systems, Inc., and Global Solar Energy, Inc., assisted by NREL's PV Manufacturing R&D program, have continued to advance CIGS production technology by developing trajectory-oriented predictive/control models, fault-tolerance control, control platform development, in-situ sensors, and process improvements. Modeling activities included developing physics-based and empirical models for CIGS and sputter-deposition processing, implementing model-based control, and applying predictive models to the construction of new evaporation sources and for control. Model-based control is enabled by implementing reduced or empirical models into a control platform. Reliability improvement activities include implementing preventive maintenance schedules; detecting failed sensors/equipment and reconfiguring to tinue processing; and systematic development of fault prevention and reconfiguration strategies for the full range of CIGS PV production deposition processes. In-situ sensor development activities have resulted in improved control and indicated the potential for enhanced process status monitoring and control of the deposition processes. Substantial process improvements have been made, including significant improvement in CIGS uniformity, thickness control, efficiency, yield, and throughput. In large measure, these gains have been driven by process optimization, which in turn have been enabled by control and reliability improvements due to this PV Manufacturing R&D program.

  17. Establishment of a production-ready manufacturing process utilizing thin silicon substrates for solar cells. Final report. Motorola report No. 2364/4

    SciTech Connect

    Pryor, R. A.

    1980-10-01

    Three inch diameter Czochralski silicon substrates sliced directly to 5 mil, 8 mil, and 27 mil thicknesses with wire saw techniques were procured. Processing sequences incorporating either diffusion or ion implantation technologies were employed to produce n+p or n+pp+ solar cell structures. These cells were evaluated for performance, ease of fabrication, and cost effectiveness. It was determined that the use of 7 mil or even 4 mil wafers would provide near term cost reductions for solar cell manufacturers.

  18. Cost Models for MMC Manufacturing Processes

    NASA Technical Reports Server (NTRS)

    Elzey, Dana M.; Wadley, Haydn N. G.

    1996-01-01

    Processes for the manufacture of advanced metal matrix composites are rapidly approaching maturity in the research laboratory and there is growing interest in their transition to industrial production. However, research conducted to date has almost exclusively focused on overcoming the technical barriers to producing high-quality material and little attention has been given to the economical feasibility of these laboratory approaches and process cost issues. A quantitative cost modeling (QCM) approach was developed to address these issues. QCM are cost analysis tools based on predictive process models relating process conditions to the attributes of the final product. An important attribute, of the QCM approach is the ability to predict the sensitivity of material production costs to product quality and to quantitatively explore trade-offs between cost and quality. Applications of the cost models allow more efficient direction of future MMC process technology development and a more accurate assessment of MMC market potential. Cost models were developed for two state-of-the art metal matrix composite (MMC) manufacturing processes: tape casting and plasma spray deposition. Quality and Cost models are presented for both processes and the resulting predicted quality-cost curves are presented and discussed.

  19. Integrated lunar materials manufacturing process

    NASA Technical Reports Server (NTRS)

    Gibson, Michael A. (Inventor); Knudsen, Christian W. (Inventor)

    1990-01-01

    A manufacturing plant and process for production of oxygen on the moon uses lunar minerals as feed and a minimum of earth-imported, process materials. Lunar feed stocks are hydrogen-reducible minerals, ilmenite and lunar agglutinates occurring in numerous, explored locations mixed with other minerals in the pulverized surface layer of lunar soil known as regolith. Ilmenite (FeTiO.sub.3) and agglutinates contain ferrous (Fe.sup.+2) iron reducible by hydrogen to yield H.sub.2 O and metallic Fe at about 700.degree.-1,200.degree. C. The H.sub.2 O is electrolyzed in gas phase to yield H.sub.2 for recycle and O.sub.2 for storage and use. Hydrogen losses to lunar vacuum are minimized, with no net hydrogen (or any other earth-derived reagent) consumption except for small leaks. Feed minerals are surface-mined by front shovels and transported in trucks to the processing area. The machines are manned or robotic. Ilmenite and agglutinates occur mixed with silicate minerals which are not hydrogen-reducible at 700.degree.-1,200.degree. C. and consequently are separated and concentrated before feeding to the oxygen generation process. Solids rejected from the separation step and reduced solids from the oxygen process are returned to the mine area. The plant is powered by nuclear or solar power generators. Vapor-phase water electrolysis, a staged, countercurrent, fluidized bed reduction reactor and a radio-frequency-driven ceramic gas heater are used to improve thermal efficiency.

  20. TX-100 manufacturing final project report.

    SciTech Connect

    Ashwill, Thomas D.; Berry, Derek S.

    2007-11-01

    This report details the work completed under the TX-100 blade manufacturing portion of the Carbon-Hybrid Blade Developments: Standard and Twist-Coupled Prototype project. The TX-100 blade is a 9 meter prototype blade designed with bend-twist coupling to augment the mitigation of peak loads during normal turbine operation. This structural coupling was achieved by locating off axis carbon fiber in the outboard portion of the blade skins. The report will present the tooling selection, blade production, blade instrumentation, blade shipping and adapter plate design and fabrication. The baseline blade used for this project was the ERS-100 (Revision D) wind turbine blade. The molds used for the production of the TX-100 were originally built for the production of the CX-100 blade. The same high pressure and low pressure skin molds were used to manufacture the TX-100 skins. In order to compensate for the difference in skin thickness between the CX-100 and the TX-100, however, a new TX-100 shear web plug and mold were required. Both the blade assembly fixture and the root stud insertion fixture used for the CX-100 blades could be utilized for the TX-100 blades. A production run of seven TX-100 prototype blades was undertaken at TPI Composites during the month of October, 2004. Of those seven blades, four were instrumented with strain gauges before final assembly. After production at the TPI Composites facility in Rhode Island, the blades were shipped to various test sites: two blades to the National Wind Technology Center at the National Renewable Energy Laboratory in Boulder, Colorado, two blades to Sandia National Laboratory in Albuquerque, New Mexico and three blades to the United States Department of Agriculture turbine field test facility in Bushland, Texas. An adapter plate was designed to allow the TX-100 blades to be installed on existing Micon 65/13M turbines at the USDA site. The conclusion of this program is the kick-off of the TX-100 blade testing at the three

  1. Compatibility of manufacturing process fluids with HFC refrigerants and ester lubricants. First draft of final report of part one and quarterly report of part two, January 3, 1994--November 30, 1994

    SciTech Connect

    Cavestri, R.C.

    1994-11-01

    Included in this report is a compiled partial list of presently used processing materials in the air-conditioning and refrigeration industry and the manufacturers, intended uses, and applications of each. Also listed are the processing materials that have received final acceptance for this contracted study. An analytical methodology discussion is presented, including the final decision and the limitations of said methodology, as well as how to establish a level of confidence in observed immiscible material components in two 32 ISO VG polyolesters: (1) Mobil EAL Arctic 32; and (2) ICI Emkarate RL32H; both with HFC 134a refrigerant solutions.

  2. Manufacturing process applications team (MATeam)

    NASA Technical Reports Server (NTRS)

    Bangs, E. R.

    1980-01-01

    Progress in the transfer of aerospace technology to solve key problems in the manufacturing sector of the economy is reported. Potential RTOP programs are summarized along with dissemination activities. The impact of transferred NASA manufacturing technology is discussed. Specific areas covered include aircraft production, robot technology, machining of alloys, and electrical switching systems.

  3. Automated Manufacturing Training Center. Final Performance Report.

    ERIC Educational Resources Information Center

    Northampton Community Coll., Bethlehem, PA.

    A project conducted by Northampton Community College established an automated manufacturing training center for use by industry in eastern Pennsylvania. The center assists small and medium-size manufacturing firms in evaluating and integrating off-the-shelf technology to make them more competitive in the global marketplace. Comprehensive services…

  4. Closed Loop Welding Controller for Manufacturing Process

    NASA Astrophysics Data System (ADS)

    Bonaccorso, F.; Bruno, C.; Cantelli, L.; Longo, D.; Muscato, G.; Rapisarda, S.

    2011-12-01

    The aim of this paper is to investigate on the closed loop welding controller of a rapid manufacturing Shaped Metal Deposition (SMD) process. SMD was developed and patented by Rolls-Royce in order to produce mechanical parts directly from a CAD model. A simplified SMD plant has been set up in order to investigate the welding dynamics and parameters and to develop a SMD automatic controller. On the basis of the experience acquired, some basic control laws have been developed, and a closed loop controller has been implemented. This controller permits to find and to maintain the process stability condition, so that the final process results totally automatic. The control is performed adjusting the welding conditions on the basis of arc voltage information obtained from the welding machine during the deposition. The experimental results reported confirm the validity of the proposed strategy.

  5. News: Good chemical manufacturing process criteria

    EPA Science Inventory

    This news column covers topics relating to manufacturing criteria, machine to machine technology, novel process windows, green chemistry indices, business resilience, immobilized enzymes, and Bt crops.

  6. U-GAS process for chemical manufacture

    SciTech Connect

    Dihu, R.; Leppin, D.; Patel, J.G.

    1980-01-01

    The U-GAS coal gasification process and its potential application to the manufacture of two important industrial chemicals, methanol and ammonia, are described. Pilot plant results, the current status of the process, and economic projections for the cost of manufacture of methanol and ammonia are presented.

  7. Encapsulation Processing and Manufacturing Yield Analysis

    NASA Technical Reports Server (NTRS)

    Willis, P. B.

    1984-01-01

    The development of encapsulation processing and a manufacturing productivity analysis for photovoltaic cells are discussed. The goals were: (1) to understand the relationships between both formulation variables and process variables; (2) to define conditions required for optimum performance; (3) to predict manufacturing yield; and (4) to provide documentation to industry.

  8. Final report: An enabling architecture for information driven manufacturing

    SciTech Connect

    Griesmeyer, J.M.

    1997-08-01

    This document is the final report for the LDRD: An Enabling Architecture for Information Driven Manufacturing. The project was motivated by the need to bring quality products to market quickly and to remain efficient and profitable with small lot sizes, intermittent production and short product life cycles. The emphasis is on integration of the product realization process and the information required to drive it. Enterprise level information was not addressed except in so far as the enterprise must provide appropriate information to the production equipment to specify what to produce, and the equipment must return enough information to record what was produced. A production script approach was developed in which the production script specifies all of the information required to produce a quality product. A task sequencer that decomposes the script into process steps which are dispatched to capable Standard Manufacturing Modules. The plug and play interface to these modules allows rapid introduction of new modules into the production system and speeds up the product realization cycle. The results of applying this approach to the Agile Manufacturing Prototyping System are described.

  9. Energetic additive manufacturing process with feed wire

    SciTech Connect

    Harwell, Lane D.; Griffith, Michelle L.; Greene, Donald L.; Pressly, Gary A.

    2000-11-07

    A process for additive manufacture by energetic wire deposition is described. A source wire is fed into a energy beam generated melt-pool on a growth surface as the melt-pool moves over the growth surface. This process enables the rapid prototyping and manufacture of fully dense, near-net shape components, as well as cladding and welding processes. Alloys, graded materials, and other inhomogeneous materials can be grown using this process.

  10. Flexible manufacturing system (FMS) evaluation. Final report

    SciTech Connect

    Setter, D.L.

    1993-02-01

    The applicability of the flexible manufacturing system (FMS) concept to automate machining and inspecting a family of stainless steel and aluminum hardware for electrical components has been evaluated. FMS was found to be appropriate and justifiable and a project was initiated to purchase and implement an FMS system. System specifications and procurement methodologies were developed that resulted in a conventional competitive bid procurement A proposal evaluation technique was developed consisting of 40% price, 40% technical compliance, and 20% supplier management capabilities.

  11. Cost Models for MMC Manufacturing Processes

    NASA Technical Reports Server (NTRS)

    Elzey, Dana M.; Wadley, Haydn N. G.

    1996-01-01

    The quality cost modeling (QCM) tool is intended to be a relatively simple-to-use device for obtaining a first-order assessment of the quality-cost relationship for a given process-material combination. The QCM curve is a plot of cost versus quality (an index indicating microstructural quality), which is unique for a given process-material combination. The QCM curve indicates the tradeoff between cost and performance, thus enabling one to evaluate affordability. Additionally, the effect of changes in process design, raw materials, and process conditions on the cost-quality relationship can be evaluated. Such results might indicate the most efficient means to obtain improved quality at reduced cost by process design refinements, the implementation of sensors and models for closed loop process control, or improvement in the properties of raw materials being fed into the process. QCM also allows alternative processes for producing the same or similar material to be compared in terms of their potential for producing competitively priced, high quality material. Aside from demonstrating the usefulness of the QCM concept, this is one of the main foci of the present research program, namely to compare processes for making continuous fiber reinforced, metal matrix composites (MMC's). Two processes, low pressure plasma spray deposition and tape casting are considered for QCM development. This document consists of a detailed look at the design of the QCM approach, followed by discussion of the application of QCM to each of the selected MMC manufacturing processes along with results, comparison of processes, and finally, a summary of findings and recommendations.

  12. Process and quality verification controls for solid propellant manufacturing

    NASA Technical Reports Server (NTRS)

    Rogers, C. J.

    1983-01-01

    It is pointed out that in-process tests to verify quality and detect discrepant propellant which could compromise motor performance are essential elements of the solid composite propellant manufacturing process. The successful performance of the 260SL-1 and 260SL-2 motors aptly verified the controls used for manufacturing the propellant. The present investigation is concerned with the selected control parameters, and their relationships to composition and final propellant properties. Control performance is evaluated by comparison with processing data experienced in the manufacture of the propellant for the 260SL-1 motor. It is found that the in-process quality verification controls utilized in the propellant manufacturing process for the 260-in. diameter motor contributed significantly to the confidence of successful and predictable motor performance.

  13. Ultra-precision processes for optics manufacturing

    NASA Astrophysics Data System (ADS)

    Martin, William R.

    1991-12-01

    The Optics MODIL (Manufacturing Operations Development and Integration Laboratory) is developing advanced manufacturing technologies for fabrication of ultra precision optical components, aiming for a ten-fold improvement in precision and a shortening of the scheduled lead time. Current work focuses on diamond single point turning, ductile grinding, ion milling, and in/on process metrology.

  14. Ultra-precision processes for optics manufacturing

    NASA Technical Reports Server (NTRS)

    Martin, William R.

    1991-01-01

    The Optics MODIL (Manufacturing Operations Development and Integration Laboratory) is developing advanced manufacturing technologies for fabrication of ultra precision optical components, aiming for a ten-fold improvement in precision and a shortening of the scheduled lead time. Current work focuses on diamond single point turning, ductile grinding, ion milling, and in/on process metrology.

  15. Manufacturing of Smart Structures Using Fiber Placement Manufacturing Processes

    NASA Technical Reports Server (NTRS)

    Thomas, Matthew M.; Glowasky, Robert A.; McIlroy, Bruce E.; Story, Todd A.

    1996-01-01

    Smart structures research and development, with the ultimate aim of rapid commercial and military production of these structures, are at the forefront of the Synthesis and Processing of Intelligent Cost-Effective Structures (SPICES) program. As part of this ARPA-sponsored program, MDA-E is using fiber placement processes to manufacture integrated smart structure systems. These systems comprise advanced composite structures with embedded fiber optic sensors, shape memory alloys, piezoelectric actuators, and miniature accelerometers. Cost-effective approaches and solutions to smart material synthesis in the fiber-placement process, based upon integrated product development, are discussed herein.

  16. Electromechanical assembly department manufacturing improvements. Final report

    SciTech Connect

    Voss, S.W.

    1991-12-01

    Techniques for streamlining the processing and flow of products is an electromechanical assembly department were evaluated. Areas looked at included a paperless system for lot identification records, automated tool and fixture storage, evaluation of product transfer methods, and queue time reduction.

  17. Manufacturing process applications team (MATeam)

    NASA Technical Reports Server (NTRS)

    Bangs, E. R.

    1980-01-01

    The objectives and activities of an aerospace technology transfer group are outlined and programs in various stages of progress are described including the orbital tube flaring device, infrared proximity sensor for robot positioning, laser stripping magnet wire, infrared imaging as welding process tracking system, carbide coating of cutting tools, nondestructive fracture toughness testing of titanium welds, portable solar system for agricultural applications, and an anerobic methane gas generator.

  18. Hazardous air pollutant emissions from process units in the thermoplastics manufacturing industry: Basis and purpose document for final standards, summary of public comments and responses

    SciTech Connect

    1996-05-01

    This document provides a summary of the public comments received on the proposed Polymers and Resins IV NESHAP (40 CFR 63, subpart V), EPA`s responses to these comments, and the final decisions made by the EPA in develping the final rule (40 CFR 63, subart JJJ) for this industry.

  19. Superconductor and process of manufacture

    SciTech Connect

    Wong, James.

    1993-07-27

    The process is described of producing a Type II superconducting alloy which is superconducting at a high magnetic field, comprising the steps of creating a composite characterized by a periodic arrangement of at least two transition metals so as to provide numerous interfaces between the different transition metals, the transition metals being selected from the elements niobium, titanium, zirconium, vanadium, hafnium, and tantalum, and alloys thereof which are not superconducting at said field, the combination of transition metals being such that one of the metals will serve as a second phase when the layers are subjected to temperatures which would produce a two-phase equilibrium state from a solid solution alloy of said transition metals, mechanically reducing and heating the composite to cause interdiffusion of the transition metals to form ductile superconducting alloy zones at the interfaces of the transition metals, there being sufficient heat treatment in the region where two phases exist in the phase diagram to form two phases, one phase being the desired superconducting Type 11 alloy and the other phase being the non superconducting normal metal or alloy, limiting the temperature of heat treatment to the two-phase region, and thereafter mechanically reducing the composite so that the two zones are each less than about 1,000 nm in thickness.

  20. Process development status report for advanced manufacturing projects

    SciTech Connect

    Brinkman, J.R.; Homan, D.A.

    1990-03-30

    This is the final status report for the approved Advanced Manufacturing Projects for FY 1989. Five of the projects were begun in FY 1987, one in FY 1988, and one in FY 1989. The approved projects cover technology areas in welding, explosive material processing and evaluation, ion implantation, and automated manufacturing. It is expected that the successful completion of these projects well result in improved quality and/or reduced cost for components produced by Mound. Those projects not brought to completion will be continued under Process development in FY 1990.

  1. Towards automatic planning for manufacturing generative processes

    SciTech Connect

    CALTON,TERRI L.

    2000-05-24

    Generative process planning describes methods process engineers use to modify manufacturing/process plans after designs are complete. A completed design may be the result from the introduction of a new product based on an old design, an assembly upgrade, or modified product designs used for a family of similar products. An engineer designs an assembly and then creates plans capturing manufacturing processes, including assembly sequences, component joining methods, part costs, labor costs, etc. When new products originate as a result of an upgrade, component geometry may change, and/or additional components and subassemblies may be added to or are omitted from the original design. As a result process engineers are forced to create new plans. This is further complicated by the fact that the process engineer is forced to manually generate these plans for each product upgrade. To generate new assembly plans for product upgrades, engineers must manually re-specify the manufacturing plan selection criteria and re-run the planners. To remedy this problem, special-purpose assembly planning algorithms have been developed to automatically recognize design modifications and automatically apply previously defined manufacturing plan selection criteria and constraints.

  2. Auxetic polyurethane foam: Manufacturing and processing analysis

    NASA Astrophysics Data System (ADS)

    Jahan, Md Deloyer

    Materials with negative Poisson's ratio are referred to as auxetic materials. They are different from conventional materials in their deformation behavior when responding to external stresses. The cross-section of the materials widens in the lateral direction when being stretched in the longitudinal direction and becomes narrower when being compressed longitudinally. While a number of natural auxetic materials exist, most auxetic materials are synthetic. They show interesting properties and have potential in several important applications. Auxetic materials exhibit better mechanical properties than conventional materials such as enhanced indentation resistance, shear resistance, toughness, damping and energy absorption capacity, sound absorption, variable permeability and capability of producing complex curvature. These properties are beneficial in a wide range of applications including personal protective equipments, sound absorbers, packaging, smart filtration, drug delivery, tissue scaffolding, seat cushioning, etc. A wide range of auxetic materials has been synthesized. They include different polymers, metals, composites and ceramics. Among these, auxetic polyurethane (PU) foam is one of the most widely studied types of auxetic materials. Auxetic PU foams are usually fabricated by altering the microstructure of conventional foams and the unusual mechanical properties originate from the deformation characteristics of the microstructures. Three most important processing parameters in fabricating auxetic PU foam that dictate auxetic behavior are processing temperature, heating time and volumetric compression ratio. This study addresses several important issues in the manufacturing and characterization of auxetic PU foam. First, an improved automatic measuring technique has been developed to determine Poisson's ratio of auxetic PU foam. The technique involves development of a Matlab based image processing program. The second part of the study includes an

  3. Computational Fluid Dynamics - Applications in Manufacturing Processes

    NASA Astrophysics Data System (ADS)

    Beninati, Maria Laura; Kathol, Austin; Ziemian, Constance

    2012-11-01

    A new Computational Fluid Dynamics (CFD) exercise has been developed for the undergraduate introductory fluid mechanics course at Bucknell University. The goal is to develop a computational exercise that students complete which links the manufacturing processes course and the concurrent fluid mechanics course in a way that reinforces the concepts in both. In general, CFD is used as a tool to increase student understanding of the fundamentals in a virtual world. A ``learning factory,'' which is currently in development at Bucknell seeks to use the laboratory as a means to link courses that previously seemed to have little correlation at first glance. A large part of the manufacturing processes course is a project using an injection molding machine. The flow of pressurized molten polyurethane into the mold cavity can also be an example of fluid motion (a jet of liquid hitting a plate) that is applied in manufacturing. The students will run a CFD process that captures this flow using their virtual mold created with a graphics package, such as SolidWorks. The laboratory structure is currently being implemented and analyzed as a part of the ``learning factory''. Lastly, a survey taken before and after the CFD exercise demonstrate a better understanding of both the CFD and manufacturing process.

  4. Friction Stir Processing for Efficient Manufacturing

    SciTech Connect

    Mr. Christopher B. Smith; Dr. Oyelayo Ajayi

    2012-01-31

    Friction at contacting surfaces in relative motion is a major source of parasitic energy loss in machine systems and manufacturing processes. Consequently, friction reduction usually translates to efficiency gain and reduction in energy consumption. Furthermore, friction at surfaces eventually leads to wear and failure of the components thereby compromising reliability and durability. In order to reduce friction and wear in tribological components, material surfaces are often hardened by a variety of methods, including conventional heat treatment, laser surface hardening, and thin-film coatings. While these surface treatments are effective when used in conjunction with lubrication to prevent failure, they are all energy intensive and could potentially add significant cost. A new concept for surface hardening of metallic materials and components is Friction Stir Processing (FSP). Compared to the current surface hardening technologies, FSP is more energy efficient has no emission or waste by products and may result in better tribological performance. FSP involves plunging a rotating tool to a predetermined depth (case layer thickness) and translating the FSP tool along the area to be processed. This action of the tool produces heating and severe plastic deformation of the processed area. For steel the temperature is high enough to cause phase transformation, ultimately forming hard martensitic phase. Indeed, FSP has been used for surface modification of several metals and alloys so as to homogenize the microstructure and refine the grain size, both of which led to improved fatigue and corrosion resistance. Based on the effect of FSP on near-surface layer material, it was expected to have beneficial effects on friction and wear performance of metallic materials. However, little or no knowledge existed on the impact of FSP concerning friction and wear performance the subject of the this project and final report. Specifically for steel, which is the most dominant

  5. Computational Process Modeling for Additive Manufacturing

    NASA Technical Reports Server (NTRS)

    Bagg, Stacey; Zhang, Wei

    2014-01-01

    Computational Process and Material Modeling of Powder Bed additive manufacturing of IN 718. Optimize material build parameters with reduced time and cost through modeling. Increase understanding of build properties. Increase reliability of builds. Decrease time to adoption of process for critical hardware. Potential to decrease post-build heat treatments. Conduct single-track and coupon builds at various build parameters. Record build parameter information and QM Meltpool data. Refine Applied Optimization powder bed AM process model using data. Report thermal modeling results. Conduct metallography of build samples. Calibrate STK models using metallography findings. Run STK models using AO thermal profiles and report STK modeling results. Validate modeling with additional build. Photodiode Intensity measurements highly linear with power input. Melt Pool Intensity highly correlated to Melt Pool Size. Melt Pool size and intensity increase with power. Applied Optimization will use data to develop powder bed additive manufacturing process model.

  6. 15 CFR 400.31 - Manufacturing and processing activity; criteria.

    Code of Federal Regulations, 2011 CFR

    2011-01-01

    ... 15 Commerce and Foreign Trade 2 2011-01-01 2011-01-01 false Manufacturing and processing activity... ZONES BOARD Manufacturing and Processing Activity-Reviews § 400.31 Manufacturing and processing activity....” When evaluating zone and subzone manufacturing and processing activity, either as proposed in...

  7. 15 CFR 400.31 - Manufacturing and processing activity; criteria.

    Code of Federal Regulations, 2010 CFR

    2010-01-01

    ... 15 Commerce and Foreign Trade 2 2010-01-01 2010-01-01 false Manufacturing and processing activity... ZONES BOARD Manufacturing and Processing Activity-Reviews § 400.31 Manufacturing and processing activity....” When evaluating zone and subzone manufacturing and processing activity, either as proposed in...

  8. 15 CFR 400.31 - Manufacturing and processing activity; criteria.

    Code of Federal Regulations, 2012 CFR

    2012-01-01

    ... 15 Commerce and Foreign Trade 2 2012-01-01 2012-01-01 false Manufacturing and processing activity... ZONES BOARD Manufacturing and Processing Activity-Reviews § 400.31 Manufacturing and processing activity....” When evaluating zone and subzone manufacturing and processing activity, either as proposed in...

  9. Microeconomics of process control in semiconductor manufacturing

    NASA Astrophysics Data System (ADS)

    Monahan, Kevin M.

    2003-06-01

    Process window control enables accelerated design-rule shrinks for both logic and memory manufacturers, but simple microeconomic models that directly link the effects of process window control to maximum profitability are rare. In this work, we derive these links using a simplified model for the maximum rate of profit generated by the semiconductor manufacturing process. We show that the ability of process window control to achieve these economic objectives may be limited by variability in the larger manufacturing context, including measurement delays and process variation at the lot, wafer, x-wafer, x-field, and x-chip levels. We conclude that x-wafer and x-field CD control strategies will be critical enablers of density, performance and optimum profitability at the 90 and 65nm technology nodes. These analyses correlate well with actual factory data and often identify millions of dollars in potential incremental revenue and cost savings. As an example, we show that a scatterometry-based CD Process Window Monitor is an economically justified, enabling technology for the 65nm node.

  10. Materials processing in zero gravity. [space manufacturing

    NASA Technical Reports Server (NTRS)

    Wuenscher, H. F.

    1973-01-01

    Manufacturing processes which are expected to show drastic changes in a space environment due to the absence of earth gravity are classified according to (1) buoyancy and thermal convection sensitive processes and (2) processes where molecular forces like cohesion and adhesion remain as the relatively strongest and hence controlling factors. Some specific process demonstration experiments carried out during the Apollo 14 mission and in the Skylab program are described. These include chemical separation by electrophoresis, the M551 metals melting experiment, the M552 exothermic brazing experiment, the M553 sphere forming experiment, the M554 composite casting experiment, and the M555 gallium arsenide crystal growth experiment.

  11. Transient period process control for continuous manufacturing

    SciTech Connect

    Nembhard, H.B.; Birge, J.R.

    1994-12-31

    We develop a multiple objective nonlinear control model to optimize decision variables for correlated process characteristics during a transient phase. Given a continuous manufacturing process we show how to use the model to improve operations from startup to the end of the transient period (when steady-state is reached). We also show how to identify the end of the transient period and compare performance using the model during steady-state to traditional SPC techniques that assume the process is in statistical control.

  12. Estimated worker exposure to 2378-TCDD and 2378-TCDF in the manufacture, processing, and commercial use of pulp, paper, and paper products. Final report

    SciTech Connect

    Krishnan, R.; Meyer, C.; Goodman, B.; Foerst, M.B.

    1990-07-01

    The report assesses potential worker exposures and risks to 2378 TCDD and 2378 TCDF in the production, processing, and commercial use of pulp, paper, and paper products. The report identifies the job categories in each operation and examines worker exposure via the following three exposure pathways: (1) inhalation of volatilized 2378 TCDD/2378 TCDF, (2) inhalation of particulates containing 2378 TCDD/2378 TCDF, and (3) dermal contact with pulp, paper, or sludge. Since no available personnel exposure monitoring data is available, various modeling techniques and assumptions are used to estimate exposures. A range (low and high values) of exposure and risk estimates are presented for each industry/worker scenario and exposure route. The low and high exposures and risks are estimated based on the lowest and highest dioxin TEQ concentrations, as reported in the 104-Mill Study, and typical to reasonable worst-case assumptions, respectively.

  13. Conformal window manufacturing process development and demonstration for polycrystalline materials

    NASA Astrophysics Data System (ADS)

    Smith, Nathan E.; Gould, Alan R.; Hordin, Tom; Medicus, Kate; Walters, Mark; Brophy, Matthew; DeGroote Nelson, Jessica

    2013-09-01

    Conformal windows pose new and unique challenges to manufacturing due to the shape, measurement of, and requested hard polycrystalline materials. Their non-rotationally symmetric shape and high departure surfaces do not lend themselves to traditional optical fabrication processes. The hard crystalline materials are another challenge due to increased processing time and possibility of grain decoration. We have developed and demonstrated a process for manufacturing various conformal windows out of fused silica, glass, zinc-sulfide multispectral, and spinel. The current process involves CNC generation/grinding, VIBE polishing, and sub-aperture figure correction. The CNC generation step incorporates an ultrasonic assisted grinding machine; the machine settings and tool are being continuously optimized for minimal sub-surface damage and surface form error. In VIBE, polishing to less than 5 nm rms surface roughness while maintaining overall form error is accomplished with a full aperture conformal polishing tool and with rapid removal rates. The final sub-aperture polishing step corrects the overall form error. Currently we utilize our CMM for surface form measurement and have shown that we can produce spinel conformal windows with form error within +/-10 micrometers of the nominal shape, without grain decoration. This conformal window manufacturing process is continuously optimized for cost reduction and precision of the final optic.

  14. A simulation study on garment manufacturing process

    NASA Astrophysics Data System (ADS)

    Liong, Choong-Yeun; Rahim, Nur Azreen Abdul

    2015-02-01

    Garment industry is an important industry and continues to evolve in order to meet the consumers' high demands. Therefore, elements of innovation and improvement are important. In this work, research studies were conducted at a local company in order to model the sewing process of clothes manufacturing by using simulation modeling. Clothes manufacturing at the company involves 14 main processes, which are connecting the pattern, center sewing and side neating, pockets sewing, backside-sewing, attaching the front and back, sleeves preparation, attaching the sleeves and over lock, collar preparation, collar sewing, bottomedge sewing, buttonholing sewing, removing excess thread, marking button, and button cross sewing. Those fourteen processes are operated by six tailors only. The last four sets of processes are done by a single tailor. Data collection was conducted by on site observation and the probability distribution of processing time for each of the processes is determined by using @Risk's Bestfit. Then a simulation model is developed using Arena Software based on the data collected. Animated simulation model is developed in order to facilitate understanding and verifying that the model represents the actual system. With such model, what if analysis and different scenarios of operations can be experimented with virtually. The animation and improvement models will be presented in further work.

  15. Big Data Analysis of Manufacturing Processes

    NASA Astrophysics Data System (ADS)

    Windmann, Stefan; Maier, Alexander; Niggemann, Oliver; Frey, Christian; Bernardi, Ansgar; Gu, Ying; Pfrommer, Holger; Steckel, Thilo; Krüger, Michael; Kraus, Robert

    2015-11-01

    The high complexity of manufacturing processes and the continuously growing amount of data lead to excessive demands on the users with respect to process monitoring, data analysis and fault detection. For these reasons, problems and faults are often detected too late, maintenance intervals are chosen too short and optimization potential for higher output and increased energy efficiency is not sufficiently used. A possibility to cope with these challenges is the development of self-learning assistance systems, which identify relevant relationships by observation of complex manufacturing processes so that failures, anomalies and need for optimization are automatically detected. The assistance system developed in the present work accomplishes data acquisition, process monitoring and anomaly detection in industrial and agricultural processes. The assistance system is evaluated in three application cases: Large distillation columns, agricultural harvesting processes and large-scale sorting plants. In this paper, the developed infrastructures for data acquisition in these application cases are described as well as the developed algorithms and initial evaluation results.

  16. Manufacturing process of nanofluidics using afm probe

    NASA Astrophysics Data System (ADS)

    Karingula, Varun Kumar

    A new process for fabricating a nano fluidic device that can be used in medical application is developed and demonstrated. Nano channels are fabricated using a nano tip in indentation mode on AFM (Atomic Force Microscopy). The nano channels are integrated between the micro channels and act as a filter to separate biomolecules. Nano channels of 4 to7 m in length, 80nm in width, and at varying depths from 100nm to 850 nm allow the resulting device to separate selected groups of lysosomes and other viruses. Sharply developed vertical micro channels are produced from a deep reaction ion etching followed by deposition of different materials, such as gold and polymers, on the top surface, allowing the study of alternative ways of manufacturing a nanofluidic device. PDMS (Polydimethylsiloxane) bonding is performed to close the top surface of the device. An experimental setup is used to test and validate the device by pouring fluid through the channels. A detailed cost evaluation is conducted to compare the economical merits of the proposed process. It is shown that there is a 47:7% manufacturing time savings and a 60:6% manufacturing cost savings.

  17. Process and control systems for composites manufacturing

    NASA Technical Reports Server (NTRS)

    Tsiang, T. H.; Wanamaker, John L.

    1992-01-01

    A precise control of composite material processing would not only improve part quality, but it would also directly reduce the overall manufacturing cost. The development and incorporation of sensors will help to generate real-time information for material processing relationships and equipment characteristics. In the present work, the thermocouple, pressure transducer, and dielectrometer technologies were investigated. The monitoring sensors were integrated with the computerized control system in three non-autoclave fabrication techniques: hot-press, self contained tool (self heating and pressurizing), and pressure vessel). The sensors were implemented in the parts and tools.

  18. Computational Process Modeling for Additive Manufacturing (OSU)

    NASA Technical Reports Server (NTRS)

    Bagg, Stacey; Zhang, Wei

    2015-01-01

    Powder-Bed Additive Manufacturing (AM) through Direct Metal Laser Sintering (DMLS) or Selective Laser Melting (SLM) is being used by NASA and the Aerospace industry to "print" parts that traditionally are very complex, high cost, or long schedule lead items. The process spreads a thin layer of metal powder over a build platform, then melts the powder in a series of welds in a desired shape. The next layer of powder is applied, and the process is repeated until layer-by-layer, a very complex part can be built. This reduces cost and schedule by eliminating very complex tooling and processes traditionally used in aerospace component manufacturing. To use the process to print end-use items, NASA seeks to understand SLM material well enough to develop a method of qualifying parts for space flight operation. Traditionally, a new material process takes many years and high investment to generate statistical databases and experiential knowledge, but computational modeling can truncate the schedule and cost -many experiments can be run quickly in a model, which would take years and a high material cost to run empirically. This project seeks to optimize material build parameters with reduced time and cost through modeling.

  19. Ceramic component manufacturing process development. Final report

    SciTech Connect

    Robinson, S.

    1996-09-30

    Ceramic materials are well suited for applications where temperature, wear, and corrosion resistance are necessary. The toughness and wear resistance properties that make ceramics desirable, also make fabrication of parts difficult. The objective of this CRADA was to increase the grinding efficiency on Ceradyne Incorporated silicon nitride. This was to be accomplished through optimization of grinding wheel life and increasing silicon nitride material removal rates. Experiments were conducted to determine the relationship between grinding parameters, wheel wear, and material removal rates. Due to excessive, unexplained variation in the experimental results, a consistent relationship between the selected grinding parameters and wheel wear could not be established. Maximum material removal rates were limited by spindle and table drive power. Additional experiments were conducted to evaluate high speed grinding. When compared to conventional grinding speeds, the material removal rates using high speed grinding (13,000 SFM) increased by a factor of five to ten with no degradation of fracture strength.

  20. Precision replenishable grinding tool and manufacturing process

    DOEpatents

    Makowiecki, Daniel M.; Kerns, John A.; Blaedel, Kenneth L.; Colella, Nicholas J.; Davis, Pete J.; Juntz, Robert S.

    1998-01-01

    A reusable grinding tool consisting of a replaceable single layer of abrasive particles intimately bonded to a precisely configured tool substrate, and a process for manufacturing the grinding tool. The tool substrate may be ceramic or metal and the abrasive particles are preferably diamond, but may be cubic boron nitride. The manufacturing process involves: coating a configured tool substrate with layers of metals, such as titanium, copper and titanium, by physical vapor deposition (PVD); applying the abrasive particles to the coated surface by a slurry technique; and brazing the abrasive particles to the tool substrate by alloying the metal layers. The precision control of the composition and thickness of the metal layers enables the bonding of a single layer or several layers of micron size abrasive particles to the tool surface. By the incorporation of an easily dissolved metal layer in the composition such allows the removal and replacement of the abrasive particles, thereby providing a process for replenishing a precisely machined grinding tool with fine abrasive particles, thus greatly reducing costs as compared to replacing expensive grinding tools.

  1. Precision replenishable grinding tool and manufacturing process

    DOEpatents

    Makowiecki, D.M.; Kerns, J.A.; Blaedel, K.L.; Colella, N.J.; Davis, P.J.; Juntz, R.S.

    1998-06-09

    A reusable grinding tool consisting of a replaceable single layer of abrasive particles intimately bonded to a precisely configured tool substrate, and a process for manufacturing the grinding tool are disclosed. The tool substrate may be ceramic or metal and the abrasive particles are preferably diamond, but may be cubic boron nitride. The manufacturing process involves: coating a configured tool substrate with layers of metals, such as titanium, copper and titanium, by physical vapor deposition (PVD); applying the abrasive particles to the coated surface by a slurry technique; and brazing the abrasive particles to the tool substrate by alloying the metal layers. The precision control of the composition and thickness of the metal layers enables the bonding of a single layer or several layers of micron size abrasive particles to the tool surface. By the incorporation of an easily dissolved metal layer in the composition such allows the removal and replacement of the abrasive particles, thereby providing a process for replenishing a precisely machined grinding tool with fine abrasive particles, thus greatly reducing costs as compared to replacing expensive grinding tools. 11 figs.

  2. Defective Reduction in Automotive Headlining Manufacturing Process

    NASA Astrophysics Data System (ADS)

    Rittichai, Saranya; Chutima, Parames

    2016-05-01

    In an automobile parts manufacturing company, currently the headlining process has a lot of wastes resulting in a high cost of quality per year. In this paper, the Six Sigma method is used to reduce the defects in the headlining process. Cause-and-effect matrix and failure mode and effect analysis (FMEA) were adopted to screen the factors that affect the quality of headlining. The 2k-1 fractional factorials design was also use to determine the potential preliminary root causes. The full factorial experiments was conducted to identify appropriate settings of the significant factors. The result showed that the process can reduce the defects of headlining from 12.21% to 6.95%

  3. Fundamental Aspects of Selective Melting Additive Manufacturing Processes

    SciTech Connect

    van Swol, Frank B.; Miller, James E.

    2014-12-01

    Certain details of the additive manufacturing process known as selective laser melting (SLM) affect the performance of the final metal part. To unleash the full potential of SLM it is crucial that the process engineer in the field receives guidance about how to select values for a multitude of process variables employed in the building process. These include, for example, the type of powder (e.g., size distribution, shape, type of alloy), orientation of the build axis, the beam scan rate, the beam power density, the scan pattern and scan rate. The science-based selection of these settings con- stitutes an intrinsically challenging multi-physics problem involving heating and melting a metal alloy, reactive, dynamic wetting followed by re-solidification. In addition, inherent to the process is its considerable variability that stems from the powder packing. Each time a limited number of powder particles are placed, the stacking is intrinsically different from the previous, possessing a different geometry, and having a different set of contact areas with the surrounding particles. As a result, even if all other process parameters (scan rate, etc) are exactly the same, the shape and contact geometry and area of the final melt pool will be unique to that particular configuration. This report identifies the most important issues facing SLM, discusses the fundamental physics associated with it and points out how modeling can support the additive manufacturing efforts.

  4. Process simulations for manufacturing of thick composites

    NASA Astrophysics Data System (ADS)

    Kempner, Evan A.

    The availability of manufacturing simulations for composites can significantly reduce the costs associated with process development. Simulations provide a tool for evaluating the effect of processing conditions on the quality of parts produced without requiring numerous experiments. This is especially significant in parts that have troublesome features such as large thickness. The development of simulations for thick walled composites has been approached by examining the mechanics of resin flow and fiber deformation during processing, applying these evaluations to develop simulations, and evaluating the simulation with experimental results. A unified analysis is developed to describe the three-dimensional resin flow and fiber preform deformation during processing regardless of the manufacturing process used. It is shown how the generic governing evaluations in the unified analysis can be applied to autoclave molding, compression molding, pultrusion, filament winding, and resin transfer molding. A comparison is provided with earlier models derived individually for these processes. The evaluations described for autoclave curing were used to produce a one-dimensional cure simulation for autoclave curing of thick composites. The simulation consists of an analysis for heat transfer and resin flow in the composite as well as bleeder plies used to absorb resin removed from the part. Experiments were performed in a hot press to approximate curing in an autoclave. Graphite/epoxy laminates of 3 cm and 5 cm thickness were cured while monitoring temperatures at several points inside the laminate and thickness. The simulation predicted temperatures fairly closely, but difficulties were encountered in correlation of thickness results. This simulation was also used to study the effects of prepreg aging on processing of thick composites. An investigation was also performed on filament winding with prepreg tow. Cylinders were wound of approximately 12 mm thickness with pressure

  5. Modeling the VARTM Composite Manufacturing Process

    NASA Technical Reports Server (NTRS)

    Song, Xiao-Lan; Loos, Alfred C.; Grimsley, Brian W.; Cano, Roberto J.; Hubert, Pascal

    2004-01-01

    A comprehensive simulation model of the Vacuum Assisted Resin Transfer Modeling (VARTM) composite manufacturing process has been developed. For isothermal resin infiltration, the model incorporates submodels which describe cure of the resin and changes in resin viscosity due to cure, resin flow through the reinforcement preform and distribution medium and compaction of the preform during the infiltration. The accuracy of the model was validated by measuring the flow patterns during resin infiltration of flat preforms. The modeling software was used to evaluate the effects of the distribution medium on resin infiltration of a flat preform. Different distribution medium configurations were examined using the model and the results were compared with data collected during resin infiltration of a carbon fabric preform. The results of the simulations show that the approach used to model the distribution medium can significantly effect the predicted resin infiltration times. Resin infiltration into the preform can be accurately predicted only when the distribution medium is modeled correctly.

  6. Dimensional Stability of Complex Shapes Manufactured by the VARTM Process

    NASA Technical Reports Server (NTRS)

    Hubert, Pascal; Grimsley, Brian W.; Cano, Roberto J.; Pipes, R. Byron

    2002-01-01

    The vacuum assisted resin transfer molding (VARTM) process is a cost effective, innovative method that is being considered for manufacture of large aircraft-quality components where high mechanical properties and dimensional tolerance are essential. In the present work, carbon fiber SAERTEX fabric/SI-ZG-5A epoxy resin C-shaped laminates were manufactured by VARTM using different cure cycles followed by the same post-cure cycle. The final part thickness was uniform except at the corner were thinning was observed. The cure cycle selected is shown to significantly affect the part spring-in and a long cycle at 66 C followed by a 178 C post-cure produced a part with negligible spring-in.

  7. Manufacturability improvements in EUV resist processing toward NXE:3300 processing

    NASA Astrophysics Data System (ADS)

    Kuwahara, Yuhei; Matsunaga, Koichi; Shimoaoki, Takeshi; Kawakami, Shinichiro; Nafus, Kathleen; Foubert, Philippe; Goethals, Anne-Marie; Shimura, Satoru

    2014-03-01

    As the design rule of semiconductor process gets finer, extreme ultraviolet lithography (EUVL) technology is aggressively studied as a process for 22nm half pitch and beyond. At present, the studies for EUV focus on manufacturability. It requires fine resolution, uniform, smooth patterns and low defectivity, not only after lithography but also after the etch process. In the first half of 2013, a CLEAN TRACKTM LITHIUS ProTMZ-EUV was installed at imec for POR development in preparation of the ASML NXE:3300. This next generation coating/developing system is equipped with state of the art defect reduction technology. This tool with advanced functions can achieve low defect levels. This paper reports on the progress towards manufacturing defectivity levels and latest optimizations towards the NXE:3300 POR for both lines/spaces and contact holes at imec.

  8. 21 CFR 1005.25 - Service of process on manufacturers.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... 21 Food and Drugs 8 2010-04-01 2010-04-01 false Service of process on manufacturers. 1005.25....25 Service of process on manufacturers. (a) Every manufacturer of electronic products, prior to... Radiation Control for Health and Safety Act of 1968) (21 U.S.C. 360mm(d)) and this section. The agent may...

  9. Adhesive materials and processing selection for environmentally conscious manufacturing

    SciTech Connect

    Tira, J.S.

    1995-06-01

    Manufacturers that use certain adhesives and related manufacturing processes must consider the impact they have on worker health, safety, and the environment. Product manufacturers must find alternate replacements for solvent-based adhesives and solvent cements. In addition, processes that use ozone-depleting solvents for hand-wipe cleaning operations as well as vapor degreasing must find suitable alternates in order to be environmentally compliant. Likewise, manufacturers that use etching solutions that contain chrome must find a replacement. This paper identifies some of the specific problems associated with using certain adhesives and manufacturing processes. Environmentally acceptable alternative adhesives and processes are presented.

  10. 10 CFR 52.171 - Finality of manufacturing licenses; information requests.

    Code of Federal Regulations, 2013 CFR

    2013-01-01

    ... 10 Energy 2 2013-01-01 2013-01-01 false Finality of manufacturing licenses; information requests... APPROVALS FOR NUCLEAR POWER PLANTS Manufacturing Licenses § 52.171 Finality of manufacturing licenses; information requests. (a)(1) Notwithstanding any provision in 10 CFR 50.109, during the term of...

  11. 10 CFR 52.171 - Finality of manufacturing licenses; information requests.

    Code of Federal Regulations, 2014 CFR

    2014-01-01

    ... 10 Energy 2 2014-01-01 2014-01-01 false Finality of manufacturing licenses; information requests... APPROVALS FOR NUCLEAR POWER PLANTS Manufacturing Licenses § 52.171 Finality of manufacturing licenses; information requests. (a)(1) Notwithstanding any provision in 10 CFR 50.109, during the term of...

  12. 10 CFR 52.171 - Finality of manufacturing licenses; information requests.

    Code of Federal Regulations, 2012 CFR

    2012-01-01

    ... 10 Energy 2 2012-01-01 2012-01-01 false Finality of manufacturing licenses; information requests... APPROVALS FOR NUCLEAR POWER PLANTS Manufacturing Licenses § 52.171 Finality of manufacturing licenses; information requests. (a)(1) Notwithstanding any provision in 10 CFR 50.109, during the term of...

  13. Simulating the Composite Propellant Manufacturing Process

    NASA Technical Reports Server (NTRS)

    Williamson, Suzanne; Love, Gregory

    2000-01-01

    There is a strategic interest in understanding how the propellant manufacturing process contributes to military capabilities outside the United States. The paper will discuss how system dynamics (SD) has been applied to rapidly assess the capabilities and vulnerabilities of a specific composite propellant production complex. These facilities produce a commonly used solid propellant with military applications. The authors will explain how an SD model can be configured to match a specific production facility followed by a series of scenarios designed to analyze operational vulnerabilities. By using the simulation model to rapidly analyze operational risks, the analyst gains a better understanding of production complexities. There are several benefits of developing SD models to simulate chemical production. SD is an effective tool for characterizing complex problems, especially the production process where the cascading effect of outages quickly taxes common understanding. By programming expert knowledge into an SD application, these tools are transformed into a knowledge management resource that facilitates rapid learning without requiring years of experience in production operations. It also permits the analyst to rapidly respond to crisis situations and other time-sensitive missions. Most importantly, the quantitative understanding gained from applying the SD model lends itself to strategic analysis and planning.

  14. Precision manufacturing using advanced optical interference lithography. Final report

    SciTech Connect

    Britten, J.A.; Hawryluk, A.M.

    1997-04-03

    Goal was to develop interference lithography (IL) as a reliable process for patterning large-area, deep-submicron scale field emission arrays for field emission display (FED) applications. We have developed a system based on IL which can easily produce an array of 0.2-0.5 micron emitters over large area (up to 400 sq. in. to date) with better than 5% height and spacing uniformity. Process development as a result of this LDRD project represents a significant advance over the current state of the art for FED manufacturing and is applicable to all types of FEDs, independent of the emitter material. Ability of IL to pattern such structures simultaneously and uniformly on a large format has application to other technology areas, such as dynamic random access memory (DRAM) production and magnetic media recording.

  15. Powder metallurgy process for manufacturing core projectile

    NASA Astrophysics Data System (ADS)

    Akbar, Taufik; Setyowati, Vuri Ayu; Widyastuti

    2013-09-01

    Bullets are part of the defense equipment which the development is very rapid. There are a variety of forms but the bullet Lead is a metal that has always been used for applications projectiles. Lead core constituent materials are combined with antimony. In this research will be conducted by making the material for the core projectile with Tin Lead. The addition of Tin will increase the stiffness of Lead which is soft in nature. The Lead Tin composition variation was given in 10% weight of Sn. The manufacturing process using powder metallurgy using temperature and holding time variations of sintering at 100, 150, and 200°C for 1,2, and 3 hours. XRD samples will be tested to determine the form and phase morphology was observed using SEM-EDX. These results revealed that Pb-10%wtSn Composite which is sintered in temperature 200°C for 3 hours has the greatest density, 10.695 g/cm3 as well as the smallest porosity, 2.2%. In agreement with theoretical analysis that increasing higher temperature and longer holding time give decrease in porosity level due to activation energy which further promotes grain growth. Moreover, there is no intermetallic phase formation as well as no oxide found on composites.

  16. Developing the Manufacturing Process for Hylene MP Curing Agent

    SciTech Connect

    Eastwood, Eric

    2009-02-16

    This report details efforts to scale-up and re-establish the manufacturing process for the curing agent known as Hylene MP. First, small scale reactions were completed with varying conditions to determine key drivers for yielding high quality product. Once the optimum conditions were determined on the small scale, the scaled-up process conditions were determined. New equipment was incorporated into the manufacturing process to create a closed production system and improve chemical exposure controls and improve worker safety. A safe, efficient manufacturing process was developed to manufacture high quality Hylene MP in large quantities.

  17. Achieving continuous manufacturing for final dosage formation: challenges and how to meet them. May 20-21, 2014 Continuous Manufacturing Symposium.

    PubMed

    Byrn, Stephen; Futran, Maricio; Thomas, Hayden; Jayjock, Eric; Maron, Nicola; Meyer, Robert F; Myerson, Allan S; Thien, Michael P; Trout, Bernhardt L

    2015-03-01

    We describe the key issues and possibilities for continuous final dosage formation, otherwise known as downstream processing or drug product manufacturing. A distinction is made between heterogeneous processing and homogeneous processing, the latter of which is expected to add more value to continuous manufacturing. We also give the key motivations for moving to continuous manufacturing, some of the exciting new technologies, and the barriers to implementation of continuous manufacturing. Continuous processing of heterogeneous blends is the natural first step in converting existing batch processes to continuous. In heterogeneous processing, there are discrete particles that can segregate, versus in homogeneous processing, components are blended and homogenized such that they do not segregate. Heterogeneous processing can incorporate technologies that are closer to existing technologies, where homogeneous processing necessitates the development and incorporation of new technologies. Homogeneous processing has the greatest potential for reaping the full rewards of continuous manufacturing, but it takes long-term vision and a more significant change in process development than heterogeneous processing. Heterogeneous processing has the detriment that, as the technologies are adopted rather than developed, there is a strong tendency to incorporate correction steps, what we call below "The Rube Goldberg Problem." Thus, although heterogeneous processing will likely play a major role in the near-term transformation of heterogeneous to continuous processing, it is expected that homogeneous processing is the next step that will follow. Specific action items for industry leaders are: Form precompetitive partnerships, including industry (pharmaceutical companies and equipment manufacturers), government, and universities. These precompetitive partnerships would develop case studies of continuous manufacturing and ideally perform joint-technology development, including

  18. Printing Processes Used to Manufacture Photovoltaic Solar Cells

    ERIC Educational Resources Information Center

    Rardin, Tina E.; Xu, Renmei

    2011-01-01

    There is a growing need for renewable energy sources, and solar power is a good option in many instances. Photovoltaic solar panels are now being manufactured via various methods, and different printing processes are being incorporated into the manufacturing process. Screen printing has been used most prevalently in the printing process to make…

  19. NEET-AMM Final Technical Report on Laser Direct Manufacturing (LDM) for Nuclear Power Components

    SciTech Connect

    Anderson, Scott; Baca, Georgina; O'Connor, Michael

    2015-12-31

    Final technical report summarizes the program progress and technical accomplishments of the Laser Direct Manufacturing (LDM) for Nuclear Power Components project. A series of experiments varying build process parameters (scan speed and laser power) were conducted at the outset to establish the optimal build conditions for each of the alloys. Fabrication was completed in collaboration with Quad City Manufacturing Laboratory (QCML). The density of all sample specimens was measured and compared to literature values. Optimal build process conditions giving fabricated part densities close to literature values were chosen for making mechanical test coupons. Test coupons whose principal axis is on the x-y plane (perpendicular to build direction) and on the z plane (parallel to build direction) were built and tested as part of the experimental build matrix to understand the impact of the anisotropic nature of the process.. Investigations are described 316L SS, Inconel 600, 718 and 800 and oxide dispersion strengthed 316L SS (Yttria) alloys.

  20. FINAL REPORT: Transformational electrode drying process

    SciTech Connect

    Claus Daniel, C.; Wixom, M.

    2013-12-19

    This report includes major findings and outlook from the transformational electrode drying project performance period from January 6, 2012 to August 1, 2012. Electrode drying before cell assembly is an operational bottleneck in battery manufacturing due to long drying times and batch processing. Water taken up during shipment and other manufacturing steps needs to be removed before final battery assembly. Conventional vacuum ovens are limited in drying speed due to a temperature threshold needed to avoid damaging polymer components in the composite electrode. Roll to roll operation and alternative treatments can increase the water desorption and removal rate without overheating and damaging other components in the composite electrode, thus considerably reducing drying time and energy use. The objective of this project was the development of an electrode drying procedure, and the demonstration of processes with no decrease in battery performance. The benchmark for all drying data was an 80°C vacuum furnace treatment with a residence time of 18 – 22 hours. This report demonstrates an alternative roll to roll drying process with a 500-fold improvement in drying time down to 2 minutes and consumption of only 30% of the energy compared to vacuum furnace treatment.

  1. 21 CFR 1005.25 - Service of process on manufacturers.

    Code of Federal Regulations, 2013 CFR

    2013-04-01

    ... 21 Food and Drugs 8 2013-04-01 2013-04-01 false Service of process on manufacturers. 1005.25 Section 1005.25 Food and Drugs FOOD AND DRUG ADMINISTRATION, DEPARTMENT OF HEALTH AND HUMAN SERVICES (CONTINUED) RADIOLOGICAL HEALTH IMPORTATION OF ELECTRONIC PRODUCTS Bonding and Compliance Procedures § 1005.25 Service of process on manufacturers....

  2. 31 CFR 500.412 - Process vs. manufacture.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 31 Money and Finance: Treasury 3 2010-07-01 2010-07-01 false Process vs. manufacture. 500.412 Section 500.412 Money and Finance: Treasury Regulations Relating to Money and Finance (Continued) OFFICE... Interpretations § 500.412 Process vs. manufacture. A commodity subject to § 500.204 remains subject howsoever...

  3. Nonterrestrial material processing and manufacturing of large space systems

    NASA Technical Reports Server (NTRS)

    Vontiesenhausen, G. F.

    1978-01-01

    An attempt is made to provide pertinent and readily usable information on the extraterrestrial processing of materials and manufacturing of components and elements of these planned large space systems from preprocessed lunar materials which are made available at a processing and manufacturing site in space. Required facilities, equipment, machinery, energy and manpower are defined.

  4. Study on Process Planning System for Holonic Manufacturing

    NASA Astrophysics Data System (ADS)

    Rais, Suyoto; Sugimura, Nobuhiro; Kokubun, Atsushi

    New architectures of manufacturing systems have been proposed aiming at realizing more flexible control structures of manufacturing systems which can cope with dynamic changes in volume and variety of products. They are so called as holonic manufacturing systems, autonomous distributed manufacturing systems, random manufacturing systems and biological manufacturing systems. The objective of the present research is to develop an integrated process planning and scheduling system which is applicable to the holonic manufacturing systems. In the previous paper, procedures were proposed to recognize the machining features from the product model. A systematic method is proposed, in this paper, to select suitable machining sequences and sequences of machining equipment, by applying the genetic algorithm (GA) and the dynamic programming (DP) methods.

  5. Optimization of steel bar manufacturing process using six sigma

    NASA Astrophysics Data System (ADS)

    Naeem, Khawar; Ullah, Misbah; Tariq, Adnan; Maqsood, Shahid; Akhtar, Rehman; Nawaz, Rashid; Hussain, Iftikhar

    2016-03-01

    Optimization of a manufacturing process results in higher productivity and reduced wastes. Production parameters of a local steel bar manufacturing industry of Pakistan is optimized by using six Sigma-Define, measure, analyze, improve, and controlmethodology. Production data is collected and analyzed. After analysis, experimental design result is used to identify significant factors affecting process performance. The significant factors are controlled to optimized level using two-level factorial design method. A regression model is developed that helps in the estimation of response under multi variable input values. Model is tested, verified, and validated by using industrial data collected at a local steel bar manufacturing industry of Peshawar(Khyber Pakhtunkhwa, Pakistan). The sigma level of the manufacturing process is improved to 4.01 from 3.58. The novelty of the research is the identification of the significant factors along with the optimum levels that affects the process yield, and the methodology to optimize the steel bar manufacturing process.

  6. Chicago Manufacturing Tech Prep. Fiscal Year 1991 Final Report.

    ERIC Educational Resources Information Center

    Chicago City Colleges, IL.

    During its first year of development in 1991, the Chicago Manufacturing Technical Preparation (Tech Prep) Program established a plan for implementing an industry-driven, articulated 4-year manufacturing technology course of study that integrates applied academic courses with technical courses and meets industry hiring standards. The project…

  7. Wellbore manufacturing processes for in situ heat treatment processes

    DOEpatents

    Davidson, Ian Alexander; Geddes, Cameron James; Rudolf, Randall Lynn; Selby, Bruce Allen; MacDonald, Duncan Charles

    2012-12-11

    A method includes making coiled tubing at a coiled tubing manufacturing unit coupled to a coiled tubing transportation system. One or more coiled tubing reels are transported from the coiled tubing manufacturing unit to one or more moveable well drilling systems using the coiled tubing transportation system. The coiled tubing transportation system runs from the tubing manufacturing unit to one or more movable well drilling systems, and then back to the coiled tubing manufacturing unit.

  8. Manufacturing Process Simulation of Large-Scale Cryotanks

    NASA Technical Reports Server (NTRS)

    Babai, Majid; Phillips, Steven; Griffin, Brian

    2003-01-01

    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

  9. Computer simulation of gear tooth manufacturing processes

    NASA Technical Reports Server (NTRS)

    Mavriplis, Dimitri; Huston, Ronald L.

    1990-01-01

    The use of computer graphics to simulate gear tooth manufacturing procedures is discussed. An analytical basis for the simulation is established for spur gears. The simulation itself, however, is developed not only for spur gears, but for straight bevel gears as well. The applications of the developed procedure extend from the development of finite element models of heretofore intractable geometrical forms, to exploring the fabrication of nonstandard tooth forms.

  10. 49 CFR 529.6 - Requirements for final-stage manufacturers.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... automobile in accordance with 40 CFR part 600. (2) If the final-stage manufacturer places the portion of the... automobile in accordance with 40 CFR part 600. (3) The final-stage manufacturer shall attach to the completed automobile in accordance with 40 CFR part 600 a fuel economy label identical to the label that is...

  11. 49 CFR 529.6 - Requirements for final-stage manufacturers.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... automobile in accordance with 40 CFR part 600. (2) If the final-stage manufacturer places the portion of the... automobile in accordance with 40 CFR part 600. (3) The final-stage manufacturer shall attach to the completed automobile in accordance with 40 CFR part 600 a fuel economy label identical to the label that is...

  12. 49 CFR 529.6 - Requirements for final-stage manufacturers.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... automobile in accordance with 40 CFR part 600. (2) If the final-stage manufacturer places the portion of the... automobile in accordance with 40 CFR part 600. (3) The final-stage manufacturer shall attach to the completed automobile in accordance with 40 CFR part 600 a fuel economy label identical to the label that is...

  13. 49 CFR 529.6 - Requirements for final-stage manufacturers.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... automobile in accordance with 40 CFR part 600. (2) If the final-stage manufacturer places the portion of the... automobile in accordance with 40 CFR part 600. (3) The final-stage manufacturer shall attach to the completed automobile in accordance with 40 CFR part 600 a fuel economy label identical to the label that is...

  14. 49 CFR 529.6 - Requirements for final-stage manufacturers.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... automobile in accordance with 40 CFR part 600. (2) If the final-stage manufacturer places the portion of the... automobile in accordance with 40 CFR part 600. (3) The final-stage manufacturer shall attach to the completed automobile in accordance with 40 CFR part 600 a fuel economy label identical to the label that is...

  15. Systematic Classifier OF Manufacturing Processes For Medium Size Shafts

    NASA Astrophysics Data System (ADS)

    Lychagin, D. V.; Lasukov, A. A.; Walter, A. V.; Arkhipova, D. A.

    2016-04-01

    The article considers some issues of increasing efficiency of manufacturing preparation as a part of manufacturing processes design at a machine building enterprise. A tree of routing manufacturing processes for machining shafts of medium size is described as an example of clustering parts according to their structural and technological characteristics. Processing route for a certain part included into a certain group is developed through choosing machining operations for elementary surfaces of a part from the process route developed for a template representative of the group.

  16. Environmentally benign manufacturing of compact disc stampers [Final Phase II report

    SciTech Connect

    1999-07-08

    Optical data storage is currently a $10B/yr. business. With the introduction of the high capacity Digital Versatile Disc (D/D) as well as the continued growth of CD-Audio and CD-ROM worldwide sales of optical data products as a whole are growing at rate of more than 10% per year. In North America, more than 2.5 billion optical discs will be sold in 1998. By 1999, the numbers of optical discs produced for the North American market will grow to almost three billion. The optical disc manufacturing industry is dominated by Asian and European companies (e.g. Sony of Japan and Philips of Netherlands). Prism Corporation has created a process that could significantly improve US competitiveness in the business of optical disc production. The objectives of the Phase II STTR project were to build and test an ion machining system (IMS) for stamper fabrication, prove overall manufacturing system feasibility by fabrication stampers and replicas, and evaluate alternative materials and alternative process parameters to optimize the process. During tie period of the Phase II project Prism Corporation was able to meet these objectives. In the course of doing so, adjustments had been made to better the project and in turn the final product. An ion machining system was designed and built that produced stampers ready for the molding process. Also, many control steps in the manufacturing process were studied to improve the current process and make it even more compatible with the industry standards, fitting seamlessly into current manufacturing lines.

  17. Effects of Manufacturing Processes and In-Service Temperature Variations on the Properties of TRIP Steels

    SciTech Connect

    Sun, Xin; Stephens, Elizabeth V.; Khaleel, Mohammad A.

    2007-04-30

    This paper examines key aspects of the manufacturing process that “Transformation Induced Plasticity” (TRIP) steels would be exposed to, and systematically evaluate how the forming and thermal histories affect final strength and ductility of the material. The paper evaluates in-service temperature variations, such as under hood and hot/cold cyclic conditions, to determine whether these conditions influence final strength, ductility and energy absorption characteristics of several available TRIP steel grades. As part of the manufacturing thermal environment evaluations, stamping process thermal histories are included in the studies. As part of the in-service conditions, different pre-straining levels are also included. Materials from four steel suppliers world wide are examined. The material properties are established over a full range of expected thermal histories and selected loading modes. Establishing these relationships will allow OEM designers to select TRIP steels for proper vehicle applications, and to specify manufacturing process conditions that yield reliable final material property levels.

  18. Manufacturing Process Simulation of Large-Scale Cryotanks

    NASA Technical Reports Server (NTRS)

    Babai, Majid; Phillips, Steven; Griffin, Brian; Munafo, Paul M. (Technical Monitor)

    2002-01-01

    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 aid 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.

  19. SDIO producibility and manufacturing intelligent processing programs

    NASA Astrophysics Data System (ADS)

    Stottlemyer, Greg

    1992-04-01

    SDIO has to fashion a comprehensive strategy to insert the capability of an industrial base into ongoing design tradeoffs. This means that there is not only a need to determine if something can be made to the precision needed to meet system performance, but also what changes need to be made in that industry sector to develop a deterministic approach to fabrication precision components. Developing and introducing advanced production and quality control systems is part of this success. To address this situation, SDIO has developed the MODIL (Manufacturing Operations Development and Integration Labs) program. MODILs were developed into three areas: Survivable Optics, Electronics and Sensors, and Spacecraft Fabrication and Test.

  20. SDIO Producibility and Manufacturing Intelligent Processing Programs

    NASA Technical Reports Server (NTRS)

    Stottlemyer, Greg

    1992-01-01

    SDIO has to fashion a comprehensive strategy to insert the capability of an industrial base into ongoing design tradeoffs. This means that there is not only a need to determine if something can be made to the precision needed to meet system performance, but also what changes need to be made in that industry sector to develop a deterministic approach to fabrication precision components. Developing and introducing advanced production and quality control systems is part of this success. To address this situation, SDIO has developed the MODIL (Manufacturing Operations Development and Integration Labs) program. MODILs were developed into three areas: Survivable Optics, Electronics and Sensors, and Spacecraft Fabrication and Test.

  1. 78 FR 18234 - Service of Process on Manufacturers; Manufacturers Importing Electronic Products Into the United...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2013-03-26

    ... Administration (FDA) is amending a final rule that appeared in the Federal Register of April 9, 2007 (72 FR 17397... From the Federal Register Online via the Government Publishing Office DEPARTMENT OF HEALTH AND...; Manufacturers Importing Electronic Products Into the United States; Agent Designation; Change of Address...

  2. A Knowledge Database on Thermal Control in Manufacturing Processes

    NASA Astrophysics Data System (ADS)

    Hirasawa, Shigeki; Satoh, Isao

    A prototype version of a knowledge database on thermal control in manufacturing processes, specifically, molding, semiconductor manufacturing, and micro-scale manufacturing has been developed. The knowledge database has search functions for technical data, evaluated benchmark data, academic papers, and patents. The database also displays trends and future roadmaps for research topics. It has quick-calculation functions for basic design. This paper summarizes present research topics and future research on thermal control in manufacturing engineering to collate the information to the knowledge database. In the molding process, the initial mold and melt temperatures are very important parameters. In addition, thermal control is related to many semiconductor processes, and the main parameter is temperature variation in wafers. Accurate in-situ temperature measurment of wafers is important. And many technologies are being developed to manufacture micro-structures. Accordingly, the knowledge database will help further advance these technologies.

  3. 47 CFR 301.5 - Manufacturers' technical approval process.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 47 Telecommunication 5 2010-10-01 2010-10-01 false Manufacturers' technical approval process. 301.5 Section 301.5 Telecommunication NATIONAL TELECOMMUNICATIONS AND INFORMATION ADMINISTRATION, DEPARTMENT OF COMMERCE DIGITAL-TO-ANALOG CONVERTER BOX COUPON PROGRAM § 301.5 Manufacturers'...

  4. 3D Machine Vision and Additive Manufacturing: Concurrent Product and Process Development

    NASA Astrophysics Data System (ADS)

    Ilyas, Ismet P.

    2013-06-01

    The manufacturing environment rapidly changes in turbulence fashion. Digital manufacturing (DM) plays a significant role and one of the key strategies in setting up vision and strategic planning toward the knowledge based manufacturing. An approach of combining 3D machine vision (3D-MV) and an Additive Manufacturing (AM) may finally be finding its niche in manufacturing. This paper briefly overviews the integration of the 3D machine vision and AM in concurrent product and process development, the challenges and opportunities, the implementation of the 3D-MV and AM at POLMAN Bandung in accelerating product design and process development, and discusses a direct deployment of this approach on a real case from our industrial partners that have placed this as one of the very important and strategic approach in research as well as product/prototype development. The strategic aspects and needs of this combination approach in research, design and development are main concerns of the presentation.

  5. Characterization of Organic Contamination in Semiconductor Manufacturing Processes

    NASA Astrophysics Data System (ADS)

    Nutsch, A.; Beckhoff, B.; Bedana, G.; Borionetti, G.; Codegoni, D.; Grasso, S.; Guerinoni, G.; Leibold, A.; Müller, M.; Otto, M.; Pfitzner, L.; Polignano, M.-L.; De Simone, D.; Frey, L.

    2009-09-01

    The impact of organic contamination on wafer surfaces on the functionality of nanostructures and advanced microelectronics becomes crucial as the continuously shrinking feature sizes become similar to the dimensions of molecules and clusters of molecules. Especially, manufacturing of highly integrated circuits requires clean surfaces as processes might cause defects involving for example carbon and sulfur. The approach to study organic contamination on wafer samples using different analytical tools enables the detection of the whole range of organic compounds including non-volatile and volatile ones. For the studies the methods used were synchrotron radiation based Near Edge X-ray Absorption Fine Structure (NEXAFS) in the soft X-Ray range at the absorption edges of light elements (e.g. C, N, O, F) combined with reference-free Total-reflection X-Ray Fluorescence (TXRF) analysis, Thermal Desorption Gas Chromatography Mass Spectrometry (TD-GCMS), and Time of Flight Secondary Ion Mass Spectrometry (TOF-SIMS). TOF-SIMS analysis of the surfaces of wafers from the lithography process after ashing showed sulfur compounds related to resist residues not identified by TD-GCMS. The source of the sulfur is assumed to be a photo acid generator of the resist. It was proven by TD-GCMS and TXRF-NEXAFS that final clean and packaging were the process steps during which detectable organic contamination was transferred to the wafer surface during wafer manufacturing. Multi-criteria evaluation of the TXRF NEXAFS spectra was used to compare the results with TD-GCMS. The TXRF-NEXAFS results are in good agreement with the TD-GCMS results. The advantage of TXRF-NEXAFS and TOF-SIMS are the sensitivity for organic contaminants that are not detectable by TD-GCMS, due to their high boiling point and low vapor pressures.

  6. Development of a Launch Vehicle Manufacturing Process. Chapter 4

    NASA Technical Reports Server (NTRS)

    Vickers, John; Munafo, Paul M. (Technical Monitor)

    2002-01-01

    One of the goals of this chapter is to provide sufficient information so that you can develop a manufacturing process for a potential launch vehicle. With the variety of manufacturing options available, you might ask how this can possibly be done in the span of a single chapter. Actually, it will be quite simple because a basic manufacturing process is nothing more than a set of logical steps that are iterated until they produce a desired product. Although these statements seem simple and logical, don't let this simplicity fool you. Manufacturing problems with launch vehicles and their subassemblies have been the primary cause of project failures because the vehicle concept delivered to the manufacturing floor could not be built as designed.

  7. Enhancing Manufacturing Process Education via Computer Simulation and Visualization

    ERIC Educational Resources Information Center

    Manohar, Priyadarshan A.; Acharya, Sushil; Wu, Peter

    2014-01-01

    Industrially significant metal manufacturing processes such as melting, casting, rolling, forging, machining, and forming are multi-stage, complex processes that are labor, time, and capital intensive. Academic research develops mathematical modeling of these processes that provide a theoretical framework for understanding the process variables…

  8. Manufacturing Technology Continuation Project--FY 92. Final Report.

    ERIC Educational Resources Information Center

    Chicago City Colleges, IL. Richard J. Daley Coll.

    A project to identify metalworking subsectors (multiple spindle screw machining and gears machining) for inclusion in the Manufacturing Technology Preparation Program is the subject of this report. The project accomplished the following: developed five courses in multiple spindle, secured large donations of equipment and tooling, established a…

  9. Workplace Literacy for World Class Manufacturing. Final Report.

    ERIC Educational Resources Information Center

    Dowling, William D.; And Others

    The Ohio State University, Inland Fisher Guide Division of General Motors, and United Auto Workers Local 969 formed a collaborative partnership in 1990 to train employees whose inadequate literacy skills made them unable to respond to the requirements of "synchronous manufacturing" (or "just in time" production). One of the goals is to reduce the…

  10. ECMT31 New Mexico Manufacturing Environmental Survey. Final Report.

    ERIC Educational Resources Information Center

    Sandia National Labs., Albuquerque, NM.

    The Environmentally Conscious Manufacturing Technology Transfer and Training Initiative (ECMT3I) is a cooperative effort among education and research institutions in New Mexico to analyze problems in transferring environmental technologies from Department of Energy laboratories to small and medium enterprises (SME's). To identify and analyze…

  11. Cost analysis of advanced turbine blade manufacturing processes

    NASA Technical Reports Server (NTRS)

    Barth, C. F.; Blake, D. E.; Stelson, T. S.

    1977-01-01

    A rigorous analysis was conducted to estimate relative manufacturing costs for high technology gas turbine blades prepared by three candidate materials process systems. The manufacturing costs for the same turbine blade configuration of directionally solidified eutectic alloy, an oxide dispersion strengthened superalloy, and a fiber reinforced superalloy were compared on a relative basis to the costs of the same blade currently in production utilizing the directional solidification process. An analytical process cost model was developed to quantitatively perform the cost comparisons. The impact of individual process yield factors on costs was also assessed as well as effects of process parameters, raw materials, labor rates and consumable items.

  12. Manufacturing process of a multifunctional composite panel with nanocharged matrix

    NASA Astrophysics Data System (ADS)

    Volponi, R.; Spena, P.; De Nicola, F.; Guadagno, L.; Raimondo, M.; Vietri, U.

    2016-05-01

    This paper proposes an effective manufacturing process developed to overcome drawbacks that can occur using a nanofilled resin as matrix in aeronautical composites. Nanoparticles embedded in epoxy resins impregnating carbon fibers are able to improve a composite with new desired functionalities. As soon as the nanoparticles are dispersed in a resin, the viscosity dizzily rises and usually, the traditional manufacturing processes are not suitable to obtain a good quality of the manufactured panels. An alternative method has been developed starting from the Resin Film Infusion (RFI) process. This method has been firstly tested on several flat panels, and then it has been transferred on a more complex shaped panel with three stringers. In this work, a flame resistant resin based on a tetrafunctional epoxy precursor filled with carbon nanotubes to increase electrical conductivity, has been used for the panel manufacturing.

  13. Laser processing for manufacturing nanocarbon materials

    NASA Astrophysics Data System (ADS)

    Van, Hai Hoang

    CNTs have been considered as the excellent candidate to revolutionize a broad range of applications. There have been many method developed to manipulate the chemistry and the structure of CNTs. Laser with non-contact treatment capability exhibits many processing advantages, including solid-state treatment, extremely fast processing rate, and high processing resolution. In addition, the outstanding monochromatic, coherent, and directional beam generates the powerful energy absorption and the resultant extreme processing conditions. In my research, a unique laser scanning method was developed to process CNTs, controlling the oxidation and the graphitization. The achieved controllability of this method was applied to address the important issues of the current CNT processing methods for three applications. The controllable oxidation of CNTs by laser scanning method was applied to cut CNT films to produce high-performance cathodes for FE devices. The production method includes two important self-developed techniques to produce the cold cathodes: the production of highly oriented and uniformly distributed CNT sheets and the precise laser trimming process. Laser cutting is the unique method to produce the cathodes with remarkable features, including ultrathin freestanding structure (~200 nm), greatly high aspect ratio, hybrid CNT-GNR emitter arrays, even emitter separation, and directional emitter alignment. This unique cathode structure was unachievable by other methods. The developed FE devices successfully solved the screening effect issue encounter by current FE devices. The laser-control oxidation method was further developed to sequentially remove graphitic walls of CNTs. The laser oxidation process was directed to occur along the CNT axes by the laser scanning direction. Additionally, the oxidation was further assisted by the curvature stress and the thermal expansion of the graphitic nanotubes, ultimately opening (namely unzipping) the tubular structure to

  14. Cleaning Process Development for Metallic Additively Manufactured Parts

    NASA Technical Reports Server (NTRS)

    Tramel, Terri L.; Welker, Roger; Lowery, Niki; Mitchell, Mark

    2014-01-01

    Additive Manufacturing of metallic components for aerospace applications offers many advantages over traditional manufacturing techniques. As a new technology, many aspects of its widespread utilization remain open to investigation. Among these are the cleaning processes that can be used for post finishing of parts and measurements to verify effectiveness of the cleaning processes. Many cleaning and drying processes and measurement methods that have been used for parts manufactured using conventional techniques are candidates that may be considered for cleaning and verification of additively manufactured parts. Among these are vapor degreasing, ultrasonic immersion and spray cleaning, followed by hot air drying, vacuum baking and solvent displacement drying. Differences in porosity, density, and surface finish of additively manufactured versus conventionally manufactured parts may introduce new considerations in the selection of cleaning and drying processes or the method used to verify their effectiveness. This presentation will review the relative strengths and weaknesses of different candidate cleaning and drying processes as they may apply to additively manufactured metal parts for aerospace applications. An ultrasonic cleaning technique for exploring the cleanability of parts will be presented along with an example using additively manufactured Inconel 718 test specimens to illustrate its use. The data analysis shows that this ultrasonic cleaning approach results in a well-behaved ultrasonic cleaning/extraction behavior. That is, it does not show signs of accelerated cavitation erosion of the base material, which was later confirmed by neutron imaging. In addition, the analysis indicated that complete cleaning would be achieved by ultrasonic immersion cleaning at approximately 5 minutes, which was verified by subsequent cleaning of additional parts.

  15. Encapsulation Processing and Manufacturing Yield Analysis

    NASA Technical Reports Server (NTRS)

    Willis, P.

    1985-01-01

    Evaluation of the ethyl vinyl acetate (EVA) encapsulation system is presented. This work is part of the materials baseline needed to demonstrate a 30 year module lifetime capability. Process and compound variables are both being studied along with various module materials. Results have shown that EVA should be stored rolled up, and enclosed in a plastic bag to retard loss of peroxide curing agents. The TBEC curing agent has superior shelf life and processing than the earlier Lupersol-101 curing agent. Analytical methods were developed to test for peroxide content, and experimental methodologies were formalized.

  16. Amorphous solid dispersions: Rational selection of a manufacturing process.

    PubMed

    Vasconcelos, Teófilo; Marques, Sara; das Neves, José; Sarmento, Bruno

    2016-05-01

    Amorphous products and particularly amorphous solid dispersions are currently one of the most exciting areas in the pharmaceutical field. This approach presents huge potential and advantageous features concerning the overall improvement of drug bioavailability. Currently, different manufacturing processes are being developed to produce amorphous solid dispersions with suitable robustness and reproducibility, ranging from solvent evaporation to melting processes. In the present paper, laboratorial and industrial scale processes were reviewed, and guidelines for a rationale selection of manufacturing processes were proposed. This would ensure an adequate development (laboratorial scale) and production according to the good manufacturing practices (GMP) (industrial scale) of amorphous solid dispersions, with further implications on the process validations and drug development pipeline. PMID:26826438

  17. Ramp Technology and Intelligent Processing in Small Manufacturing

    NASA Technical Reports Server (NTRS)

    Rentz, Richard E.

    1992-01-01

    To address the issues of excessive inventories and increasing procurement lead times, the Navy is actively pursuing flexible computer integrated manufacturing (FCIM) technologies, integrated by communication networks to respond rapidly to its requirements for parts. The Rapid Acquisition of Manufactured Parts (RAMP) program, initiated in 1986, is an integral part of this effort. The RAMP program's goal is to reduce the current average production lead times experienced by the Navy's inventory control points by a factor of 90 percent. The manufacturing engineering component of the RAMP architecture utilizes an intelligent processing technology built around a knowledge-based shell provided by ICAD, Inc. Rules and data bases in the software simulate an expert manufacturing planner's knowledge of shop processes and equipment. This expert system can use Product Data Exchange using STEP (PDES) data to determine what features the required part has, what material is required to manufacture it, what machines and tools are needed, and how the part should be held (fixtured) for machining, among other factors. The program's rule base then indicates, for example, how to make each feature, in what order to make it, and to which machines on the shop floor the part should be routed for processing. This information becomes part of the shop work order. The process planning function under RAMP greatly reduces the time and effort required to complete a process plan. Since the PDES file that drives the intelligent processing is 100 percent complete and accurate to start with, the potential for costly errors is greatly diminished.

  18. Survey of US Department of Defense Manufacturing Technology Program activities applicable to civilian manufacturing industries. Final report

    SciTech Connect

    Azimi, S.A.; Conrad, J.L.; Reed, J.E.

    1985-03-01

    Intent of the survey was to identify and characterize activities potentially applicable to improving energy efficiency and overall productivity in the civilian manufacturing industries. The civilian industries emphasized were the general manufacturing industries (including fabricated metals, glass, machinery, paper, plastic, textile, and transportation equipment manufacturing) and the primary metals industries (including primary aluminum, copper, steel, and zinc production). The principal steps in the survey were to: develop overview taxonomies of the general manufacturing and primary metals industries as well as specific industry taxonomies; identify needs and opportunities for improving process energy efficiency and productivity in the industries included; identify federal programs, capabilities, and special technical expertise that might be relevant to industry's needs and opportunities; contact federal laboratories/facilities, through visits and other forms of inquiry; prepare formatted profiles (descriptions) potentially applicable work efforts; review findings with industry; and compile and evaluate industry responses.

  19. Manufacture of Mould with a High Energy Efficiency Using Rapid Manufacturing Process

    NASA Astrophysics Data System (ADS)

    Ahn, Dong-Gyu; Kim, Hyun-Woo; Park, Seung-Hwa; Kim, Hyong-Soo

    2010-06-01

    The aim of this paper is to investigate into the manufacturing technology of injection mould with a high energy efficiency using rapid manufacturing (RM) process. Two types of injection moulds, including thermally conductive mould with volumetric heat sink and uniform cooling mould with conformal cooling channels, were manufactured from hybrid RM process combining direct metal rapid tooling process with machining process to reduce the cooling time and the used energy in moulding of the plastic parts as well as to improve the product quality. Through the injection moulding experiments using the manufactured moulds, it was shown that the designed moulds can highly reduce the cycle and cooling times in comparison to conventional moulds with only injection tool steel and linear cooling channels. In addition, it was noted that the designed moulds can improve the qualities of the moulded product induced by uniform heat transfer from the mould surface to cooling channels. From these results, it was considered that the two types of injection mould can remarkably improve the energy efficiency and the environmental impact of the injection moulding process.

  20. Modeling Manufacturing Processes to Mitigate Technological Risk

    SciTech Connect

    Allgood, G.O.; Manges, W.W.

    1999-10-24

    An economic model is a tool for determining the justifiable cost of new sensors and subsystems with respect to value and operation. This process balances the R and D costs against the expense of maintaining current operations and allows for a method to calculate economic indices of performance that can be used as control points in deciding whether to continue development or suspend actions. The model can also be used as an integral part of an overall control loop utilizing real-time process data from the sensor groups to make production decisions (stop production and repair machine, continue and warn of anticipated problems, queue for repairs, etc.). This model has been successfully used and deployed in the CAFE Project. The economic model was one of seven (see Fig. 1) elements critical in developing an investment strategy. It has been successfully used in guiding the R and D activities on the CAFE Project, suspending activities on three new sensor technologies, and continuing development o f two others. The model has also been used to justify the development of a new prognostic approach for diagnosing machine health using COTS equipment and a new algorithmic approach. maintaining current operations and allows for a method to calculate economic indices of performance that can be used as control points in deciding whether to continue development or suspend actions. The model can also be used as an integral part of an overall control loop utilizing real-time process data from the sensor groups to make production decisions (stop production and repair machine, continue and warn of anticipated problems, queue for repairs, etc.).

  1. A novel process for manufacture of methanol

    SciTech Connect

    Tierney, J.W.; Wender, I.

    1990-01-01

    A bench-scale reactor is being used to conduct studies of the conversion of synthesis gas to methanol by a novel process. During the last quarter, the effect of potassium methoxide and Cu-chromite loading on the MeOH formation rate was investigated. The rate obtained with Cu-chromite was compared to that using Cu-ZnO as catalyst. Work also continued on the modification of the experimental equipment to permit on-line monitoring of liquid and gas compositions.

  2. A DMAIC approach for process capability improvement an engine crankshaft manufacturing process

    NASA Astrophysics Data System (ADS)

    Sharma, G. V. S. S.; Rao, P. Srinivasa

    2014-05-01

    The define-measure-analyze-improve-control (DMAIC) approach is a five-strata approach, namely DMAIC. This approach is the scientific approach for reducing the deviations and improving the capability levels of the manufacturing processes. The present work elaborates on DMAIC approach applied in reducing the process variations of the stub-end-hole boring operation of the manufacture of crankshaft. This statistical process control study starts with selection of the critical-to-quality (CTQ) characteristic in the define stratum. The next stratum constitutes the collection of dimensional measurement data of the CTQ characteristic identified. This is followed by the analysis and improvement strata where the various quality control tools like Ishikawa diagram, physical mechanism analysis, failure modes effects analysis and analysis of variance are applied. Finally, the process monitoring charts are deployed at the workplace for regular monitoring and control of the concerned CTQ characteristic. By adopting DMAIC approach, standard deviation is reduced from 0.003 to 0.002. The process potential capability index ( C P) values improved from 1.29 to 2.02 and the process performance capability index ( C PK) values improved from 0.32 to 1.45, respectively.

  3. RFID-Based Critical Path Expert System for Agility Manufacture Process Management

    NASA Astrophysics Data System (ADS)

    Cheng, Haifang; Xiang, Yuli

    This paper presents a critical path expert system for the agility manufacture process management based on radio frequency identification (RFID) technology. The paper explores that the agility manufacture processes can be visible and controllable with RFID. The critical paths or activities can be easily found out and tracked by the RFID tracing technology. And the expert system can optimize the bottle neck of the task process of the agility management with the critical path adjusting and reforming method. Finally, the paper gives a simple application example of the system to discuss how to adjust the critical paths and how to make the process more agility and flexibility with the critical path expert system. With an RFID-based critical path expert system, the agility manufacture process management will be more effective and efficient.

  4. 76 FR 36078 - Milk for Manufacturing Purposes and Its Production and Processing; Requirements Recommended for...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2011-06-21

    ... Agricultural Marketing Service Milk for Manufacturing Purposes and Its Production and Processing; Requirements... regulations relating to quality and sanitation requirements for the production and processing of manufacturing... Change the document, ``Milk for Manufacturing Purposes and Its Production and Processing;...

  5. 77 FR 76518 - Certain Paper Shredders, Certain Processes for Manufacturing or Relating to Same and Certain...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2012-12-28

    ... COMMISSION Certain Paper Shredders, Certain Processes for Manufacturing or Relating to Same and Certain... Certain Paper Shredders, Certain Processes for Manufacturing or Relating to Same and Certain Products... United States after importation of certain paper shredders, certain processes for manufacturing...

  6. Planning and scheduling for agile manufacturers: The Pantex Process Model

    SciTech Connect

    Kjeldgaard, E.A.; Jones, D.A.; List, G.F.; Tumquist, M.A.

    1998-02-01

    Effective use of resources that are shared among multiple products or processes is critical for agile manufacturing. This paper describes the development and implementation of a computerized model to support production planning in a complex manufacturing system at the Pantex Plant, a US Department of Energy facility. The model integrates two different production processes (nuclear weapon disposal and stockpile evaluation) that use common facilities and personnel at the plant. The two production processes are characteristic of flow-shop and job shop operations. The model reflects the interactions of scheduling constraints, material flow constraints, and the availability of required technicians and facilities. Operational results show significant productivity increases from use of the model.

  7. Developing the Manufacturing Process for VCE: Binder for Filled Elastomers

    SciTech Connect

    E.A. Eastwood

    2009-11-01

    This topical report presents work completed to re-establish the manufacturing process for poly(ethylene-co-vinyl acetate-co-vinyl alcohol) terpolymer called VCE. The new VCE formulations meet the material requirements and have lower melt viscosity, which results in improved production for the next assembly. In addition, the reaction conditions were optimized in order to achieve a satisfactory conversion rate to enable production in a single work shift. Several equipment and process changes were made to yield a manufacturing process with improved product quality, yield, efficiency, and worker safety.

  8. Process for the manufacture of lubricating oils

    SciTech Connect

    Unmuth, E.E.; Mahoney, J.A.

    1987-01-13

    A process is described for reducing the pour point of a hydrocarbon feedstock containing nitrogen and sulfur-containing compounds which comprises: passing the hydrocarbon feedstock to a solvent extraction zone wherein N-methyl-2-pyrrolidone is used to extract a portion of the aromatic compounds contained in the hydrocarbon and thereby form an extraction zone raffinate; passing at least a portion of the extraction zone raffinate to a hydrotreating zone wherein hydrogen is contacted with the extraction zone raffinate in the presence of a hydrotreating catalyst at hydrotreating conditions wherein a substantial portion of the nitrogen and sulfur-containing compounds are converted to hydrogen sulfide and ammonia to form a hydrotreating zone effluent; passing at least a portion of the effluent from the hydrotreating zone to a stripping zone wherein hydrogen sulfide and ammonia are removed from the hydrotreating zone effluent to form a stripping zone effluent; and passing at least a portion of the stripping zone effluent to a dewaxing zone wherein hydrogen is contacted with the stripping zone effluent at catalytic dewaxing conditions in the presence of a catalyst composition comprising a shape selective molecular sieve component and a hydrogenation component selected from the group consisting of Group VIB and Group VIII metals.

  9. Manufacturing Squares: An Integrative Statistical Process Control Exercise

    ERIC Educational Resources Information Center

    Coy, Steven P.

    2016-01-01

    In the exercise, students in a junior-level operations management class are asked to manufacture a simple product. Given product specifications, they must design a production process, create roles and design jobs for each team member, and develop a statistical process control plan that efficiently and effectively controls quality during…

  10. Competitive position of natural gas: Manufacturing automation and process controls

    SciTech Connect

    Karamchetty, S.D.; Kothari, V.S.; Holmes, J.G.; Minsker, B.S. )

    1989-04-01

    In previous GRI studies, the need for improvements in industrial automation and process controls has been mentioned most frequently and ranked highest by industry managers suggesting R D needs for gas equipment. Significant energy savings have been achieved through automation in many applications. Within the manufacturing sector, process heat applications constitute a significant use of natural gas and total energy. Therefore, widespread implementation of manufacturing automation can have significant impacts on gas use in process heat applications. In the study of manufacturing automation, three interacting areas were examined --- industrial processes, process components, and automation components. Taxonomies were developed for each of these areas to focus the analysis. The interactions between automation developments and gas use was studied in detail for five processes --- metal heat treating, steel reheating, forging, glass making, and paper drying. Recent developments reported in the literature were reviewed and within each industry, areas of gas and automation systems, vendors of manufacturing automation systems, and systems designs and integrators were interviewed. Through this approach, current and future developments in automation and their impacts were identified. R D opportunities for the five specific processes studied, and generic areas were also identified. 97 refs., 12 figs.

  11. A factory concept for processing and manufacturing with lunar material

    NASA Technical Reports Server (NTRS)

    Driggers, G. W.

    1977-01-01

    A conceptual design for an orbital factory sized to process 1.5 million metric tons per year of raw lunar fines into 0.3 million metric tons of manufacturing materials is presented. A conservative approach involving application of present earth-based technology leads to a design devoid of new inventions. Earth based counterparts to the factory machinery were used to generate subsystem masses and lumped parameters for volume and mass estimates. The results are considered to be conservative since technologies more advanced than those assumed are presently available in many areas. Some attributes of potential space processing technologies applied to material refinement and component manufacture are discussed.

  12. Investigations on Manufacturability and Process Reliability of Selective Laser Melting

    NASA Astrophysics Data System (ADS)

    Krauss, H.; Zaeh, M. F.

    Selective laser melting is a layer-wise manufacturing process that enables the use of complex geometric shapes in part design and production. An infrared laser beam is focused on a thin layer of metallic powder and selectively deflected in order to scan the cross-section of the parts being built. The process quality is dominated by the consolidation of powder particles through laser beam interaction, the part geometry itself and the arrangement of multiple parts. In this paper, the manufacturability is investigated by characterizing single melt tracks and the buildup of thin wall structures consisting of a few aligned scan tracks.

  13. Integration Framework of Process Planning based on Resource Independent Operation Summary to Support Collaborative Manufacturing

    SciTech Connect

    Kulvatunyou, Boonserm; Wysk, Richard A.; Cho, Hyunbo; Jones, Albert

    2004-06-01

    In today's global manufacturing environment, manufacturing functions are distributed as never before. Design, engineering, fabrication, and assembly of new products are done routinely in many different enterprises scattered around the world. Successful business transactions require the sharing of design and engineering data on an unprecedented scale. This paper describes a framework that facilitates the collaboration of engineering tasks, particularly process planning and analysis, to support such globalized manufacturing activities. The information models of data and the software components that integrate those information models are described. The integration framework uses an Integrated Product and Process Data (IPPD) representation called a Resource Independent Operation Summary (RIOS) to facilitate the communication of business and manufacturing requirements. Hierarchical process modeling, process planning decomposition and an augmented AND/OR directed graph are used in this representation. The Resource Specific Process Planning (RSPP) module assigns required equipment and tools, selects process parameters, and determines manufacturing costs based on two-level hierarchical RIOS data. The shop floor knowledge (resource and process knowledge) and a hybrid approach (heuristic and linear programming) to linearize the AND/OR graph provide the basis for the planning. Finally, a prototype system is developed and demonstrated with an exemplary part. Java and XML (Extensible Markup Language) are used to ensure software and information portability.

  14. Clean salt process final report

    SciTech Connect

    Herting, D.L.

    1996-09-30

    A process has been demonstrated in the laboratory for separating clean, virtually non-radioactive sodium nitrate from Hanford tank waste using fractional crystallization. The name of the process is the Clean Salt Process. Flowsheet modeling has shown that the process is capable of reducing the volume of vitrified low activity waste (LAW) by 80 to 90 %. Construction of the Clean Salt processing plant would cost less than $1 10 million, and would eliminate the need for building a $2.2 billion large scale vitrification plant planned for Privatization Phase 11. Disposal costs for the vitrified LAW would also be reduced by an estimated $240 million. This report provides a summary of five years of laboratory and engineering development activities, beginning in fiscal year 1992. Topics covered include laboratory testing of a variety of processing options; proof-of-principle demonstrations with actual waste samples from Hanford tanks 241-U-110 (U-110), 241-SY-101 (101-SY), and 241-AN-102 (102-AN); descriptions of the primary solubility phase diagrams that govem the process; a review of environmental regulations governing disposition of the reclaimed salt and an assessment of the potential beneficial uses of the reclaimed salt; preliminary plant design and construction cost estimates. A detailed description is given for the large scale laboratory demonstration of the process using waste from tank 241-AW-101 (101-AW), a candidate waste for 0044vitrification during Phase I Privatization.

  15. Monitoring Chlorfenapyr in Green Tea during the Manufacturing Process

    NASA Astrophysics Data System (ADS)

    Takahashi, Atsushi; Kishi, Yasuhiro; Ogawa, Hideyuki; Nakajima, Kenta

    In order to clarify the change in the leaves of agricultural chemicals during the green tea manufacturing process, we analyzed chlorfenapyr in tea leaves obtained at each processing stage by using an immunoassay. Chlorfenapyr is a novel broad-spectrum insecticide-miticide registered in many countries for the control of various insects and mite pests. Chlorfenapyr is stable and persistent in the environment. Furthermore, it is widely applied for tea cultivation in Japan. Therefore, we selected chlorfenapyr for analysis in this study. In the unrefined tea (Aracha) manufacturing process, the highest level of chlorfenapyr was 16.5 ppm, which was obtained in tea powder separated from leaves at the secondary drying stage. However, the level at the other processing stages in tea leaves was approximately 9 ppm, and no significant difference in the chlorfenapyr level was detected between the processing stages. After Aracha processing, tea leaves are classified on the basis of their size, shape and color; this is the refined tea (Shiagecha) manufacturing process. After this process, although a high level of chlorfenapyr was detected in bud tea (8.1 ppm) and honcha (on-grade tea; 6.2 ppm), the level in the other classified teas was approximately 4.0 ppm. Thus, this paper shows the difference in the chlorfenapyr level in tea leaves obtained at each processing stage. This indicated that there are significant differences in the agricultural chemical levels between the green tea processing stages.

  16. Sustainable manufacturing: Effect of material selection and design on the environmental impact in the manufacturing process

    NASA Astrophysics Data System (ADS)

    Hazwan Syafiq Harun, Mohd; Taha, Zahari; Salaam, Hadi Abdul

    2013-12-01

    The environmental impact of a manufacturing process is also dependent on the selection of the material and design of a product. This is because the manufacturing of a product is directly connected to the amount of carbon emitted in consuming the electrical energy for that manufacturing process. The difference in the general properties of materials such as strength, hardness and impact will have significant effect on the power consumption of the machine used to complete the product. In addition the environmental impact can also be reduced if the proposed designs use less material. In this study, an LCA tool called Eco-It is used. Evaluate the environmental impact caused by manufacturing simple jig. A simple jig with 4 parts was used as a case study. Two experiments were carried out. The first experiment was to study the environmental effects of different material, and the second experiment was to study the environmental impact of different design. The materials used for the jig are Aluminium and mild steel. The results showed a decrease in the rate of carbon emissions by 60% when Aluminium is use instead from mild steel, and a decrease of 26% when the-design is modified.

  17. Integration of Advanced Simulation and Visualization for Manufacturing Process Optimization

    NASA Astrophysics Data System (ADS)

    Zhou, Chenn; Wang, Jichao; Tang, Guangwu; Moreland, John; Fu, Dong; Wu, Bin

    2016-05-01

    The integration of simulation and visualization can provide a cost-effective tool for process optimization, design, scale-up and troubleshooting. The Center for Innovation through Visualization and Simulation (CIVS) at Purdue University Northwest has developed methodologies for such integration with applications in various manufacturing processes. The methodologies have proven to be useful for virtual design and virtual training to provide solutions addressing issues on energy, environment, productivity, safety, and quality in steel and other industries. In collaboration with its industrial partnerships, CIVS has provided solutions to companies, saving over US38 million. CIVS is currently working with the steel industry to establish an industry-led Steel Manufacturing Simulation and Visualization Consortium through the support of National Institute of Standards and Technology AMTech Planning Grant. The consortium focuses on supporting development and implementation of simulation and visualization technologies to advance steel manufacturing across the value chain.

  18. Development of Probabilistic Structural Analysis Integrated with Manufacturing Processes

    NASA Technical Reports Server (NTRS)

    Pai, Shantaram S.; Nagpal, Vinod K.

    2007-01-01

    An effort has been initiated to integrate manufacturing process simulations with probabilistic structural analyses in order to capture the important impacts of manufacturing uncertainties on component stress levels and life. Two physics-based manufacturing process models (one for powdered metal forging and the other for annular deformation resistance welding) have been linked to the NESSUS structural analysis code. This paper describes the methodology developed to perform this integration including several examples. Although this effort is still underway, particularly for full integration of a probabilistic analysis, the progress to date has been encouraging and a software interface that implements the methodology has been developed. The purpose of this paper is to report this preliminary development.

  19. Incorporating manufacturability constraints into the design process of heterogeneous objects

    NASA Astrophysics Data System (ADS)

    Hu, Yuna; Blouin, Vincent Y.; Fadel, Georges M.

    2004-11-01

    Rapid prototyping (RP) technology, such as Laser Engineering Net Shaping (LENSTM), can be used to fabricate heterogeneous objects with gradient variations in material composition. These objects are generally characterized by enhanced functional performance. Past research on the design of such objects has focused on representation, modeling, and functional performance. However, the inherent constraints in RP processes, such as system capability and processing time, lead to heterogeneous objects that may not meet the designer's original intent. To overcome this situation, the research presented in this paper focuses on the identification and implementation of manufacturing constraints into the design process. A node-based finite element modeling technique is used for the representation and analysis and the multicriteria design problem corresponds to finding the nodal material compositions that minimize structural weight and maximize thermal performance. The optimizer used in this research is a real-valued Evolutionary Strategies (ES), which is well suited for this type of multi-modal problem. Two limitations of the LENS manufacturing process, which have an impact on the design process, are identified and implemented. One of them is related to the manufacturing time, which is considered as an additional criterion to be minimized in the design problem for a preselected tool path. A brake disc rotor made of two materials, aluminum for lightweight and steel for superior thermal characteristics, is used to illustrate the tradeoff between manufacturability and functionality.

  20. Assessment of VOC emissions and their control from baker's yeast manufacturing facilities. Final report

    SciTech Connect

    Barker, R.; Williamson, M.

    1992-01-01

    The Environmental Protection Agency's (EPA's) Control Technology Center (CTC) conducted a study to obtain information on the baker's yeast manufacturing industry. Baker's yeast is produced by a fermentation process that generates large quantities of ethanol and acetaldehyde. Currently, 13 facilities produce baker's yeast in the United States. The volatile organic compound (VOC) emission rate from a typical facility is estimated at 82 megagrams per year (90 tons per year). The majority of these emissions occurs in the final trade fermentations. The VOC emission alternatives that were evaluated during the study were process control measures to reduce the formation of VOC emissions as well as wet scrubbers, carbon adsorbers, incinerators, condensers, and biological filters to control VOC emissions. Of these approaches, it appears that process control measures, catalytic incinerators, or a combination of add-on control techniques (e.g., wet scrubbers followed by an incinerator or a biological filter) are the most feasible approaches for controlling yeast process emissions. Based on the results of the study, the control efficiency associated with the add-on control systems is estimated to be 95 to 98 percent. The report contains information on the baker's yeast fermentation process, the number and locations of yeast plants, the potential emissions from the process, and an evaluation of potential emission control options.

  1. Porosity of additive manufacturing parts for process monitoring

    SciTech Connect

    Slotwinski, J. A.; Garboczi, E. J.

    2014-02-18

    Some metal additive manufacturing processes can produce parts with internal porosity, either intentionally (with careful selection of the process parameters) or unintentionally (if the process is not well-controlled.) Material porosity is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants, since surface-breaking pores allow for better integration with biological tissue. Changes in a part's porosity during an additive manufacturing build may also be an indication of an undesired change in the process. We are developing an ultrasonic sensor for detecting changes in porosity in metal parts during fabrication on a metal powder bed fusion system, for use as a process monitor. This paper will describe our work to develop an ultrasonic-based sensor for monitoring part porosity during an additive build, including background theory, the development and detailed characterization of reference additive porosity samples, and a potential design for in-situ implementation.

  2. Porosity of additive manufacturing parts for process monitoring

    NASA Astrophysics Data System (ADS)

    Slotwinski, J. A.; Garboczi, E. J.

    2014-02-01

    Some metal additive manufacturing processes can produce parts with internal porosity, either intentionally (with careful selection of the process parameters) or unintentionally (if the process is not well-controlled.) Material porosity is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants, since surface-breaking pores allow for better integration with biological tissue. Changes in a part's porosity during an additive manufacturing build may also be an indication of an undesired change in the process. We are developing an ultrasonic sensor for detecting changes in porosity in metal parts during fabrication on a metal powder bed fusion system, for use as a process monitor. This paper will describe our work to develop an ultrasonic-based sensor for monitoring part porosity during an additive build, including background theory, the development and detailed characterization of reference additive porosity samples, and a potential design for in-situ implementation.

  3. Incorporating VIBE into the precision optics manufacturing process

    NASA Astrophysics Data System (ADS)

    DeGroote Nelson, Jessica; Gould, Alan; Klinger, Charles; Mandina, Michael

    2011-09-01

    The VIBE™ process is a full-aperture, conformal polishing process incorporating high frequency and random motion designed to rapidly remove sub-surface damage in a VIBE pre-polish step and eliminate mid-spatial frequency (MSF) errors in a VIBE finishing step. The VIBE process has potential to be introduced in two areas of today's modern optics manufacturing process. The first instance is replacing the conventional pre-polishing step with the rapid VIBE pre-polish step. Results will be discussed in this paper that show 10 - 50x higher removal rates compared to conventional polishing for a variety of optical materials. High removal rates combined with the compliant lap results in damage-free surfaces that have the same form that was generated by the CNC generation process for spherical and non-spherical surfaces. The second potential area to incorporate VIBE into today's modern optics manufacturing process is as a finishing step after deterministic sub-aperture polishing to remove mid-spatial frequency errors. By selectively altering the compliant properties of the VIBE pad, and adjusting the frequency of the VIBE motion, VIBE finishing can reduce the mid-spatial frequencies caused from sub-aperture polishing processes while maintaining the desired corrected surface form. This paper will serve as an in-depth review of the VIBE process and how it complements other modern CNC optics manufacturing technologies, as well as highlighting recent VIBE advances specifically in the area of conformal optic fabrication.

  4. NICE3 SO3 Cleaning Process in Semiconductor Manufacturing

    SciTech Connect

    Blazek, S.

    1999-01-29

    This fact sheet explains how Anon, Inc., has developed a novel method of removing photoresist--a light-sensitive material used to produce semiconductor wafers for computers--from the computer manufacturing process at reduced cost and greater efficiency. The new technology is technically superior to existing semiconductor cleaning methods and results in reduced use of hazardous chemicals.

  5. 21 CFR 1005.25 - Service of process on manufacturers.

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... 21 Food and Drugs 8 2012-04-01 2012-04-01 false Service of process on manufacturers. 1005.25 Section 1005.25 Food and Drugs FOOD AND DRUG ADMINISTRATION, DEPARTMENT OF HEALTH AND HUMAN SERVICES... Radiation Control of the Federal Food, Drug, and Cosmetic Act (formerly the Radiation Control for Health...

  6. Manufacturing Demonstration Facility: Roll-to-Roll Processing

    SciTech Connect

    Datskos, Panos G; Joshi, Pooran C; List III, Frederick Alyious; Duty, Chad E; Armstrong, Beth L; Ivanov, Ilia N; Jacobs, Christopher B; Graham, David E; Moon, Ji Won

    2015-08-01

    This Manufacturing Demonstration Facility (MDF)e roll-to-roll processing effort described in this report provided an excellent opportunity to investigate a number of advanced manufacturing approaches to achieve a path for low cost devices and sensors. Critical to this effort is the ability to deposit thin films at low temperatures using nanomaterials derived from nanofermentation. The overarching goal of this project was to develop roll-to-roll manufacturing processes of thin film deposition on low-cost flexible substrates for electronics and sensor applications. This project utilized ORNL s unique Pulse Thermal Processing (PTP) technologies coupled with non-vacuum low temperature deposition techniques, ORNL s clean room facility, slot dye coating, drop casting, spin coating, screen printing and several other equipment including a Dimatix ink jet printer and a large-scale Kyocera ink jet printer. The roll-to-roll processing project had three main tasks: 1) develop and demonstrate zinc-Zn based opto-electronic sensors using low cost nanoparticulate structures manufactured in a related MDF Project using nanofermentation techniques, 2) evaluate the use of silver based conductive inks developed by project partner NovaCentrix for electronic device fabrication, and 3) demonstrate a suite of low cost printed sensors developed using non-vacuum deposition techniques which involved the integration of metal and semiconductor layers to establish a diverse sensor platform technology.

  7. Relational-database model for improving quality assurance and process control in a composite manufacturing environment

    NASA Astrophysics Data System (ADS)

    Gentry, Jeffery D.

    2000-05-01

    A relational database is a powerful tool for collecting and analyzing the vast amounts of inner-related data associated with the manufacture of composite materials. A relational database contains many individual database tables that store data that are related in some fashion. Manufacturing process variables as well as quality assurance measurements can be collected and stored in database tables indexed according to lot numbers, part type or individual serial numbers. Relationships between manufacturing process and product quality can then be correlated over a wide range of product types and process variations. This paper presents details on how relational databases are used to collect, store, and analyze process variables and quality assurance data associated with the manufacture of advanced composite materials. Important considerations are covered including how the various types of data are organized and how relationships between the data are defined. Employing relational database techniques to establish correlative relationships between process variables and quality assurance measurements is then explored. Finally, the benefits of database techniques such as data warehousing, data mining and web based client/server architectures are discussed in the context of composite material manufacturing.

  8. The metallurgy and processing science of metal additive manufacturing

    SciTech Connect

    Sames, William J.; List, III, Frederick Alyious; Pannala, Sreekanth; Dehoff, Ryan R.; Babu, Sudarsanam Suresh

    2016-01-01

    Here, additive Manufacturing (AM), widely known as 3D printing, is a method of manufacturing that forms parts from powder, wire, or sheets in a process that proceeds layer-by-layer.Many techniques (using many different names) have been developed to accomplish this via melting or solid - state joining. In this review, these techniques for producing metal parts are explored, with a focus on the science of metal AM: processing defects, heat transfer, solidification, solid- state precipitation, mechanical properties, and post-processing metallurgy. The various metal AM techniques are compared, with analysis of the strengths and limitations of each. Few alloys have been developed for commercial production, but recent development efforts are presented as a path for the ongoing development of new materials for AM processes.

  9. The metallurgy and processing science of metal additive manufacturing

    DOE PAGESBeta

    Sames, William J.; List, III, Frederick Alyious; Pannala, Sreekanth; Dehoff, Ryan R.; Babu, Sudarsanam Suresh

    2016-03-07

    Here, additive Manufacturing (AM), widely known as 3D printing, is a method of manufacturing that forms parts from powder, wire, or sheets in a process that proceeds layer-by-layer.Many techniques (using many different names) have been developed to accomplish this via melting or solid - state joining. In this review, these techniques for producing metal parts are explored, with a focus on the science of metal AM: processing defects, heat transfer, solidification, solid- state precipitation, mechanical properties, and post-processing metallurgy. The various metal AM techniques are compared, with analysis of the strengths and limitations of each. Few alloys have been developedmore » for commercial production, but recent development efforts are presented as a path for the ongoing development of new materials for AM processes.« less

  10. Influence of Manufacturing Processes on the Performance of Phantom Lungs

    SciTech Connect

    Traub, Richard J.

    2008-10-01

    Chest counting is an important tool for estimating the radiation dose to individuals who have inhaled radioactive materials. Chest counting systems are calibrated by counting the activity in the lungs of phantoms where the activity in the phantom lungs is known. In the United States a commonly used calibration phantom was developed at the Lawrence Livermore National Laboratory and is referred to as the Livermore Torso Phantom. An important feature of this phantom is that the phantom lungs can be interchanged so that the counting system can be challenged by different combinations of radionuclides and activity. Phantom lungs are made from lung tissue substitutes whose constituents are foaming plastics and various adjuvants selected to make the lung tissue substitute similar to normal healthy lung tissue. Some of the properties of phantom lungs cannot be readily controlled by phantom lung manufacturers. Some, such as density, are a complex function of the manufacturing process, while others, such as elemental composition of the bulk plastic are controlled by the plastics manufacturer without input, or knowledge of the phantom manufacturer. Despite the fact that some of these items cannot be controlled, they can be measured and accounted for. This report describes how manufacturing processes can influence the performance of phantom lungs. It is proposed that a metric that describes the brightness of the lung be employed by the phantom lung manufacturer to determine how well the phantom lung approximates the characteristics of a human lung. For many purposes, the linear attenuation of the lung tissue substitute is an appropriate surrogate for the brightness.

  11. Infrared Signature Analysis: Real Time Monitoring Of Manufacturing Processes

    NASA Astrophysics Data System (ADS)

    Bangs, Edmund R.

    1988-01-01

    The ability to monitor manufacturing processes in an adaptive control mode and perform an inspection in real time is of interest to fabricators in the pressure vessel, aerospace, automotive, nuclear and shipbuilding industries. Results of a series of experiments using infrared thermography as the principal sensing mode are presented to show how artificial intelligence contained in infrared isotherm, contains vast critical process variables. Image processing computer software development has demonstrated in a spot welding application how the process can be monitored and controlled in real time. The IR vision sensor program is now under way. Research thus far has focused on fusion welding, resistance spot welding and metal removal.

  12. Scaling up of manufacturing processes of recycled carpet based composites

    NASA Astrophysics Data System (ADS)

    Lakshminarayanan, Krishnan

    2011-12-01

    In this work, feasibility of recycling post-consumer carpets using a modified vacuum assisted resisted molding process into large-scale components was successfully demonstrated. The scale up also included the incorporation of nano-clay films in the carpet composites. It is expected that the films will enhance the ability of the composite to withstand environmental degradation and also serve as a fire retardant. Low-cost resins were used to fabricate the recycled carpet-based composites. The scale up in terms of process was achieved by manufacturing composites without a hot press and thereby saving additional equipment cost. Mechanical and physical properties were evaluated. Large-scale samples demonstrated mechanical properties that were different from results from small samples. Acoustic tests indicate good sound absorption of the carpet composite. Cost analysis of the composite material based on the cost of the raw materials and the manufacturing process has been presented.

  13. Influence of Manufacturing Processes and Microstructures on the Performance and Manufacturability of Advanced High Strength Steels

    SciTech Connect

    Choi, Kyoo Sil; Liu, Wenning N.; Sun, Xin; Khaleel, Mohammad A.

    2009-10-01

    Advanced high strength steels (AHSS) are performance-based steel grades and their global material properties can be achieved with various steel chemistries and manufacturing processes, leading to various microstructures. In this paper, we investigate the influence of supplier variation and resulting microstructure difference on the overall mechanical properties as well as local formability behaviors of advanced high strength steels (AHSS). For this purpose, we first examined the basic material properties and the transformation kinetics of TRansformation Induced Plasticity (TRIP) 800 steels from three different suppliers under different testing temperatures. The experimental results show that there is a significant supplier (i.e., manufacturing process) dependency of the TRIP 800 steel mechanical and microstructure properties. Next, we examined the local formability of two commercial Dual Phase (DP) 980 steels during stamping process. The two commercial DP 980 steels also exhibit noticeably different formability during stamping process in the sense that one of them shows severe tendency for shear fracture. Microstructure-based finite element analyses are carried out next to simulate the localized deformation process with the two DP 980 microstructures, and the results suggest that the possible reason for the difference in formability lies in the morphology of the hard martensite phase in the DP microstructure.

  14. Model based control of polymer composite manufacturing processes

    NASA Astrophysics Data System (ADS)

    Potaraju, Sairam

    2000-10-01

    The objective of this research is to develop tools that help process engineers design, analyze and control polymeric composite manufacturing processes to achieve higher productivity and cost reduction. Current techniques for process design and control of composite manufacturing suffer from the paucity of good process models that can accurately represent these non-linear systems. Existing models developed by researchers in the past are designed to be process and operation specific, hence generating new simulation models is time consuming and requires significant effort. To address this issue, an Object Oriented Design (OOD) approach is used to develop a component-based model building framework. Process models for two commonly used industrial processes (Injected Pultrusion and Autoclave Curing) are developed using this framework to demonstrate the flexibility. Steady state and dynamic validation of this simulator is performed using a bench scale injected pultrusion process. This simulator could not be implemented online for control due to computational constraints. Models that are fast enough for online implementation, with nearly the same degree of accuracy are developed using a two-tier scheme. First, lower dimensional models that captures essential resin flow, heat transfer and cure kinetics important from a process monitoring and control standpoint are formulated. The second step is to reduce these low dimensional models to Reduced Order Models (ROM) suited for online model based estimation, control and optimization. Model reduction is carried out using Proper Orthogonal Decomposition (POD) technique in conjunction with a Galerkin formulation procedure. Subsequently, a nonlinear model-based estimation and inferential control scheme based on the ROM is implemented. In particular, this research work contributes in the following general areas: (1) Design and implementation of versatile frameworks for modeling and simulation of manufacturing processes using object

  15. Additive Manufacturing of High-Entropy Alloys by Laser Processing

    NASA Astrophysics Data System (ADS)

    Ocelík, V.; Janssen, N.; Smith, S. N.; De Hosson, J. Th. M.

    2016-07-01

    This contribution concentrates on the possibilities of additive manufacturing of high-entropy clad layers by laser processing. In particular, the effects of the laser surface processing parameters on the microstructure and hardness of high-entropy alloys (HEAs) were examined. AlCoCrFeNi alloys with different amounts of aluminum prepared by arc melting were investigated and compared with the laser beam remelted HEAs with the same composition. Attempts to form HEAs coatings with a direct laser deposition from the mixture of elemental powders were made for AlCoCrFeNi and AlCrFeNiTa composition. A strong influence of solidification rate on the amounts of face-centered cubic and body-centered cubic phase, their chemical composition, and spatial distribution was detected for two-phase AlCoCrFeNi HEAs. It is concluded that a high-power laser is a versatile tool to synthesize interesting HEAs with additive manufacturing processing. Critical issues are related to the rate of (re)solidification, the dilution with the substrate, powder efficiency during cladding, and differences in melting points of clad powders making additive manufacturing processing from a simple mixture of elemental powders a challenging approach.

  16. Additive Manufacturing of High-Entropy Alloys by Laser Processing

    NASA Astrophysics Data System (ADS)

    Ocelík, V.; Janssen, N.; Smith, S. N.; De Hosson, J. Th. M.

    2016-04-01

    This contribution concentrates on the possibilities of additive manufacturing of high-entropy clad layers by laser processing. In particular, the effects of the laser surface processing parameters on the microstructure and hardness of high-entropy alloys (HEAs) were examined. AlCoCrFeNi alloys with different amounts of aluminum prepared by arc melting were investigated and compared with the laser beam remelted HEAs with the same composition. Attempts to form HEAs coatings with a direct laser deposition from the mixture of elemental powders were made for AlCoCrFeNi and AlCrFeNiTa composition. A strong influence of solidification rate on the amounts of face-centered cubic and body-centered cubic phase, their chemical composition, and spatial distribution was detected for two-phase AlCoCrFeNi HEAs. It is concluded that a high-power laser is a versatile tool to synthesize interesting HEAs with additive manufacturing processing. Critical issues are related to the rate of (re)solidification, the dilution with the substrate, powder efficiency during cladding, and differences in melting points of clad powders making additive manufacturing processing from a simple mixture of elemental powders a challenging approach.

  17. 15 CFR 400.33 - Restrictions on manufacturing and processing activity.

    Code of Federal Regulations, 2011 CFR

    2011-01-01

    ... 15 Commerce and Foreign Trade 2 2011-01-01 2011-01-01 false Restrictions on manufacturing and...-TRADE ZONES BOARD Manufacturing and Processing Activity-Reviews § 400.33 Restrictions on manufacturing and processing activity. (a) In general. In approving manufacturing or processing activity for a...

  18. 15 CFR 400.33 - Restrictions on manufacturing and processing activity.

    Code of Federal Regulations, 2010 CFR

    2010-01-01

    ... 15 Commerce and Foreign Trade 2 2010-01-01 2010-01-01 false Restrictions on manufacturing and...-TRADE ZONES BOARD Manufacturing and Processing Activity-Reviews § 400.33 Restrictions on manufacturing and processing activity. (a) In general. In approving manufacturing or processing activity for a...

  19. 15 CFR 400.33 - Restrictions on manufacturing and processing activity.

    Code of Federal Regulations, 2012 CFR

    2012-01-01

    ... 15 Commerce and Foreign Trade 2 2012-01-01 2012-01-01 false Restrictions on manufacturing and...-TRADE ZONES BOARD Manufacturing and Processing Activity-Reviews § 400.33 Restrictions on manufacturing and processing activity. (a) In general. In approving manufacturing or processing activity for a...

  20. Development and characterization of a cell culture manufacturing process using quality by design (QbD) principles.

    PubMed

    Marasco, Daniel M; Gao, Jinxin; Griffiths, Kristi; Froggatt, Christopher; Wang, Tongtong; Wei, Gan

    2014-01-01

    The principles of quality by design (QbD) have been applied in cell culture manufacturing process development and characterization in the biotech industry. Here we share our approach and practice in developing and characterizing a cell culture manufacturing process using QbD principles for establishing a process control strategy. Process development and characterization start with critical quality attribute identification, followed by process parameter and incoming raw material risk assessment, design of experiment, and process parameter classification, and conclude with a design space construction. Finally, a rational process control strategy is established and documented. PMID:23828505

  1. Foreword: Additive Manufacturing: Interrelationships of Fabrication, Constitutive Relationships Targeting Performance, and Feedback to Process Control

    DOE PAGESBeta

    Carpenter, John S.; Beese, Allison M.; Bourell, David L.; Hamilton, Reginald F.; Mishra, Rajiv; Sears, James

    2015-06-26

    Additive manufacturing (AM) offers distinct advantages over conventional manufacturing processes including the capability to both build and repair complex part shapes; to integrate and consolidate parts and thus overcome joining concerns; and to locally tailor material compositions as well as properties. Moreover, a variety of fields such as aerospace, military, automotive, and biomedical are employing this manufacturing technique as a way to decrease costs, increase manufacturing agility, and explore novel geometry/functionalities. In order to increase acceptance of AM as a viable processing method, pathways for qualifying both the material and the process need to be developed and, perhaps, standardized. Thismore » symposium was designed to serve as a venue for the international AM community—including government, academia, and industry—to define the fundamental interrelationships between feedstock, processing, microstructure, shape, mechanical behavior/materials properties, and function/performance. Eventually, insight into the connections between processing, microstructure, property, and performance will be achieved through experimental observations, theoretical advances, and computational modeling of physical processes. Finally, once this insight matures, AM will be able to move from the realm of making parts to making qualified materials that are certified for use with minimal need for post-fabrication characterization.« less

  2. Foreword: Additive Manufacturing: Interrelationships of Fabrication, Constitutive Relationships Targeting Performance, and Feedback to Process Control

    SciTech Connect

    Carpenter, John S.; Beese, Allison M.; Bourell, David L.; Hamilton, Reginald F.; Mishra, Rajiv; Sears, James

    2015-06-26

    Additive manufacturing (AM) offers distinct advantages over conventional manufacturing processes including the capability to both build and repair complex part shapes; to integrate and consolidate parts and thus overcome joining concerns; and to locally tailor material compositions as well as properties. Moreover, a variety of fields such as aerospace, military, automotive, and biomedical are employing this manufacturing technique as a way to decrease costs, increase manufacturing agility, and explore novel geometry/functionalities. In order to increase acceptance of AM as a viable processing method, pathways for qualifying both the material and the process need to be developed and, perhaps, standardized. This symposium was designed to serve as a venue for the international AM community—including government, academia, and industry—to define the fundamental interrelationships between feedstock, processing, microstructure, shape, mechanical behavior/materials properties, and function/performance. Eventually, insight into the connections between processing, microstructure, property, and performance will be achieved through experimental observations, theoretical advances, and computational modeling of physical processes. Finally, once this insight matures, AM will be able to move from the realm of making parts to making qualified materials that are certified for use with minimal need for post-fabrication characterization.

  3. Small Scale Turbopump Manufacturing Technology and Material Processes

    NASA Technical Reports Server (NTRS)

    Alvarez, Erika; Morgan, Kristin; Wells, Doug; Zimmerman, Frank

    2011-01-01

    As part of an internal research and development project, NASA Marshall Space Flight Center (MSFC) has been developing a high specific impulse 9,000-lbf LOX/LH2 pump-fed engine testbed with the capability to throttle 10:1. A Fuel Turbopump (FTP) with the ability to operate across a speed range of 30,000-rpm to 100,000-rpm was developed and analyzed. This small size and flight-like Fuel Turbopump has completed the design and analysis phase and is currently in the manufacturing phase. This paper highlights the manufacturing and processes efforts to fabricate an approximately 20-lb turbopump with small flow passages, intricately bladed components and approximately 3-in diameter impellers. As a result of the small scale and tight tolerances of the hardware on this turbopump, several unique manufacturing and material challenges were encountered. Some of the technologies highlighted in this paper include the use of powder metallurgy technology to manufacture small impellers, electron beam welding of a turbine blisk shroud, and casting challenges. The use of risk reduction efforts such as non-destructive testing (NDT) and evaluation (NDE), fractography, material testing, and component spin testing are also discussed in this paper.

  4. Perspectives on the design of safer nanomaterials and manufacturing processes

    PubMed Central

    Geraci, Charles; Heidel, Donna; Sayes, Christie; Hodson, Laura; Schulte, Paul; Eastlake, Adrienne; Brenner, Sara

    2015-01-01

    A concerted effort is being made to insert Prevention through Design principles into discussions of sustainability, occupational safety and health, and green chemistry related to nanotechnology. Prevention through Design is a set of principles that includes solutions to design out potential hazards in nanomanufacturing including the design of nanomaterials, and strategies to eliminate exposures and minimize risks that may be related to the manufacturing processes and equipment at various stages of the lifecycle of an engineered nanomaterial. PMID:26435688

  5. Media fill for validation of a good manufacturing practice-compliant cell production process.

    PubMed

    Serra, Marta; Roseti, Livia; Bassi, Alessandra

    2015-01-01

    According to the European Regulation EC 1394/2007, the clinical use of Advanced Therapy Medicinal Products, such as Human Bone Marrow Mesenchymal Stem Cells expanded for the regeneration of bone tissue or Chondrocytes for Autologous Implantation, requires the development of a process in compliance with the Good Manufacturing Practices. The Media Fill test, consisting of a simulation of the expansion process by using a microbial growth medium instead of the cells, is considered one of the most effective ways to validate a cell production process. Such simulation, in fact, allows to identify any weakness in production that can lead to microbiological contamination of the final cell product as well as qualifying operators. Here, we report the critical aspects concerning the design of a Media Fill test to be used as a tool for the further validation of the sterility of a cell-based Good Manufacturing Practice-compliant production process. PMID:25096172

  6. Manufacturing process and material selection in concurrent collaborative design of MEMS devices

    NASA Astrophysics Data System (ADS)

    Zha, Xuan F.; Du, H.

    2003-09-01

    In this paper we present knowledge of an intensive approach and system for selecting suitable manufacturing processes and materials for microelectromechanical systems (MEMS) devices in concurrent collaborative design environment. In the paper, fundamental issues on MEMS manufacturing process and material selection such as concurrent design framework, manufacturing process and material hierarchies, and selection strategy are first addressed. Then, a fuzzy decision support scheme for a multi-criteria decision-making problem is proposed for estimating, ranking and selecting possible manufacturing processes, materials and their combinations. A Web-based prototype advisory system for the MEMS manufacturing process and material selection, WebMEMS-MASS, is developed based on the client-knowledge server architecture and framework to help the designer find good processes and materials for MEMS devices. The system, as one of the important parts of an advanced simulation and modeling tool for MEMS design, is a concept level process and material selection tool, which can be used as a standalone application or a Java applet via the Web. The running sessions of the system are inter-linked with webpages of tutorials and reference pages to explain the facets, fabrication processes and material choices, and calculations and reasoning in selection are performed using process capability and material property data from a remote Web-based database and interactive knowledge base that can be maintained and updated via the Internet. The use of the developed system including operation scenario, use support, and integration with an MEMS collaborative design system is presented. Finally, an illustration example is provided.

  7. Recommendations for composite manufacturing pultrusion process and equipment

    NASA Astrophysics Data System (ADS)

    Steiner, R. L.; Cole, J. D.; Strong, A. B.; Todd, R. H.

    1992-10-01

    Pultrusion is an important composite manufacturing process that holds great potential for reducing the cost of composite parts. However, pultrusion machine manufacturers and those using this continuous process have generally worked in relative isolation from each other and have, therefore, repeated many of the same errors. This paper reports the findings of a research program involving input from 15 pultruder manufacturers who have contributed non-proprietary information for the "best" design for the pultrusion machine. Key areas of design difficulty have been identified and some suggested remedies given. The results of this program will be used to construct a "state-of-the-art" pultrusion machine in the authors' laboratory. The initial findings provided input for a Quality Function Deployment (QFD) study which is basis for the functional specification for the pultrusion machine. By using QFD, capabilities of existing machines were determined and design requirements for an improved state-of-the-art machine were established. The QFD exercise provided an in-depth look at the relationship between desired machine capabilities and machine design requirements.

  8. Green tea flavour determinants and their changes over manufacturing processes.

    PubMed

    Han, Zhuo-Xiao; Rana, Mohammad M; Liu, Guo-Feng; Gao, Ming-Jun; Li, Da-Xiang; Wu, Fu-Guang; Li, Xin-Bao; Wan, Xiao-Chun; Wei, Shu

    2016-12-01

    Flavour determinants in tea infusions and their changes during manufacturing processes were studied using Camellia sinensis cultivars 'Bai-Sang Cha' ('BAS') possessing significant floral scents and 'Fuding-Dabai Cha' ('FUD') with common green tea odour. Metabolite profiling based on odour activity threshold revealed that 'BAS' contained higher levels of the active odorants β-ionone, linalool and its two oxides, geraniol, epoxylinalool, decanal and taste determinant catechins than 'FUD' (p<0.05). Enhanced transcription of some terpenoid and catechin biosynthetic genes in 'BAS' suggested genetically enhanced production of those flavour compounds. Due to manufacturing processes, the levels of linalool and geraniol decreased whereas those of β-ionone, linalool oxides, indole and cis-jasmone increased. Compared with pan-fire treatment, steam treatment reduced the levels of catechins and proportion of geraniol, linalool and its derivatives, consequently, reducing catechin-related astringency and monoterpenol-related floral scent. Our study suggests that flavour determinant targeted modulation could be made through genotype and manufacturing improvements. PMID:27374591

  9. A process monitoring strategy for a Precision Flexible Manufacturing System

    SciTech Connect

    Barkman, W.E.; Babelay, E.F.; Hebble, T.L.; Williams, R.R.

    1990-01-01

    For a number of years, the Oak Ridge Y-12 Plant has been involved in an endeavor which is described as a Precision Flexible Manufacturing System (PFMS). The objective of this project is to enhance the existing manufacturing operations for the production of precision hemispherical workpieces. The present fabrication process uses T-base lathes, similar to the one shown in figure 1, which are equipped with a Computer Numerical Control (CNC) system. The CNC systems are coupled to a host computer over a local area network (LAN). Currently, this link is used to download machining part programs and upload limited process information. While the enhanced system will use the same machine tools and LAN, additional capabilities will be provided to perform automatic tool changing, part and fixture handling, on-machine gagging, and chip control. The project's quality goals are to automatically manufacture workpieces to tolerances of +/- 0.0005 in. on contour and +/- 0.001 in. on wall thickness with a 3 to 5 sigma level of confidence. The parts will range from 4 to 10 in. in diameter with a wall thickness as large as one inch. 2 refs., 6 figs.

  10. Wear processes in manufacturing. ASTM special technical publication 1362

    SciTech Connect

    Bahadur, S.B.; Magee, J.

    1998-07-01

    The importance of tribological phenomena in engineering has long been recognized. The evidence for this lies in the extensive studies on tool wear performed over many decades. The same is the case with studies related to the friction and lubrication in deformation processing as evidenced by a number of conferences and related publications. In spite of this, the interaction between the tribologists and manufacturing researchers has not been great. The objective of this symposium was to provide a forum for these researchers for a mutually beneficial interaction. The collection of papers published in this volume may be grouped into the following categories. These categories are: abrasion in ceramic grinding, wear of cutting tools, friction in vibratory conveyers, and erosion in manufacturing. Separate abstracts were prepared for 11 papers.

  11. A senior manufacturing laboratory for determining injection molding process capability

    NASA Technical Reports Server (NTRS)

    Wickman, Jerry L.; Plocinski, David

    1992-01-01

    The following is a laboratory experiment designed to further understanding of materials science. This subject material is directed at an upper level undergraduate/graduate student in an Engineering or Engineering Technology program. It is assumed that the student has a thorough understanding of the process and quality control. The format of this laboratory does not follow that which is normally recommended because of the nature of process capability and that of the injection molding equipment and tooling. This laboratory is instead developed to be used as a point of departure for determining process capability for any process in either a quality control laboratory or a manufacturing environment where control charts, process capability, and experimental or product design are considered important topics.

  12. FAME: Freeform Active Mirrors Experiment: manufacturing process development

    NASA Astrophysics Data System (ADS)

    Challita, Zalpha; Hugot, Emmanuel; Venema, Lars; Schnetler, Hermine; Ferrari, Marc; Cuby, Jean-Gabriel

    2014-07-01

    Extreme freeform mirrors couple a non-axisymmetrical shape and an extreme asphericity, i.e. more than one millimeter of deviation from the best fit sphere. In astronomical instrumentation, such a large asphericity allows compact instruments, using less optical components. However, the lack of freeform mirrors manufacturing facilities is a real issue. We present the concept and development of an innovative manufacturing process based on plasticity forming which allow imprinting permanent deformations on mirrors, following a pre-defined mold. The aim of this activity, pursued in the frame of the OPTICON-FAME (Freeform Active Mirrors Experiment) project, is to demonstrate the suitability of this method for VIS/NIR/MIR applications. The process developed can operate on thin and flat polished initial substrates. Three study cases have been highlighted by FEA (Finite Element Analysis) and the real tests associated were performed on thin substrates in AISI420b stainless steel with 100 mm optical diameter. A comparison between FEA and tests is performed to study the evolution of the mechanical behaviour and the optical quality. The opto-mechanical results will allow a fine tuning of FEA parameters to optimize the residual form errors obtained through this process to converge toward an innovative and recurrent process.

  13. MIDAS: a framework for integrated design and manufacturing process

    NASA Astrophysics Data System (ADS)

    Chung, Moon Jung; Kwon, Patrick; Pentland, Brian

    2000-10-01

    In this paper, we present a development of a framework for managing design and manufacturing process in a distributed environment. The framework offers the following facilities: (1) to represent the complicated engineering design processes (2) to coordinate design activities and execute the process in a distributed environment and (3) to support a collaborative design by sharing data and processes. In this paper, the process flow graphs, which consist in tasks and the corresponding input and output data, are used to depict the engineering design process on a process modeling browser. The engineering activities in the represented processes can be executed in a distributed environment through the cockpit of the framework. The communication among the related engineers to support a collaborative design is made on the collaborative design browser with SML underlying data structures of representing process information to make the framework extensible and platform- independent. The formal and flexible approach of the proposed framework to integrate the engineering design processes can be also effectively applied to coordinate concurrent engineering activities in a distributed environment.

  14. Final Design And Manufacturing of the PEP II High Energy Ring Arc Bellows Module

    SciTech Connect

    Kurita, Nadine R.; Kulikov, Artem; Corlett, John; /LBL, Berkeley

    2011-09-01

    A novel RF shield bellows module developed at SLAC has been successfully manufactured and installed in the PEP-II High Energy Ring (HER). Tests indicate that the module meets its performance and operational requirements. The primary function of the bellows module is to allow for thermal expansion of the chambers and for lateral, longitudinal and angular offsets due to tolerances and alignment, while providing RF continuity between adjoining chambers. An update on the Arc bellows module for the PEP-II High Energy Ring is presented. Final design, manufacturing issues, material and coating selection, and tribological and RF testing are discussed. Performance and operational requirements are also reviewed. The RF shield design has been proven during assembly to allow for large manufacturing tolerances without reducing the mechanical spring force below required values. In addition, the RF shield maintains electrical contact even with large misalignments across the module.

  15. Thermally stable booster explosive and process for manufacture

    DOEpatents

    Quinlin, William T.; Thorpe, Raymond; Lightfoot, James M.

    2006-03-21

    A thermally stable booster explosive and process for the manufacture of the explosive. The product explosive is 2,4,7,9-tetranitro-10H-benzo[4,5]furo[3,2-b]indole (TNBFI). A reactant/solvent such as n-methylpyrrolidone (NMP) or dimethyl formamide (DMF) is made slightly basic. The solution is heated to reduce the water content. The solution is cooled and hexanitrostilbene is added. The solution is heated to a predetermined temperature for a specific time period, cooled, and the product is collected by filtration.

  16. Advanced computational research in materials processing for design and manufacturing

    SciTech Connect

    Zacharia, T.

    1994-12-31

    The computational requirements for design and manufacture of automotive components have seen dramatic increases for producing automobiles with three times the mileage. Automotive component design systems are becoming increasingly reliant on structural analysis requiring both overall larger analysis and more complex analyses, more three-dimensional analyses, larger model sizes, and routine consideration of transient and non-linear effects. Such analyses must be performed rapidly to minimize delays in the design and development process, which drives the need for parallel computing. This paper briefly describes advanced computational research in superplastic forming and automotive crash worthiness.

  17. Advanced Manufacturing Processes Laboratory Building 878 hazards assessment document

    SciTech Connect

    Wood, C.; Thornton, W.; Swihart, A.; Gilman, T.

    1994-07-01

    The introduction of the hazards assessment process is to document the impact of the release of hazards at the Advanced Manufacturing Processes Laboratory (AMPL) that are significant enough to warrant consideration in Sandia National Laboratories` operational emergency management program. This hazards assessment is prepared in accordance with the Department of Energy Order 5500.3A requirement that facility-specific hazards assessments be prepared, maintained, and used for emergency planning purposes. This hazards assessment provides an analysis of the potential airborne release of chemicals associated with the operations and processes at the AMPL. This research and development laboratory develops advanced manufacturing technologies, practices, and unique equipment and provides the fabrication of prototype hardware to meet the needs of Sandia National Laboratories, Albuquerque, New Mexico (SNL/NM). The focus of the hazards assessment is the airborne release of materials because this requires the most rapid, coordinated emergency response on the part of the AMPL, SNL/NM, collocated facilities, and surrounding jurisdiction to protect workers, the public, and the environment.

  18. Process to manufacture effervescent tablets: air forced oven melt granulation.

    PubMed

    Yanze, F M; Duru, C; Jacob, M

    2000-12-01

    In the present study we apply melt granulation in an air forced oven, called "are forced oven melt granulation" to the single-stage manufacture of effervescent granules consisting of anhydrous citric acid (43.2%) and sodium bicarbonate (56.8%) in order to make tablets. This study established that process parameters such as concentration of PEG 6000, residence time in the air forced oven, fineness of PEG 6000, fineness of the initial effervescent mix and efficiency of two lubricants markedly influenced several granule and tablet characteristics. The granules ready to be compressed into tablets were stable for 7 days at 60% RH/18 degrees C. It is a dry, simple, rapid, effective, economical, reproducible process particularly well suited to the manufacture of effervescent granules which are easily compressed into effervescent tablets. Of all the formulations tested, only formulations B2 and E2 melt granulated for 30 minutes gave tablets which had optimum compression characteristics without processing problems during compression. PMID:11189868

  19. Mixing processes following the final stratospheric warming

    NASA Technical Reports Server (NTRS)

    Hess, Peter G.

    1991-01-01

    An investigation is made of the dynamics responsible for the mixing and dissolution of the polar vortex during the final stratospheric warmings. The dynamics and transport during a Northern Hemisphere final stratospheric warming are simulated via a GCM and an associated offline N2O transport model. The results are compared with those obtained from LIMS data for the final warming of 1979, with emphasis on the potential vorticity evolution in the two datasets, the modeled N2O evolution, and the observed O3 evolution. Following each warming, the remnants of the originally intact vortex are found to gradually homogenize with the atmosphere at large. Two processes leading to this homogenization are identified following the final warmings, namely, the potential vorticity field becomes decorrelated from that of the chemical tracer, and the vortex remnants begin to tilt dramatically in a vertical direction.

  20. 40 CFR 761.187 - Reporting importers and by persons generating PCBs in excluded manufacturing processes.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... generating PCBs in excluded manufacturing processes. 761.187 Section 761.187 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) TOXIC SUBSTANCES CONTROL ACT POLYCHLORINATED BIPHENYLS (PCBs... Reporting importers and by persons generating PCBs in excluded manufacturing processes. In addition...

  1. 75 FR 61418 - Milk for Manufacturing Purposes and Its Production and Processing; Requirements Recommended for...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2010-10-05

    ... Agricultural Marketing Service Milk for Manufacturing Purposes and Its Production and Processing; Requirements... relating to quality and sanitation requirements for the production and processing of manufacturing grade.... The requirements of Executive Order 13132, Federalism, were considered in developing this notice,...

  2. Hot-gas filter manufacturing assessments: Volume 5. Final report, April 15, 1997

    SciTech Connect

    Boss, D.E.

    1997-12-31

    The development of advanced filtration media for advanced fossil-fueled power generating systems is a critical step in meeting the performance and emissions requirements for these systems. While porous metal and ceramic candle-filters have been available for some time, the next generation of filters will include ceramic-matrix composites (CMCs), intermetallic alloys, and alternate filter geometries. The goal of this effort was to perform a cursory review of the manufacturing processes used by 5 companies developing advanced filters from the perspective of process repeatability and the ability for their processes to be scale-up to production volumes. It was found that all of the filter manufacturers had a solid understanding of the product development path. Given that these filters are largely developmental, significant additional work is necessary to understand the process-performance relationships and projecting manufacturing costs. While each organization had specific needs, some common among all of the filter manufacturers were access to performance testing of the filters to aide process/product development, a better understanding of the stresses the filters will see in service for use in structural design of the components, and a strong process sensitivity study to allow optimization of processing.

  3. Manufacturing Industrial Development for the Alternative Energy Systems-Final Report

    SciTech Connect

    Dr. Chuck Ryan, National Center for Manufacturing Sciences; Dr. Dawn White, Accio Energy; Mr. Duncan Pratt, General Electric Global Research

    2013-01-30

    NCMS identified and developed critical manufacturing technology assessments vital to the affordable manufacturing of alternative-energy systems. NCMS leveraged technologies from other industrial sectors and worked with our extensive member organizations to provide DOE with two projects with far-reaching impact on the generation of wind energy. In the response for a call for project ideas, 26 project teams submitted ideas. Following a detailed selection criteria, two projects were chosen for development: Advanced Manufacturing for Modular Electro-kinetic (E-K) Wind Energy Conversion Technology - The goal of this project was to demonstrate that a modular wind energy technology based on electrohydrodynamic wind energy principles and employing automotive heritage high volume manufacturing techniques and modular platform design concepts can result in significant cost reductions for wind energy systems at a range of sizes from 100KW to multi-MW. During this program, the Accio/Boeing team made major progress on validating the EHD wind energy technology as commercially viable in the wind energy sector, and moved along the manufacturing readiness axis with a series of design changes that increased net system output. Hybrid Laser Arc Welding for Manufacture of Wind Towers - The goal of this research program was to reduce the cost of manufacturing wind towers through the introduction of hybrid laser arc welding (HLAW) into the supply chain for manufacturing wind towers. HLAW has the potential to enhance productivity while reducing energy consumption to offset the foreign low-cost labor advantage and thereby enhance U.S. competitiveness. HLAW technology combines laser welding and arc welding to produce an energy efficient, high productivity, welding process for heavy manufacturing. This process leverages the ability of a laser to produce deep weld penetration and the ability of gas metal arc welding (GMAW) to deposit filler material, thereby producing stable, high quality

  4. Photovoltaic manufacturing technology, Phase 1. Final technical report, 1 May 1991--10 May 1991

    SciTech Connect

    Not Available

    1992-10-01

    This report describes subcontracted research by the Chronar Corporation, prepared by Advanced Photovoltaic Systems, Inc. (APS) for Phase 1 of the Photovoltaic Manufacturing Technology Development project. Amorphous silicon is chosen as the PV technology that Chronar Corporation and APS believe offers the greatest potential for manufacturing improvements, which, in turn, will result in significant cost reductions and performance improvements in photovoltaic products. The APS ``Eureka`` facility was chosen as the manufacturing system that can offer the possibility of achieving these production enhancements. The relationship of the ``Eureka`` facility to Chronar`s ``batch`` plants is discussed. Five key areas are also identified that could meet the objectives of manufacturing potential that could lead to improved performance, reduced manufacturing costs, and significantly increased production. The projected long-term potential benefits of these areas are discussed, as well as problems that may impede the achievement of the hoped-for developments. A significant number of the problems discussed are of a generic nature and could be of general interest to the industry. The final section of this document addresses the cost and time estimates for achieving the solutions to the problems discussed earlier. Emphasis is placed on the number, type, and cost of the human resources required for the project.

  5. Application of low intensity ultrasonics to cheese manufacturing processes.

    PubMed

    Benedito, J; Carcel, J A; Gonzalez, R; Mulet, A

    2002-05-01

    Ultrasound has been used to non-destructively assess the quality of many foods such as meat, fish, vegetables and dairy products. This paper addresses the applications of low intensity ultrasonics in the cheese manufacturing processes and highlights the areas where ultrasonics could be successfully implemented in the future. The decrease of ultrasonic attenuation during the renneting process can be used to determine the optimum cut time for cheese making. The ultrasonic velocity increases during maturation for those types of cheese that become harder during this manufacturing stage, thus being an indicator of the maturity degree. Moreover, ultrasonic measurements could be linked to sensory parameters. From the ultrasonic velocity measurements at two different temperatures, it is possible to assess cheese composition, thus allowing an improvement in the quality and uniformity of cheese commercialization. In addition, in pulse-echo mode it is possible to detect cracked pieces due to abnormal fermentations and also to assess the distance of the crack from the surface. PMID:12159930

  6. Practical Framework: Implementing OEE Method in Manufacturing Process Environment

    NASA Astrophysics Data System (ADS)

    Maideen, N. C.; Sahudin, S.; Mohd Yahya, N. H.; Norliawati, A. O.

    2016-02-01

    Manufacturing process environment requires reliable machineries in order to be able to satisfy the market demand. Ideally, a reliable machine is expected to be operated and produce a quality product at its maximum designed capability. However, due to some reason, the machine usually unable to achieved the desired performance. Since the performance will affect the productivity of the system, a measurement technique should be applied. Overall Equipment Effectiveness (OEE) is a good method to measure the performance of the machine. The reliable result produced from OEE can then be used to propose a suitable corrective action. There are a lot of published paper mentioned about the purpose and benefit of OEE that covers what and why factors. However, the how factor not yet been revealed especially the implementation of OEE in manufacturing process environment. Thus, this paper presents a practical framework to implement OEE and a case study has been discussed to explain in detail each steps proposed. The proposed framework is beneficial to the engineer especially the beginner to start measure their machine performance and later improve the performance of the machine.

  7. Optimisation of Shape Parameters and Process Manufacturing for an Automotive Safety Part

    NASA Astrophysics Data System (ADS)

    Gildemyn, Eric; Dal Santo, Philippe; Potiron, Alain; Saïdane, Delphine

    2007-05-01

    In recent years, the weight and the cost of automotive vehicles have considerably increased due to the importance devoted to safety systems. It is therefore necessary to reduce the weight and the production cost of components by improving their shape and manufacturing process. This work deals with a numerical approach for optimizing the manufacturing process parameters of a safety belt anchor using a genetic algorithm (NSGA II). This type of component is typically manufactured in three stages: blanking, rounding of the edges by punching and finally, bending with a 90° angle. In this study, only the rounding and the bending will be treated. The numerical model is linked to the genetic algorithm in order to optimize the process parameters. This is implemented by using ABAQUSscript files developed in the Python programming language. The algorithm modifies the script files and restarts the FEM analysis automatically. Lemaitre's damage model is introduced in the material behaviour laws and implemented in the FEM analysis by using a FORTRAN subroutine. The influence of two process parameters (die radius and the rounding punch radius) and five shape parameters were investigated. The objective functions are (i) the material damage state at the end of the forming process, (ii) the stress field and (iii) the maximum Von Mises stress in the folded zone.

  8. Silicon Valley's Processing Needs versus San Jose State University's Manufacturing Systems Processing Component: Implications for Industrial Technology

    ERIC Educational Resources Information Center

    Obi, Samuel C.

    2004-01-01

    Manufacturing professionals within universities tend to view manufacturing systems from a global perspective. This perspective tends to assume that manufacturing processes are employed equally in every manufacturing enterprise, irrespective of the geography and the needs of the people in those diverse regions. But in reality local and societal…

  9. 40 CFR 761.80 - Manufacturing, processing and distribution in commerce exemptions.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... 40 Protection of Environment 32 2013-07-01 2013-07-01 false Manufacturing, processing and... AGENCY (CONTINUED) TOXIC SUBSTANCES CONTROL ACT POLYCHLORINATED BIPHENYLS (PCBs) MANUFACTURING, PROCESSING, DISTRIBUTION IN COMMERCE, AND USE PROHIBITIONS Exemptions § 761.80 Manufacturing, processing...

  10. 21 CFR 201.122 - Drugs for processing, repacking, or manufacturing.

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... 21 Food and Drugs 4 2012-04-01 2012-04-01 false Drugs for processing, repacking, or manufacturing... for processing, repacking, or manufacturing. A drug in a bulk package, except tablets, capsules, or... manufacturing, processing, or repacking”; and if in substantially all dosage forms in which it may be...

  11. 21 CFR 201.122 - Drugs for processing, repacking, or manufacturing.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... 21 Food and Drugs 4 2010-04-01 2010-04-01 false Drugs for processing, repacking, or manufacturing... for processing, repacking, or manufacturing. A drug in a bulk package, except tablets, capsules, or... manufacturing, processing, or repacking”; and if in substantially all dosage forms in which it may be...

  12. 21 CFR 801.122 - Medical devices for processing, repacking, or manufacturing.

    Code of Federal Regulations, 2013 CFR

    2013-04-01

    ... manufacturing. 801.122 Section 801.122 Food and Drugs FOOD AND DRUG ADMINISTRATION, DEPARTMENT OF HEALTH AND....122 Medical devices for processing, repacking, or manufacturing. A device intended for processing... act if its label bears the statement “Caution: For manufacturing, processing, or repacking”....

  13. 40 CFR 761.80 - Manufacturing, processing and distribution in commerce exemptions.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... 40 Protection of Environment 31 2014-07-01 2014-07-01 false Manufacturing, processing and... AGENCY (CONTINUED) TOXIC SUBSTANCES CONTROL ACT POLYCHLORINATED BIPHENYLS (PCBs) MANUFACTURING, PROCESSING, DISTRIBUTION IN COMMERCE, AND USE PROHIBITIONS Exemptions § 761.80 Manufacturing, processing...

  14. 21 CFR 201.122 - Drugs for processing, repacking, or manufacturing.

    Code of Federal Regulations, 2013 CFR

    2013-04-01

    ... 21 Food and Drugs 4 2013-04-01 2013-04-01 false Drugs for processing, repacking, or manufacturing... for processing, repacking, or manufacturing. A drug in a bulk package, except tablets, capsules, or... manufacturing, processing, or repacking”; and if in substantially all dosage forms in which it may be...

  15. 21 CFR 801.122 - Medical devices for processing, repacking, or manufacturing.

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... manufacturing. 801.122 Section 801.122 Food and Drugs FOOD AND DRUG ADMINISTRATION, DEPARTMENT OF HEALTH AND....122 Medical devices for processing, repacking, or manufacturing. A device intended for processing... act if its label bears the statement “Caution: For manufacturing, processing, or repacking”....

  16. 21 CFR 201.122 - Drugs for processing, repacking, or manufacturing.

    Code of Federal Regulations, 2011 CFR

    2011-04-01

    ... 21 Food and Drugs 4 2011-04-01 2011-04-01 false Drugs for processing, repacking, or manufacturing... for processing, repacking, or manufacturing. A drug in a bulk package, except tablets, capsules, or... manufacturing, processing, or repacking”; and if in substantially all dosage forms in which it may be...

  17. 21 CFR 201.122 - Drugs for processing, repacking, or manufacturing.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... 21 Food and Drugs 4 2014-04-01 2014-04-01 false Drugs for processing, repacking, or manufacturing... for processing, repacking, or manufacturing. A drug in a bulk package, except tablets, capsules, or... manufacturing, processing, or repacking”; and if in substantially all dosage forms in which it may be...

  18. 21 CFR 801.122 - Medical devices for processing, repacking, or manufacturing.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... manufacturing. 801.122 Section 801.122 Food and Drugs FOOD AND DRUG ADMINISTRATION, DEPARTMENT OF HEALTH AND....122 Medical devices for processing, repacking, or manufacturing. A device intended for processing... act if its label bears the statement “Caution: For manufacturing, processing, or repacking”....

  19. 40 CFR 761.80 - Manufacturing, processing and distribution in commerce exemptions.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... 40 Protection of Environment 31 2011-07-01 2011-07-01 false Manufacturing, processing and... AGENCY (CONTINUED) TOXIC SUBSTANCES CONTROL ACT POLYCHLORINATED BIPHENYLS (PCBs) MANUFACTURING, PROCESSING, DISTRIBUTION IN COMMERCE, AND USE PROHIBITIONS Exemptions § 761.80 Manufacturing, processing...

  20. 40 CFR 761.80 - Manufacturing, processing and distribution in commerce exemptions.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... 40 Protection of Environment 32 2012-07-01 2012-07-01 false Manufacturing, processing and... AGENCY (CONTINUED) TOXIC SUBSTANCES CONTROL ACT POLYCHLORINATED BIPHENYLS (PCBs) MANUFACTURING, PROCESSING, DISTRIBUTION IN COMMERCE, AND USE PROHIBITIONS Exemptions § 761.80 Manufacturing, processing...

  1. 40 CFR 761.80 - Manufacturing, processing and distribution in commerce exemptions.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 40 Protection of Environment 30 2010-07-01 2010-07-01 false Manufacturing, processing and... AGENCY (CONTINUED) TOXIC SUBSTANCES CONTROL ACT POLYCHLORINATED BIPHENYLS (PCBs) MANUFACTURING, PROCESSING, DISTRIBUTION IN COMMERCE, AND USE PROHIBITIONS Exemptions § 761.80 Manufacturing, processing...

  2. 77 FR 31875 - Certain Rubber Resins and Processes for Manufacturing Same; Notice of Receipt of Complaint...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2012-05-30

    ... COMMISSION Certain Rubber Resins and Processes for Manufacturing Same; Notice of Receipt of Complaint... complaint entitled Certain Rubber Resins and Processes for Manufacturing Same, DN 2897; the Commission is... importation of certain rubber resins and processes for manufacturing same. The complaint names as...

  3. Applications Of Laser Processing For Automotive Manufacturing In Japan

    NASA Astrophysics Data System (ADS)

    Ito, Masashi; Ueda, Katsuhiko; Takagi, Soya

    1986-11-01

    Recently in Japan, laser processing is increasingly being employed for production, so that laser cutting, laser welding and other laser material processing have begun to be used in various industries. As a result, the number of lasers sold has been increasing year by year in Japan. In the Japanese automotive industry, a number applications have been introduced in laboratories and production lines. In this paper, several current instances of such laser applications will be introduced. In the case of welding, studies have been conducted on applying laser welding to automatic transmission components, in place of electron beam welding. Another example of application, the combination of lasers and robots to form highly flexible manufacturing systems, has been adopted for trimming steel panel and plastic components.

  4. Carbon dioxide capture from a cement manufacturing process

    DOEpatents

    Blount, Gerald C.; Falta, Ronald W.; Siddall, Alvin A.

    2011-07-12

    A process of manufacturing cement clinker is provided in which a clean supply of CO.sub.2 gas may be captured. The process also involves using an open loop conversion of CaO/MgO from a calciner to capture CO.sub.2 from combustion flue gases thereby forming CaCO.sub.3/CaMg(CO.sub.3).sub.2. The CaCO.sub.3/CaMg(CO.sub.3).sub.2 is then returned to the calciner where CO.sub.2 gas is evolved. The evolved CO.sub.2 gas, along with other evolved CO.sub.2 gases from the calciner are removed from the calciner. The reactants (CaO/MgO) are feed to a high temperature calciner for control of the clinker production composition.

  5. A Digital Methodology for the Design Process of Aerospace Assemblies with Sustainable Composite Processes & Manufacture

    NASA Astrophysics Data System (ADS)

    McEwan, W.; Butterfield, J.

    2011-05-01

    The well established benefits of composite materials are driving a significant shift in design and manufacture strategies for original equipment manufacturers (OEMs). Thermoplastic composites have advantages over the traditional thermosetting materials with regards to sustainability and environmental impact, features which are becoming increasingly pertinent in the aerospace arena. However, when sustainability and environmental impact are considered as design drivers, integrated methods for part design and product development must be developed so that any benefits of sustainable composite material systems can be assessed during the design process. These methods must include mechanisms to account for process induced part variation and techniques related to re-forming, recycling and decommissioning, which are in their infancy. It is proposed in this paper that predictive techniques related to material specification, part processing and product cost of thermoplastic composite components, be integrated within a Through Life Management (TLM) product development methodology as part of a larger strategy of product system modeling to improve disciplinary concurrency, realistic part performance, and to place sustainability at the heart of the design process. This paper reports the enhancement of digital manufacturing tools as a means of drawing simulated part manufacturing scenarios, real time costing mechanisms, and broader lifecycle performance data capture into the design cycle. The work demonstrates predictive processes for sustainable composite product manufacture and how a Product-Process-Resource (PPR) structure can be customised and enhanced to include design intent driven by `Real' part geometry and consequent assembly. your paper.

  6. Assessing processes in uncertain, complex physical phenomena and manufacturing

    SciTech Connect

    Booker, J. M.; Kerscher, W. J. III; Smith, R. E.

    2002-01-01

    PREDICT (Performance and Reliability Evaluation with Diverse Information Combination and Tracking) is a set of structured quantitative approaches for the evaluation of system performance based on multiple information sources. The methodology integrates diverse types and sources of information, and their associated uncertainties, to develop full distributions for performance metrics, such as reliability. The successful application of PREDICT has involved system performance assessment in automotive product development, aging nuclear weapons, and fatigued turbine jet engines. In each of these applications, complex physical, mechanical and materials processes affect performance, safety and reliability assessments. Processes also include the physical actions taken during manufacturing, quality control, inspections, assembly, etc. and the steps involved in product design, development and certification. In this paper, we will examine the various types of processes involved in the decision making leading to production in an automotive system reliability example. Analysis of these processes includes not only understanding their impact on performance and reliability, but also the uncertainties associated with them. The automotive example demonstrates some of the tools used in tackling the complex problem of understanding processes. While some tools and methods exist for understanding processes (man made and natural) and the uncertainties associated with them, many of the complex issues discussed are open for continued research efforts.

  7. Statistics-enhanced multistage process models for integrated design &manufacturing of poly (vinyl alcohol) treated buckypaper

    NASA Astrophysics Data System (ADS)

    Wang, Kan

    Carbon nanotube (CNT) is considered a promising engineering material because of its exceptional mechanical, electrical, and thermal properties. Buckypaper (BP), a thin sheet of assembled CNTs, is an effective way to handle CNTs in macro scale. Pristine BP is a fragile material which is held together by weak van der Waals attractions among CNTs. This dissertation introduces a modified filtration based manufacturing process which uses poly (vinyl alcohol) (PVA) to treat BP. This treatment greatly improves the handleability of BP, reduces the spoilage during transferring, and shortens the production time. The multistage manufacturing process of PVA-treated BP is discussed in this dissertation, and process models are developed to predict the nanostructure of final products from the process parameters. Based on the nanostructure, a finite element based physical model for prediction of Young's modulus is also developed. This accuracy of this physical model is further improved by statistical methods. The aim of this study is to investigate and improve the scalability of the manufacturing process of PVA-treated BP. To achieve this goal, various statistical tools are employed. The unique issues in nanomanufacturing also motivate the development of new statistical tools and modification of existing tools. Those issues include the uncertainties in nanostructure characterization due to the scale, limited number experimental data due to high cost of raw materials, large variation in final product due to the random nature in structure, and the high complexity in physical models due to the small scale of structural building blocks. This dissertation addresses those issues by combining engineering field knowledge and statistical methods. The resulting statistics-enhanced physical model provides an approach to design the manufacturing process of PVA-treated BP for a targeting property and tailor the robustness of the final product by manipulating the process parameters. In addition

  8. Porosity Measurements and Analysis for Metal Additive Manufacturing Process Control

    PubMed Central

    Slotwinski, John A; Garboczi, Edward J; Hebenstreit, Keith M

    2014-01-01

    Additive manufacturing techniques can produce complex, high-value metal parts, with potential applications as critical metal components such as those found in aerospace engines and as customized biomedical implants. Material porosity in these parts is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants - since surface-breaking pores allows for better integration with biological tissue. Changes in a part’s porosity during an additive manufacturing build may also be an indication of an undesired change in the build process. Here, we present efforts to develop an ultrasonic sensor for monitoring changes in the porosity in metal parts during fabrication on a metal powder bed fusion system. The development of well-characterized reference samples, measurements of the porosity of these samples with multiple techniques, and correlation of ultrasonic measurements with the degree of porosity are presented. A proposed sensor design, measurement strategy, and future experimental plans on a metal powder bed fusion system are also presented. PMID:26601041

  9. Porosity Measurements and Analysis for Metal Additive Manufacturing Process Control.

    PubMed

    Slotwinski, John A; Garboczi, Edward J; Hebenstreit, Keith M

    2014-01-01

    Additive manufacturing techniques can produce complex, high-value metal parts, with potential applications as critical metal components such as those found in aerospace engines and as customized biomedical implants. Material porosity in these parts is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants - since surface-breaking pores allows for better integration with biological tissue. Changes in a part's porosity during an additive manufacturing build may also be an indication of an undesired change in the build process. Here, we present efforts to develop an ultrasonic sensor for monitoring changes in the porosity in metal parts during fabrication on a metal powder bed fusion system. The development of well-characterized reference samples, measurements of the porosity of these samples with multiple techniques, and correlation of ultrasonic measurements with the degree of porosity are presented. A proposed sensor design, measurement strategy, and future experimental plans on a metal powder bed fusion system are also presented. PMID:26601041

  10. Continuous, Automated Manufacturing of String Ribbon Si PV Modules: Final Report, 21 May 1998 - 20 May 2001

    SciTech Connect

    Hanoka, J. I.

    2001-08-01

    This report summarizes the work done under a three-year PVMaT Phase 5A2 program. The overall goal was to attain a continuous, highly automated, fully integrated PV production line. In crystal growth, advances were made that resulted in lower substrate costs, higher yields, and lower capital and labor costs. A new string material was developed and implemented. Following this development, better control of the edge meniscus was achieved. A completely new furnace design was accomplished, and this became the standard platform in our new factory. Automation included ribbon thickness control and laser cutting of String Ribbon strips. Characterization of Evergreen's String Ribbon silicon was done with extensive help from the NREL laboratories, and this work provided a foundation for higher efficiency cells in the future. Advances in cell manufacturing included the development of high-speed printing and drying methods for Evergreen's unique cell making method and the design and building of a completely automated cell line from the beginning of front-contact application to the final tabbing of the cells. A so-called no-etch process whereby substrates from crystal growth go directly into p-n junction formation and emerge from this sequence without needing to go in and out of plastic carriers for any wet-chemical processing was developed. Process development as well as automation were brought to bear on improvements in soldering technology and cell interconnection in general. Using state-of-the-art manufacturing science, the Fraunhofer USA Center for Manufacturing Innovation at Boston University facilitated layout and process flow for the operation of our new factory. Evergreen Solar's new factory began operations in the second quarter of 2001. A good measure of the significant impact of this PVMaT subcontract is that virtually all of the manufacturing developments stemming from this project have been incorporated in this new factory.

  11. Process for manufacturing a lithium alloy electrochemical cell

    DOEpatents

    Bennett, William R.

    1992-10-13

    A process for manufacturing a lithium alloy, metal sulfide cell tape casts slurried alloy powders in an organic solvent containing a dissolved thermoplastic organic binder onto casting surfaces. The organic solvent is then evaporated to produce a flexible tape removable adhering to the casting surface. The tape is densified to increase its green strength and then peeled from the casting surface. The tape is laminated with a separator containing a lithium salt electrolyte and a metal sulfide electrode to form a green cell. The binder is evaporated from the green cell at a temperature lower than the melting temperature of the lithium salt electrolyte. Lithium alloy, metal sulfide and separator powders may be tape cast.

  12. Solid electrolyte material manufacturable by polymer processing methods

    DOEpatents

    Singh, Mohit; Gur, Ilan; Eitouni, Hany Basam; Balsara, Nitash Pervez

    2012-09-18

    The present invention relates generally to electrolyte materials. According to an embodiment, the present invention provides for a solid polymer electrolyte material that is ionically conductive, mechanically robust, and can be formed into desirable shapes using conventional polymer processing methods. An exemplary polymer electrolyte material has an elastic modulus in excess of 1.times.10.sup.6 Pa at 90 degrees C. and is characterized by an ionic conductivity of at least 1.times.10.sup.-5 Scm-1 at 90 degrees C. An exemplary material can be characterized by a two domain or three domain material system. An exemplary material can include material components made of diblock polymers or triblock polymers. Many uses are contemplated for the solid polymer electrolyte materials. For example, the present invention can be applied to improve Li-based batteries by means of enabling higher energy density, better thermal and environmental stability, lower rates of self-discharge, enhanced safety, lower manufacturing costs, and novel form factors.

  13. Process monitoring of additive manufacturing by using optical tomography

    SciTech Connect

    Zenzinger, Guenter E-mail: alexander.ladewig@mtu.de; Bamberg, Joachim E-mail: alexander.ladewig@mtu.de; Ladewig, Alexander E-mail: alexander.ladewig@mtu.de; Hess, Thomas E-mail: alexander.ladewig@mtu.de; Henkel, Benjamin E-mail: alexander.ladewig@mtu.de; Satzger, Wilhelm E-mail: alexander.ladewig@mtu.de

    2015-03-31

    Parts fabricated by means of additive manufacturing are usually of complex shape and owing to the fabrication procedure by using selective laser melting (SLM), potential defects and inaccuracies are often very small in lateral size. Therefore, an adequate quality inspection of such parts is rather challenging, while non-destructive-techniques (NDT) are difficult to realize, but considerable efforts are necessary in order to ensure the quality of SLM-parts especially used for aerospace components. Thus, MTU Aero Engines is currently focusing on the development of an Online Process Control system which monitors and documents the complete welding process during the SLM fabrication procedure. A high-resolution camera system is used to obtain images, from which tomographic data for a 3dim analysis of SLM-parts are processed. From the analysis, structural irregularities and structural disorder resulting from any possible erroneous melting process become visible and may be allocated anywhere within the 3dim structure. Results of our optical tomography (OT) method as obtained on real defects are presented.

  14. Process monitoring of additive manufacturing by using optical tomography

    NASA Astrophysics Data System (ADS)

    Zenzinger, Guenter; Bamberg, Joachim; Ladewig, Alexander; Hess, Thomas; Henkel, Benjamin; Satzger, Wilhelm

    2015-03-01

    Parts fabricated by means of additive manufacturing are usually of complex shape and owing to the fabrication procedure by using selective laser melting (SLM), potential defects and inaccuracies are often very small in lateral size. Therefore, an adequate quality inspection of such parts is rather challenging, while non-destructive-techniques (NDT) are difficult to realize, but considerable efforts are necessary in order to ensure the quality of SLM-parts especially used for aerospace components. Thus, MTU Aero Engines is currently focusing on the development of an Online Process Control system which monitors and documents the complete welding process during the SLM fabrication procedure. A high-resolution camera system is used to obtain images, from which tomographic data for a 3dim analysis of SLM-parts are processed. From the analysis, structural irregularities and structural disorder resulting from any possible erroneous melting process become visible and may be allocated anywhere within the 3dim structure. Results of our optical tomography (OT) method as obtained on real defects are presented.

  15. Cost analysis of composite fan blade manufacturing processes

    NASA Technical Reports Server (NTRS)

    Stelson, T. S.; Barth, C. F.

    1980-01-01

    The relative manufacturing costs were estimated for large high technology fan blades prepared by advanced composite fabrication methods using seven candidate materials/process systems. These systems were identified as laminated resin matrix composite, filament wound resin matrix composite, superhybrid solid laminate, superhybrid spar/shell, metal matrix composite, metal matrix composite with a spar and shell, and hollow titanium. The costs were calculated utilizing analytical process models and all cost data are presented as normalized relative values where 100 was the cost of a conventionally forged solid titanium fan blade whose geometry corresponded to a size typical of 42 blades per disc. Four costs were calculated for each of the seven candidate systems to relate the variation of cost on blade size. Geometries typical of blade designs at 24, 30, 36 and 42 blades per disc were used. The impact of individual process yield factors on costs was also assessed as well as effects of process parameters, raw materials, labor rates and consumable items.

  16. Manufacture of die casting dies by hot isostatic pressing. CRADA final report

    SciTech Connect

    Viswanathan, S.; Ren, W.; Luk, K.; Brucher, H.G.

    1998-09-01

    The reason for this Cooperative Research and Development Agreement (CRADA) between the Oak Ridge National Laboratory (ORNL) and Doehler-Jarvis was to investigate the manufacture die-casting dies with internal water-cooling lines by hot-isostatic pressing (HIPing) of H13 tool steel powder. The use of HIPing will allow the near-net-shape manufacture of dies and the strategic placement of water-cooling lines during manufacture. The production of near-net-shape dies by HIPing involves the generation of HIPing diagrams, the design of the can that can be used for HIPing a die with complex details, strategic placement of water-cooling lines in the die, computer modeling to predict movement of the water lines during HIPing, and the development of strategies for placing water lines in the appropriate locations. The results presented include a literature review, particle analysis and characterization of H13 tool steel powder, and modeling of the HIPing process.

  17. 27 CFR 40.1 - Manufacture of tobacco products, cigarette papers and tubes, and processed tobacco.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... 27 Alcohol, Tobacco Products and Firearms 2 2014-04-01 2014-04-01 false Manufacture of tobacco... MANUFACTURE OF TOBACCO PRODUCTS, CIGARETTE PAPERS AND TUBES, AND PROCESSED TOBACCO Scope of Regulations § 40.1 Manufacture of tobacco products, cigarette papers and tubes, and processed tobacco. This part...

  18. 27 CFR 40.1 - Manufacture of tobacco products, cigarette papers and tubes, and processed tobacco.

    Code of Federal Regulations, 2013 CFR

    2013-04-01

    ... 27 Alcohol, Tobacco Products and Firearms 2 2013-04-01 2013-04-01 false Manufacture of tobacco... MANUFACTURE OF TOBACCO PRODUCTS, CIGARETTE PAPERS AND TUBES, AND PROCESSED TOBACCO Scope of Regulations § 40.1 Manufacture of tobacco products, cigarette papers and tubes, and processed tobacco. This part...

  19. 27 CFR 40.1 - Manufacture of tobacco products, cigarette papers and tubes, and processed tobacco.

    Code of Federal Regulations, 2011 CFR

    2011-04-01

    ... 27 Alcohol, Tobacco Products and Firearms 2 2011-04-01 2011-04-01 false Manufacture of tobacco... MANUFACTURE OF TOBACCO PRODUCTS, CIGARETTE PAPERS AND TUBES, AND PROCESSED TOBACCO Scope of Regulations § 40.1 Manufacture of tobacco products, cigarette papers and tubes, and processed tobacco. This part...

  20. 27 CFR 40.1 - Manufacture of tobacco products, cigarette papers and tubes, and processed tobacco.

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... 27 Alcohol, Tobacco Products and Firearms 2 2012-04-01 2011-04-01 true Manufacture of tobacco... MANUFACTURE OF TOBACCO PRODUCTS, CIGARETTE PAPERS AND TUBES, AND PROCESSED TOBACCO Scope of Regulations § 40.1 Manufacture of tobacco products, cigarette papers and tubes, and processed tobacco. This part...

  1. Application of Resin Transfer Molding to the Manufacture of Wind Turbine Blade Substructures. Final Report

    SciTech Connect

    Hedley, C. W.; Ritter, W. J.; Ashwill, T.

    2001-07-26

    The U.S. has generally lacked the capability for an iterative process of detailed structural design, manufacturing, and testing at the full blade level to achieve specific structural performance, cost, and weight targets. This project examined the effects that different composites processing methods had on the performance of representative blade substructures. In addition, the results of the testing of these substructures was used to validate NuMAD, the design tool developed at Sandia National Laboratories.

  2. ATAC Process Proof of Concept Final Report

    SciTech Connect

    Bri Rolston; Sarah Freeman

    2014-03-01

    Researchers at INL with funding from the Department of Energy’s Office of Electricity Delivery and Energy Reliability (DOE-OE) evaluated a novel approach for near real-time consumption of threat intelligence. Demonstration testing in an industry environment supported the development of this new process to assist the electric sector in securing their critical networks. This report provides the reader with an understanding of the methods used during this proof of concept project. The processes and templates were further advanced with an industry partner during an onsite assessment. This report concludes with lessons learned and a roadmap for final development of these materials for use by industry.

  3. Airborne Windshear Detection and Warning Systems. Fifth and Final Combined Manufacturers' and Technologists' Conference, part 1

    NASA Technical Reports Server (NTRS)

    Delnore, Victor E. (Compiler)

    1994-01-01

    The Fifth (and Final) Combined Manufacturers' and Technologists' Airborne Windshear Review Meeting was hosted jointly by the NASA Langley Research Center (LaRC) and the Federal Aviation Administration (FAA) in Hampton, Virginia, on September 28-30, 1993. The purpose of the meeting was to report on the highly successful windshear experiments conducted by government, academic institutions, and industry; to transfer the results to regulators, manufacturers, and users; and to set initiatives for future aeronautics technology research. The formal sessions covered recent developments in windshear flight testing; windshear modeling, flight management, and ground-based systems; airborne windshear detection systems; certification and regulatory issues; development and applications of sensors for wake vortex detection; and synthetic and enhanced vision systems.

  4. 40 CFR 761.193 - Maintenance of monitoring records by persons who import, manufacture, process, distribute in...

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... persons who import, manufacture, process, distribute in commerce, or use chemicals containing... records by persons who import, manufacture, process, distribute in commerce, or use chemicals containing inadvertently generated PCBs. (a) Persons who import, manufacture, process, distribute in commerce, or...

  5. 40 CFR 761.193 - Maintenance of monitoring records by persons who import, manufacture, process, distribute in...

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... persons who import, manufacture, process, distribute in commerce, or use chemicals containing... records by persons who import, manufacture, process, distribute in commerce, or use chemicals containing inadvertently generated PCBs. (a) Persons who import, manufacture, process, distribute in commerce, or...

  6. 40 CFR 761.193 - Maintenance of monitoring records by persons who import, manufacture, process, distribute in...

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... persons who import, manufacture, process, distribute in commerce, or use chemicals containing... records by persons who import, manufacture, process, distribute in commerce, or use chemicals containing inadvertently generated PCBs. (a) Persons who import, manufacture, process, distribute in commerce, or...

  7. Data quality and processing for decision making: divergence between corporate strategy and manufacturing processes

    NASA Astrophysics Data System (ADS)

    McNeil, Ronald D.; Miele, Renato; Shaul, Dennis

    2000-10-01

    Information technology is driving improvements in manufacturing systems. Results are higher productivity and quality. However, corporate strategy is driven by a number of factors and includes data and pressure from multiple stakeholders, which includes employees, managers, executives, stockholders, boards, suppliers and customers. It is also driven by information about competitors and emerging technology. Much information is based on processing of data and the resulting biases of the processors. Thus, stakeholders can base inputs on faulty perceptions, which are not reality based. Prior to processing, data used may be inaccurate. Sources of data and information may include demographic reports, statistical analyses, intelligence reports (e.g., marketing data), technology and primary data collection. The reliability and validity of data as well as the management of sources and information is critical element to strategy formulation. The paper explores data collection, processing and analyses from secondary and primary sources, information generation and report presentation for strategy formulation and contrast this with data and information utilized to drive internal process such as manufacturing. The hypothesis is that internal process, such as manufacturing, are subordinate to corporate strategies. The impact of possible divergence in quality of decisions at the corporate level on IT driven, quality-manufacturing processes based on measurable outcomes is significant. Recommendations for IT improvements at the corporate strategy level are given.

  8. Low-cost mirror substrates: manufacturing process evolution

    NASA Astrophysics Data System (ADS)

    Rosala, Francois; Meyer, Michele; Bes de Berc, Jean-Sebastien; Roussel, Andre; Beriot, Emmanuel

    1997-12-01

    In the framework of the Megajoule Laser project driven by the French Atomic Energy Board, one of the most valuable optical programs in term of material volume as well as in term of component size, the actual glasses and production means appear to be inconsistent with the economical objectives. Corning proposed an alternative, based on the use of a low cost glass, together with an evolution of the production process. Combining its experience in quality optical glasses manufacturing and its mastery of forming processes, Corning conducted a production cost reduction program; the objective of this program was to validate the concept of large slab melting (about 2000 kg each), where blocks are cut off, versus the conventional single block (about 100 kg) melting. Economical improvements are based on a reduction of lost time (mold change) and production lead- time by increasing the feeding yield, on a better glass utilization, and a reduced number of molds. The technical issues were: increase the feeding yield maintaining a given glass quality level, reduce the glass allowance, improve the materials of the molds, reinforce the thermal process control, automatism of critical operations, especially at the start-up and at the end of the mold feeding. Despite the long production cycle, about 3 months including melting and annealing, the first results carry the technological options set-up.

  9. Low-cost mirror substrates: manufacturing process evolution

    NASA Astrophysics Data System (ADS)

    Rosala, Francois; Meyer, Michele; Bes de Berc, Jean-Sebastien; Roussel, Andre; Beriot, Emmanuel

    1996-08-01

    In the framework of the megajoule laser project driven by the french atomic energy board, one of the most valuable optical programs in terms of material volume as well as in terms of component size, the actual glasses and production means appear to be inconsistent with the economical objectives. Corning proposed an alternative, based on the use of a low cost glass, together with an evolution of the production process. Combining its experience in quality optical glasses manufacturing and its mastery of forming processes, Corning conducted a production cost reduction program; the objective of this program was to validate the concept of large slab melting, where blocks are cut off, versus the conventional single block melting. Economical improvements are based on a reduction of lost time and production lead-time by increasing the feeding yield, on a better glass utilization, and a reduced number of molds. The technical issues were: increase the feeding yield maintaining a given glass quality level, reduce the glass allowance, improve the materials of the molds, reinforce the thermal process control, automatism of critical operations, especially at the start-up and at the end of the mold feeding.

  10. Additive manufacturing of stretchable tactile sensors: Processes, materials, and applications

    NASA Astrophysics Data System (ADS)

    Vatani, Morteza

    3D printing technology is becoming more ubiquitous every day especially in the area of smart structures. However, fabrication of multi-material, functional, and smart structures is problematic because of the process and material limitations. This thesis sought to develop a Direct Print Photopolymerization (DPP) fabrication technique that appreciably extends the manufacturing space for the 3D smart structures. This method employs a robotically controlled micro-extrusion of a filament equipped with a photopolymerization process. The ability to use polymers and ultimately their nanocomposites in this process is the advantage of the proposed process over the current fabrication methods in the fabrication of 3D structures featuring mechanical, physical, and electrical functionalities. In addition, this study focused to develop a printable, conductive, and stretchable nanocomposite based on a photocurable and stretchable liquid resin filled with multi-walled carbon nanotubes (MWNTs). This nanocomposite exhibited piezoresistivity, means its resistivity changes as it deforms. This property is a favorable factor in developing resistance based tactile sensors. They were also able to resist high tensile strains while they showed conductivity. Furthermore, this study offered a possible and low-cost method to have a unique and highly stretchable pressure sensitive polymer. This disruptive pressure sensitive polymer composed of an Ionic Liquid (IL) and a stretchable photopolymer embedded between two layers of Carbon Nanotube (CNTs) based stretchable electrodes. The developed IL-polymer showed both field effect property and piezoresistivity that can detect large tensile strains up 30%. In summary, this research study focused to present feasible methods and materials for printing a 3D smart structure especially in the context of flexible tactile sensors. This study provides a foundation for the future efforts in fabrication of skin like tactile sensors in three-dimensional motifs

  11. Photovoltaic Manufacturing Technology (PVMaT) improvements for ENTECH`s concentrator module. Final technical report, 9 January 1991--14 April 1991

    SciTech Connect

    O`Neill, M.J.; McDanal, A.J.; Perry, J.L.; Jackson, M.C.; Walters, R.R.

    1991-11-01

    This final technical report documents ENTECH`s Phase 1 contract with Photovoltaic Manufacturing Technology (PVMaT) project. Under this project we prepared a detailed description of our current manufacturing process for making our unique linear Fresnel lens photovoltaic concentrator modules. In addition, we prepared a detailed description of an improved manufacturing process, which will simultaneously increase module production rates, enhance module quality, and substantially reduce module costs. We also identified potential problems in implementing the new manufacturing process, and we proposed solutions to these anticipated problems. Before discussing the key results of our program, however, we present a brief description of our unique photovoltaic technology. The key conclusion of our PVMAT Phase 1 study is that our module technology, without further breakthroughs, can realistically meet the near-term DOE goal of 12 cents/kWh levelized electricity cost, provided that we successfully implement the new manufacturing process at a production volume of at least 10 megawatts per year. The key recommendation from our Phase 1 study is to continue our PVMaT project into Phase 2A, which is directed toward the actual manufacturing technology development required for our new module production process. 15 refs.

  12. The inverse problems of wing panel manufacture processes

    NASA Astrophysics Data System (ADS)

    Oleinikov, A. I.; Bormotin, K. S.

    2013-12-01

    It is shown that inverse problems of steady-state creep bending of plates in both the geometrically linear and nonlinear formulations can be represented in a variational formulation. Steady-state values of the obtained functionals corresponding to the solutions of the problems of inelastic deformation and springback are determined by applying a finite element procedure to the functionals. Optimal laws of creep deformation are formulated using the criterion of minimizing damage in the functionals of the inverse problems. The formulated problems are reduced to the problems solved by the finite element method using MSC.Marc software. Currently, forming of light metals poses tremendous challenges due to their low ductility at room temperature and their unusual deformation characteristics at hot-cold work: strong asymmetry between tensile and compressive behavior, and a very pronounced anisotropy. We used the constitutive models of steady-state creep of initially transverse isotropy structural materials the kind of the stress state has influence. The paper gives basics of the developed computer-aided system of design, modeling, and electronic simulation targeting the processes of manufacture of wing integral panels. The modeling results can be used to calculate the die tooling, determine the panel processibility, and control panel rejection in the course of forming.

  13. The inverse problems of wing panel manufacture processes

    SciTech Connect

    Oleinikov, A. I.; Bormotin, K. S.

    2013-12-16

    It is shown that inverse problems of steady-state creep bending of plates in both the geometrically linear and nonlinear formulations can be represented in a variational formulation. Steady-state values of the obtained functionals corresponding to the solutions of the problems of inelastic deformation and springback are determined by applying a finite element procedure to the functionals. Optimal laws of creep deformation are formulated using the criterion of minimizing damage in the functionals of the inverse problems. The formulated problems are reduced to the problems solved by the finite element method using MSC.Marc software. Currently, forming of light metals poses tremendous challenges due to their low ductility at room temperature and their unusual deformation characteristics at hot-cold work: strong asymmetry between tensile and compressive behavior, and a very pronounced anisotropy. We used the constitutive models of steady-state creep of initially transverse isotropy structural materials the kind of the stress state has influence. The paper gives basics of the developed computer-aided system of design, modeling, and electronic simulation targeting the processes of manufacture of wing integral panels. The modeling results can be used to calculate the die tooling, determine the panel processibility, and control panel rejection in the course of forming.

  14. Heat pipe cooling of an aerospace foam mold manufacturing process

    SciTech Connect

    Hahn, D.R.; Feldman, K.T.; Marjon, P.L.

    1980-01-01

    A passive heat pipe cooling system was developed to cool a Bendix foam mold used to manufacture aerospace foam parts. The cooling system consists of ten copper-water heat pipes with cooling fins implanted into the aluminum mold and cooled by a domestic size fan blowing ambient air. The number and location of the heat pipes was determined to provide the most effective cooling and mold isothermalization based on experimental measurements of mold temperatures during the exothermic foaming process and from practical considerations of the mold geometry and use. Performance tests were cnducted on an individual heat pipe and on the ten heat pipes implanted in the mold. Both exothermic foam heating and internal electrical heat input were used in the experiments. The experimental test results indicate that the heat pipe cooling system with a fan is four to six times faster than free convection cooling of the mold with no heat pipes or fan and nearly twice as fast as cooling by the fan only. Similarly fast increases in mold heating time in the cure furnace could be realized if the heat pipes are used during this part of the production process. The heat pipes also cool hot spots in the mold and help isothermalize the mold so that better quality foam parts should be produced.

  15. Economic analysis of final effluent limitations guidelines and standards for the pharmaceutical manufacturing industry

    SciTech Connect

    1998-07-01

    This economic analysis (EA) examines compliance costs and economic impacts resulting from the US Environmental Protection Agency`s (EPA`s) Final Effluent Limitations Guidelines and Standards for the Pharmaceutical Manufacturing Industry Point Source Category. It also investigates the costs and impacts associated with an air rule requiring Maximum Achievable Control Technology (MACT) to control air emissions, both separately and together with the Final Pharmaceutical Industry Effluent Guidelines. The EA estimates the economic effects of compliance with both final rules in terms of total aggregate annualized costs of compliance, facility closures, impacts on firms (likelihood of bankruptcy and effects on profit margins), and impacts on new sources. The EA also investigates secondary impacts on employment and communities, foreign trade, specific demographic groups, and environmental justice. This report includes a Final Regulatory Flexibility Analysis (FRFA) detailing the impacts on small businesses within the pharmaceutical industry to meet the requirements of the Regulatory Flexibility Act (RFA), as amended by the Small Business Regulatory Enforcement Fairness Act (SBREFA). Finally, the EA presents a cost-benefit analysis to meet the requirements of Executive Order 12866 and the Unfunded Mandates Reform Act.

  16. The Enterprise Derivative Application: Flexible Software for Optimizing Manufacturing Processes

    SciTech Connect

    Ward, Richard C; Allgood, Glenn O; Knox, John R

    2008-11-01

    The Enterprise Derivative Application (EDA) implements the enterprise-derivative analysis for optimization of an industrial process (Allgood and Manges, 2001). It is a tool to help industry planners choose the most productive way of manufacturing their products while minimizing their cost. Developed in MS Access, the application allows users to input initial data ranging from raw material to variable costs and enables the tracking of specific information as material is passed from one process to another. Energy-derivative analysis is based on calculation of sensitivity parameters. For the specific application to a steel production process these include: the cost to product sensitivity, the product to energy sensitivity, the energy to efficiency sensitivity, and the efficiency to cost sensitivity. Using the EDA, for all processes the user can display a particular sensitivity or all sensitivities can be compared for all processes. Although energy-derivative analysis was originally designed for use by the steel industry, it is flexible enough to be applied to many other industrial processes. Examples of processes where energy-derivative analysis would prove useful are wireless monitoring of processes in the petroleum cracking industry and wireless monitoring of motor failure for determining the optimum time to replace motor parts. One advantage of the MS Access-based application is its flexibility in defining the process flow and establishing the relationships between parent and child process and products resulting from a process. Due to the general design of the program, a process can be anything that occurs over time with resulting output (products). So the application can be easily modified to many different industrial and organizational environments. Another advantage is the flexibility of defining sensitivity parameters. Sensitivities can be determined between all possible variables in the process flow as a function of time. Thus the dynamic development of the

  17. Final Report - Advanced MEA's for Enhanced Operating Conditions, Amenable to High Volume Manufacture

    SciTech Connect

    Debe, Mark K.

    2007-09-30

    This report summarizes the work completed under a 3M/DOE contract directed at advancing the key fuel cell (FC) components most critical for overcoming the polymer electrolyte membrane fuel cell (PEMFC) performance, durability & cost barriers. This contract focused on the development of advanced ion exchange membranes & electrocatalysts for PEMFCs that will enable operation under ever more demanding automotive operating conditions & the use high volume compatible processes for their manufacture. Higher performing & more durable electrocatalysts must be developed for PEMFCs to meet the power density & lifetime hours required for FC vehicles. At the same time the amount of expensive Pt catalyst must be reduced to lower the MEA costs. While these two properties are met, the catalyst must be made resistant to multiple degradation mechanisms to reach necessary operating lifetimes. In this report, we present the work focused on the development of a completely new approach to PEMFC electrocatalyts, called nanostructured thin film (NSTF) catalysts. The carbon black supports are eliminated with this new approach which eliminates the carbon corrosion issue. The thin film nature of the catalyst significantly improves its robustness against dissolution & grain growth, preserving the surface area. Also, the activity of the NSTF for oxygen reduction is improved by over 500% compared to dispersed Pt catalyts. Finally, the process for fabricating the NSTF catalysts is consistent with high volume roll-good manufacturing & extremely flexible towards the introduction of new catalyst compositions & structures. This report documents the work done to develop new multi-element NSTF catalysts with properties that exceed pure Pt, that are optimized for use with the membranes discussed below, & advance the state-of-the-art towards meeting the DOE 2010 targets for PEMFC electrocatalysts. The work completed advances the understanding of the NSTF catalyst technology, identifies new NSTF

  18. Implementation of Lean System on Erbium Doped Fibre Amplifier Manufacturing Process to Reduce Production Time

    NASA Astrophysics Data System (ADS)

    Maneechote, T.; Luangpaiboon, P.

    2010-10-01

    A manufacturing process of erbium doped fibre amplifiers is complicated. It needs to meet the customers' requirements under a present economic status that products need to be shipped to customers as soon as possible after purchasing orders. This research aims to study and improve processes and production lines of erbium doped fibre amplifiers using lean manufacturing systems via an application of computer simulation. Three scenarios of lean tooled box systems are selected via the expert system. Firstly, the production schedule based on shipment date is combined with a first in first out control system. The second scenario focuses on a designed flow process plant layout. Finally, the previous flow process plant layout combines with production schedule based on shipment date including the first in first out control systems. The computer simulation with the limited data via an expected value is used to observe the performance of all scenarios. The most preferable resulted lean tooled box systems from a computer simulation are selected to implement in the real process of a production of erbium doped fibre amplifiers. A comparison is carried out to determine the actual performance measures via an analysis of variance of the response or the production time per unit achieved in each scenario. The goodness of an adequacy of the linear statistical model via experimental errors or residuals is also performed to check the normality, constant variance and independence of the residuals. The results show that a hybrid scenario of lean manufacturing system with the first in first out control and flow process plant lay out statistically leads to better performance in terms of the mean and variance of production times.

  19. Assessment of low-cost manufacturing process sequences. [photovoltaic solar arrays

    NASA Technical Reports Server (NTRS)

    Chamberlain, R. G.

    1979-01-01

    An extensive research and development activity to reduce the cost of manufacturing photovoltaic solar arrays by a factor of approximately one hundred is discussed. Proposed and actual manufacturing process descriptions were compared to manufacturing costs. An overview of this methodology is presented.

  20. Current good manufacturing practices, quality control procedures, quality factors, notification requirements, and records and reports, for infant formula. Final rule.

    PubMed

    2014-06-10

    The Food and Drug Administration (FDA or we) is issuing a final rule that adopts, with some modifications, the interim final rule (IFR) entitled "Current Good Manufacturing Practices, Quality Control Procedures, Quality Factors, Notification Requirements, and Records and Reports, for Infant Formula'' (February 10, 2014). This final rule affirms the IFR's changes to FDA's regulations and provides additional modifications and clarifications. The final rule also responds to certain comments submitted in response to the request for comments in the IFR. PMID:24922980

  1. Improvements in process performance for immersion technology high volume manufacturing

    NASA Astrophysics Data System (ADS)

    Nafus, K.; Shimoaoki, T.; Enomoto, M.; Shite, H.; Otsuka, T.; Kosugi, H.; Shibata, T.; Mallmann, J.; Maas, R.; Verspaget, C.; van der Heijden, E.; van Setten, E.; Finders, J.; Wang, S.; Boudou, N.; Zoldesi, C.

    2009-03-01

    Through collaborative efforts ASML and TEL are continuously improving the process performance for the LITHIUS Pro -i/ TWINSCAN XT:1900Gi litho cluster. In previous work from this collaboration, TEL and ASML have investigated the CDU and defectivity performance for the 45nm node with high through put processing. CDU performance for both memory and logic illumination conditions were shown to be on target for ITRS roadmap specifications. Additionally, it was shown that the current defect metrology is able to measure the required defect size of 30nm with a 90% capture rate. For the target through put of 180wph, no added impact to defectivity was seen from the multi-module processing on the LITHIUS Pro -i, using a topcoat resist process. For increased productivity, a new bevel cut strategy was investigated and shown to have no adverse impact while increasing the usable wafer surface. However, with the necessity of double patterning for at least the next technology node, more stringent requirements are necessary to prevent, in the worst case, doubling of the critical dimension variation and defectivity. In this work, improvements in process performance with regards to critical dimension uniformity and defectivity are investigated to increase the customer's productivity and yield for whichever double patterning scheme is utilized. Specifically, TEL has designed, evaluated and proven the capability of the latest technology hardware for post exposure bake and defect reduction. For the new post exposure bake hardware, process capability data was collected for 40nm CD targets. For defectivity reduction, a novel concept in rinse technology and processing was investigated on hydrophobic non top coat resists processes. Additionally, improvements to reduce micro bridging were evaluated. Finally bevel rinse hardware to prevent contamination of the immersion scanner was tested.

  2. Collaborative Evolution of Process Plans in Distributed Manufacturing

    SciTech Connect

    Woo, Jungyub; Cho, Hyunbo; Kulvatunyou, Boonserm

    2003-09-01

    Global production has become a new trend in the today?s competitive business environment in pursuit of lower cost, shorter time-to-market, and better quality. This forces manufacturing enterprises to separate design houses and manufacturing facilities. The design houses are located at the forefront of customers to respond to the rapidly changing customers? demands. The manufacturing facilities can be placed in the cost and quality-competitive areas. This physical and logical separation between designers and manufacturers (or between upstream manufacturers and downstream manufacturers), however, raises various integration issues. Particular issues addressed in this paper are the framework for representing the data necessary to communicate requirements and objectives of the designer and the methodology for utilizing such data to optimize the business objectives related to production cost and quality. The proposed representation and collaboration framework as well as methodology enables design houses and manufacturing facilities to realize the actual benefits of global production. They can scale to accommodate management of loosely integrated supply chain.

  3. Model-predictive control of polymer composite manufacturing processes

    NASA Astrophysics Data System (ADS)

    Voorakaranam, Srikanth

    Quality control is crucial for reducing costs and enabling a more widespread use of fiber-resin composites. This research focuses on development of model-based control strategies for controlling product quality in continuous processes for manufacturing polymer composites with injected pultrusion as a prototype. The control objective is to maximize production rates, meeting quality criteria such as eliminating voids, achieving desired degree of cure and preventing backflow of resin from the die entrance. A 2-D mathematical model of IP developed by Kommu is extended to incorporate die dynamics. Exercising the model over a range of operating conditions, the requirements for a control system are formulated. Simultaneous requirements of optimization and control are met by using a cascade strategy consisting of supervisory and regulatory layers. The supervisory layer consists of an optimizer in conjunction with a steady-state cure model and an injection pressure model. The cure model is linear in important process variables. The injection pressure model is also linear in pullspeed. A linear program generates setpoints for pullspeed, injection pressure and temperatures in the three zones of the die which are implemented by the regulatory layer using multiple PID controllers. This formulation operates the process optimally. A major problem in feedback control of the IP process is the inability to measure quality variables on-line. An inferential control strategy is proposed to tackle this. It is then extended so that it can be implemented in a model predictive control formulation. This novel strategy called model predictive inferential control is general enough to accommodate multiple secondary measurements as well as nonlinear estimators and controllers. Collinearity among multiple measurements is addressed through principal component regression. The estimator uses frequent secondary measurements to estimate the effect of the disturbances on the primary variable which are

  4. Intelligent processing equipment developments within the Navy's Manufacturing Technology Centers of Excellence

    NASA Astrophysics Data System (ADS)

    Nanzetta, Philip

    1992-04-01

    The U.S. Navy has had an active Manufacturing Technology (MANTECH) Program aimed at developing advanced production processes and equipment since the late-1960's. During the past decade, however, the resources of the MANTECH program were concentrated in Centers of Excellence. Today, the Navy sponsors four manufacturing technology Centers of Excellence: the Automated Manufacturing Research Facility (AMRF); the Electronics Manufacturing Productivity Facility (EMPF); the National Center for Excellence in Metalworking Technology (NCEMT); and the Center of Excellence for Composites Manufacturing Technology (CECMT). This paper briefly describes each of the centers and summarizes typical Intelligent Equipment Processing (IEP) projects that were undertaken.

  5. Intelligent Processing Equipment Developments Within the Navy's Manufacturing Technology Centers of Excellence

    NASA Technical Reports Server (NTRS)

    Nanzetta, Philip

    1992-01-01

    The U.S. Navy has had an active Manufacturing Technology (MANTECH) Program aimed at developing advanced production processes and equipment since the late-1960's. During the past decade, however, the resources of the MANTECH program were concentrated in Centers of Excellence. Today, the Navy sponsors four manufacturing technology Centers of Excellence: the Automated Manufacturing Research Facility (AMRF); the Electronics Manufacturing Productivity Facility (EMPF); the National Center for Excellence in Metalworking Technology (NCEMT); and the Center of Excellence for Composites Manufacturing Technology (CECMT). This paper briefly describes each of the centers and summarizes typical Intelligent Equipment Processing (IEP) projects that were undertaken.

  6. Developing an inventor support service which performs early stage market and manufacturing evaluations. Final report

    SciTech Connect

    Not Available

    1991-10-01

    American businesses are learning the difficult high cost lesson of ignoring production and market factors (producibility, unit product cost (UPC), marketability, etc) during the engineering design phase of product development. Studies have shown that the Japanese spend three times as long as Americans in the design feasibility and decision process of new product introductions and one third the amount of time in the implementation of those products. There is a 20 to 1 cost benefit on effort applied in the design phase versus the production phase of the product life cycle. The number one goal of this project was to establish an organization that has, as one of its purposes, the providing of services responsive to the needs of independent inventors. The number two goal was to demonstrate the value of providing marketing and manufacturing counsel at an early stage in the product development process. The first study goal was met by providing the materials and information necessary to establish an evaluation team and an organization to handle such evaluations. The second study goal was met by demonstrating the impact of early market analysis and manufacturing considerations on product design and therefore on the description of the invention for four different inventions. These inventions were selected at various stages of development. Regardless of stage of development, the marketing and manufacturing reviews resulted in significant changes in design and/or market positioning.

  7. Developing an inventor support service which performs early stage market and manufacturing evaluations. [Final Report

    SciTech Connect

    Not Available

    1991-10-01

    American businesses are learning the difficult high cost lesson of ignoring production and market factors (producibility, unit product cost (UPC), marketability, etc) during the engineering design phase of product development. Studies have shown that the Japanese spend three times as long as Americans in the design feasibility and decision process of new product introductions and one third the amount of time in the implementation of those products. There is a 20 to 1 cost benefit on effort applied in the design phase versus the production phase of the product life cycle. The number one goal of this project was to establish an organization that has, as one of its purposes, the providing of services responsive to the needs of independent inventors. The number two goal was to demonstrate the value of providing marketing and manufacturing counsel at an early stage in the product development process. The first study goal was met by providing the materials and information necessary to establish an evaluation team and an organization to handle such evaluations. The second study goal was met by demonstrating the impact of early market analysis and manufacturing considerations on product design and therefore on the description of the invention for four different inventions. These inventions were selected at various stages of development. Regardless of stage of development, the marketing and manufacturing reviews resulted in significant changes in design and/or market positioning.

  8. Process for manufacture of semipermeable silicon nitride membranes

    DOEpatents

    Galambos, Paul Charles; Shul, Randy J.; Willison, Christi Gober

    2003-12-09

    A new class of semipermeable membranes, and techniques for their fabrication, have been developed. These membranes, formed by appropriate etching of a deposited silicon nitride layer, are robust, easily manufacturable, and compatible with a wide range of silicon micromachining techniques.

  9. Carbon black dispersion pre-plating technology for printed wire board manufacturing. Final technology evaluation report

    SciTech Connect

    Folsom, D.W.; Gavaskar, A.R.; Jones, J.A.; Olfenbuttel, R.F.

    1993-10-01

    The project compared chemical use, waste generation, cost, and product quality between electroless copper and carbon-black-based preplating technologies at the printed wire board (PWB) manufacturing facility of McCurdy Circuits in Orange, CA. The carbon-black based preplating technology evaluated is used as an alternative process for electroless copper (EC) plating of through-holes before electrolytic copper plating. The specific process used at McCurdy is the BlackHole (BH) technology process, which uses a dispersion of carbon black in an aqueous solution to provide a conductive surface for subsequent electrolytic copper plating. The carbon-black dispersion technology provided effective waste reduction and long-term cost savings. The economic analysis determined that the new process was cost efficient because chemical use was reduced and the process proved more efficient; the payback period was less than 4 yrs.

  10. Evaluation of Select Surface Processing Techniques for In Situ Application During the Additive Manufacturing Build Process

    NASA Astrophysics Data System (ADS)

    Book, Todd A.; Sangid, Michael D.

    2016-07-01

    Although additive manufacturing offers numerous performance advantages for different applications, it is not being used for critical applications due to uncertainties in structural integrity as a result of innate process variability and defects. To minimize uncertainty, the current approach relies on the concurrent utilization of process monitoring, post-processing, and non-destructive inspection in addition to an extensive material qualification process. This paper examines an alternative approach by evaluating the application of select surface process techniques, to include sliding severe plastic deformation (SPD) and fine particle shot peening, on direct metal laser sintering-produced AlSi10Mg materials. Each surface processing technique is compared to baseline as-built and post-processed samples as a proof of concept for surface enhancement. Initial results pairing sliding SPD with the manufacture's recommended thermal stress relief cycle demonstrated uniform recrystallization of the microstructure, resulting in a more homogeneous distribution of strain among the microstructure than as-built or post-processed conditions. This result demonstrates the potential for the in situ application of various surface processing techniques during the layerwise direct metal laser sintering build process.

  11. Evaluation of Select Surface Processing Techniques for In Situ Application During the Additive Manufacturing Build Process

    NASA Astrophysics Data System (ADS)

    Book, Todd A.; Sangid, Michael D.

    2016-03-01

    Although additive manufacturing offers numerous performance advantages for different applications, it is not being used for critical applications due to uncertainties in structural integrity as a result of innate process variability and defects. To minimize uncertainty, the current approach relies on the concurrent utilization of process monitoring, post-processing, and non-destructive inspection in addition to an extensive material qualification process. This paper examines an alternative approach by evaluating the application of select surface process techniques, to include sliding severe plastic deformation (SPD) and fine particle shot peening, on direct metal laser sintering-produced AlSi10Mg materials. Each surface processing technique is compared to baseline as-built and post-processed samples as a proof of concept for surface enhancement. Initial results pairing sliding SPD with the manufacture's recommended thermal stress relief cycle demonstrated uniform recrystallization of the microstructure, resulting in a more homogeneous distribution of strain among the microstructure than as-built or post-processed conditions. This result demonstrates the potential for the in situ application of various surface processing techniques during the layerwise direct metal laser sintering build process.

  12. 77 FR 38083 - Certain Rubber Resins and Processes for Manufacturing Same Institution of Investigation Pursuant...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2012-06-26

    ... COMMISSION Certain Rubber Resins and Processes for Manufacturing Same Institution of Investigation Pursuant... importation, and the sale within the United States after importation of certain rubber resins and processes... rubber resins and processes for manufacturing same by reason of misappropriation of trade secrets,...

  13. 27 CFR 40.1 - Manufacture of tobacco products, cigarette papers and tubes, and processed tobacco.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... products, cigarette papers and tubes, and processed tobacco. 40.1 Section 40.1 Alcohol, Tobacco Products... MANUFACTURE OF TOBACCO PRODUCTS, CIGARETTE PAPERS AND TUBES, AND PROCESSED TOBACCO Scope of Regulations § 40.1 Manufacture of tobacco products, cigarette papers and tubes, and processed tobacco. This part...

  14. 16 CFR 300.25 - Country where wool products are processed or manufactured.

    Code of Federal Regulations, 2010 CFR

    2010-01-01

    ... 16 Commercial Practices 1 2010-01-01 2010-01-01 false Country where wool products are processed or... Country where wool products are processed or manufactured. (a) In addition to the other information... country where such imported product was processed or manufactured; (2) Each wool product completely...

  15. Product and process for manufacturing an optical disc master

    SciTech Connect

    Dobbin, R.B.; Loeppky, D.G.; Norton, J.R.; Del Mar, B.E.

    1994-01-11

    The invention discloses a simplified four step process for making an optical disc master or alternatively a WORM disc by first making or obtaining a transparent polymer disc with a tracking groove of desired geometry molded therein, then spin coating an optically active lamina on the grooved side of the disc, then recording data on said polymer disc with groove controlled and tracked laser means by ablating active lamina, forming pits, the shape of which is determined by the groove geometry and finally depositing a conductive and reflective lamina over the pitted active lamina. To change the OD master to an OD WORM, a protective cover is added to the electrically conductive and optically reflective lamina. 12 figs.

  16. Fuzzy methods in decision making process - A particular approach in manufacturing systems

    NASA Astrophysics Data System (ADS)

    Coroiu, A. M.

    2015-11-01

    We are living in a competitive environment, so we can see and understand that the most of manufacturing firms do the best in order to accomplish meeting demand, increasing quality, decreasing costs, and delivery rate. In present a stake point of interest is represented by the development of fuzzy technology. A particular approach for this is represented through the development of methodologies to enhance the ability to managed complicated optimization and decision making aspects involving non-probabilistic uncertainty with the reason to understand, development, and practice the fuzzy technologies to be used in fields such as economic, engineering, management, and societal problems. Fuzzy analysis represents a method for solving problems which are related to uncertainty and vagueness; it is used in multiple areas, such as engineering and has applications in decision making problems, planning and production. As a definition for decision making process we can use the next one: result of mental processes based upon cognitive process with a main role in the selection of a course of action among several alternatives. Every process of decision making can be represented as a result of a final choice and the output can be represented as an action or as an opinion of choice. Different types of uncertainty can be discovered in a wide variety of optimization and decision making problems related to planning and operation of power systems and subsystems. The mixture of the uncertainty factor in the construction of different models serves for increasing their adequacy and, as a result, the reliability and factual efficiency of decisions based on their analysis. Another definition of decision making process which came to illustrate and sustain the necessity of using fuzzy method: the decision making is an approach of choosing a strategy among many different projects in order to achieve some purposes and is formulated as three different models: high risk decision, usual risk

  17. Process window limiting hot spot monitoring for high-volume manufacturing

    NASA Astrophysics Data System (ADS)

    Jochemsen, Marinus; Anunciado, Roy; Timoshkov, Vadim; Hunsche, Stefan; Zhou, Xinjian; Jones, Chris; Callan, Neal

    2016-03-01

    As process window margins for cutting edge DUV lithography continue to shrink, the impact of systematic patterning defects on final yield increases. Finding process window limiting hot spot patterns and monitoring them in high volume manufacturing (HVM) is increasingly challenging with conventional methods, as the size of critical defects can be below the resolution of traditional HVM inspection tools. We utilize a previously presented computational method of finding hot spot patterns by full chip simulation and use this to guide high resolution review tools by predicting the state of the hot spots on all fields of production wafers. In experiments with a 10nm node Metal LELELE vehicle we show a 60% capture rate of after-etch defects down to 3nm in size, at specific hot spot locations. By using the lithographic focus and dose correction knobs we can reduce the number of patterning defects for this test case by ~60%.

  18. Changes in the Microbial Composition of Microbrewed Beer during the Process in the Actual Manufacturing Line.

    PubMed

    Kim, S A; Jeon, S H; Kim, N H; Kim, H W; Lee, N Y; Cho, T J; Jung, Y M; Lee, S H; Hwang, I G; Rhee, M S

    2015-12-01

    This study investigated changes in the microbial composition of microbrewed beer during the manufacturing processes and identified potential microbial hazards, effective critical quality control points, and potential contamination routes. Comprehensive quantitative (aerobic plate count, lactic acid bacteria, fungi, acetic acid bacteria, coliforms, and Bacillus cereus) and qualitative (Escherichia coli and eight foodborne pathogens) microbiological analyses were performed using samples of raw materials (malt and manufacturing water), semiprocessed products (saccharified wort, boiled wort, and samples taken during the fermentation and maturation process), and the final product obtained from three plants. The initial aerobic plate count and lactic acid bacteria counts in malt were 5.2 and 4.3 log CFU/g, respectively. These counts were reduced to undetectable levels by boiling but were present at 2.9 and 0.9 log CFU/ml in the final product. Fungi were initially present at 3.6 log CFU/g, although again, the microbes were eliminated by boiling; however, the level in the final product was 4.6 log CFU/ml. No E. coli or foodborne pathogens (except B. cereus) were detected. B. cereus was detected at all stages, although it was not present in the water or boiled wort (total detection rate ¼ 16.4%). Results suggest that boiling of the wort is an effective microbial control measure, but careful management of raw materials and implementation of effective control measures after boiling are needed to prevent contamination of the product after the boiling step. The results of this study may constitute useful and comprehensive information regarding the microbiological quality of microbrewed beer. PMID:26613919

  19. System level analysis and control of manufacturing process variation

    DOEpatents

    Hamada, Michael S.; Martz, Harry F.; Eleswarpu, Jay K.; Preissler, Michael J.

    2005-05-31

    A computer-implemented method is implemented for determining the variability of a manufacturing system having a plurality of subsystems. Each subsystem of the plurality of subsystems is characterized by signal factors, noise factors, control factors, and an output response, all having mean and variance values. Response models are then fitted to each subsystem to determine unknown coefficients for use in the response models that characterize the relationship between the signal factors, noise factors, control factors, and the corresponding output response having mean and variance values that are related to the signal factors, noise factors, and control factors. The response models for each subsystem are coupled to model the output of the manufacturing system as a whole. The coefficients of the fitted response models are randomly varied to propagate variances through the plurality of subsystems and values of signal factors and control factors are found to optimize the output of the manufacturing system to meet a specified criterion.

  20. Fundamental Processes in Plasmas. Final report

    SciTech Connect

    O'Neil, Thomas M.; Driscoll, C. Fred

    2009-11-30

    This research focuses on fundamental processes in plasmas, and emphasizes problems for which precise experimental tests of theory can be obtained. Experiments are performed on non-neutral plasmas, utilizing three electron traps and one ion trap with a broad range of operating regimes and diagnostics. Theory is focused on fundamental plasma and fluid processes underlying collisional transport and fluid turbulence, using both analytic techniques and medium-scale numerical simulations. The simplicity of these systems allows a depth of understanding and a precision of comparison between theory and experiment which is rarely possible for neutral plasmas in complex geometry. The recent work has focused on three areas in basic plasma physics. First, experiments and theory have probed fundamental characteristics of plasma waves: from the low-amplitude thermal regime, to inviscid damping and fluid echoes, to cold fluid waves in cryogenic ion plasmas. Second, the wide-ranging effects of dissipative separatrices have been studied experimentally and theoretically, finding novel wave damping and coupling effects and important plasma transport effects. Finally, correlated systems have been investigated experimentally and theoretically: UCSD experients have now measured the Salpeter correlation enhancement, and theory work has characterized the 'guiding center atoms of antihydrogen created at CERN.

  1. Process for the manufacture of 117Sn diethylenetriaminepentaacetic acids

    DOEpatents

    Srivastava, Suresh C.; Li, Zizhong; Meinken, George

    2003-01-01

    Novel methods are provided for the manufacture of .sup.117m Sn(Sn.sup.4+) DTPA. The method allows the use of DTPA, a toxic chelating agent, in an approximately 1:1 ratio to .sup.117m Sn(Sn.sup.4+) via either aqueous conditions, or using various organic solvents, such as methylene chloride. A pharmaceutical composition manufactured by the novel method is also provided, as well as methods for treatment of bone tumors and pain associated with bone cancer using the pharmaceutical composition of the invention.

  2. Development of multifunctional carbon fiber reinforced composites (CFRCs) - Manufacturing process

    NASA Astrophysics Data System (ADS)

    Guadagno, Liberata; Raimondo, Marialuigia; Vietri, Umberto; Barra, Giuseppina; Vertuccio, Luigi; Volponi, Ruggero; Cosentino, Giovanni; De Nicola, Felice; Grilli, Andrea; Spena, Paola

    2014-05-01

    This work describes a successful attempt toward the development of CFRCs based on nanofilled epoxy resins. The epoxy matrix was prepared by mixing a tetrafunctional epoxy precursor with a reactive diluent which allows to reduce the viscosity of the initial epoxy precursor and facilitate the nanofiller dispersion step. As nanofiller, multiwall carbon nanotubes (MWCNTs) were embedded in the epoxy matrix with the aim of improving the electrical properties of the resin used to manufacture CFRCs. Panels were manufactured by Resin Film Infusion (RFI) using a non-usual technique to infuse a nano-filled resin into a carbon fiber dry preform.

  3. 27 CFR 19.4 - Recovery and reuse of denatured spirits in manufacturing processes.

    Code of Federal Regulations, 2011 CFR

    2011-04-01

    ... 27 Alcohol, Tobacco Products and Firearms 1 2011-04-01 2011-04-01 false Recovery and reuse of denatured spirits in manufacturing processes. 19.4 Section 19.4 Alcohol, Tobacco Products and Firearms... General Provisions § 19.4 Recovery and reuse of denatured spirits in manufacturing processes....

  4. 27 CFR 19.4 - Recovery and reuse of denatured spirits in manufacturing processes.

    Code of Federal Regulations, 2013 CFR

    2013-04-01

    ... 27 Alcohol, Tobacco Products and Firearms 1 2013-04-01 2013-04-01 false Recovery and reuse of denatured spirits in manufacturing processes. 19.4 Section 19.4 Alcohol, Tobacco Products and Firearms... General Provisions § 19.4 Recovery and reuse of denatured spirits in manufacturing processes....

  5. 27 CFR 19.4 - Recovery and reuse of denatured spirits in manufacturing processes.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... 27 Alcohol, Tobacco Products and Firearms 1 2014-04-01 2014-04-01 false Recovery and reuse of denatured spirits in manufacturing processes. 19.4 Section 19.4 Alcohol, Tobacco Products and Firearms... General Provisions § 19.4 Recovery and reuse of denatured spirits in manufacturing processes....

  6. 27 CFR 19.4 - Recovery and reuse of denatured spirits in manufacturing processes.

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... 27 Alcohol, Tobacco Products and Firearms 1 2012-04-01 2012-04-01 false Recovery and reuse of denatured spirits in manufacturing processes. 19.4 Section 19.4 Alcohol, Tobacco Products and Firearms... General Provisions § 19.4 Recovery and reuse of denatured spirits in manufacturing processes....

  7. An approach to selection of material and manufacturing processes for rocket motor cases using weighted performance index

    NASA Astrophysics Data System (ADS)

    Rajan, K. M.; Narasimhan, K.

    2002-08-01

    Material selection is a very critical design decision, which has a profound influence on the entire development program for rocket motor cases. In the selection process, the main performance parameters and the most appropriate fabrication technology with proven processes must be considered. Many years of practical experience in material selection process with a thorough understanding of materials behavior under various loading environments and hands-on experiences with various available manufacturing processes are of immense help to the design and development engineer for successful completion of the development program. In this paper, an attempt has been made to present an approach for selecting appropriate material and manufacturing process for rocket motor case based on method of Weighted Performance Index (WPI) with the hope that this approach will also provide additional aid to the design engineer for the selection of material and manufacturing process for rocket motor cases. In this method, different properties are assigned a certain weight depending upon their importance to the service requirements. Different properties are normalized using a scaling factor, and finally a weighted property index is computed. The material that scored the maximum numerical value is chosen as the material for fabrication. This approach closely matches with the actual performance. Maraging steel and D6AC are found to be the preferred materials for rocket motor cases for critical missions. HSLA steels are appropriate for less-critical applications, in which rocket motor cases are required in very large numbers (e.g., flow-formed AISI 4130 motor cases[8]). For the selection of an appropriate manufacturing method, the major parameters considered are dimensional accuracy, cost of production, minimum material waste, and flexibility in design. Again, these properties are given a relative grading, which is then converted into a scaled property. Finally, the weighted performance indices

  8. Development of an Improved Process for Installation Projects of High Technology Manufacturing Equipment

    SciTech Connect

    Quintana, Sarah V.

    2014-04-30

    High technology manufacturing equipment is utilized at Los Alamos National Laboratory (LANL) to support nuclear missions. This is undertaken from concept initiation where equipment is designed and then taken through several review phases, working closely with system engineers (SEs) responsible for each of the affected systems or involved disciplines (from gasses to HVAC to structural, etc.). After the design is finalized it moves to procurement and custom fabrication of the equipment and equipment installation, including all of the paperwork involved. Not only are the engineering and manufacturing aspects important, but also the scheduling, financial forecasting, and planning portions that take place initially and are sometimes modified as the project progresses should requirements, changes or additions become necessary. The process required to complete a project of this type, including equipment installation, is unique and involves numerous steps to complete. These processes can be improved and recent work on the Direct Current Arc (DC Arc) Glovebox Design, Fabrication and Installation Project provides an opportunity to identify some important lessons learned (LL) that can be implemented in the future for continued project improvement and success.

  9. Double Vacuum Bag Process for Resin Matrix Composite Manufacturing

    NASA Technical Reports Server (NTRS)

    Hou, Tan-Hung (Inventor); Jensen, Brian J. (Inventor)

    2007-01-01

    A double vacuum bag molding assembly with improved void management and laminate net shape control which provides a double vacuum enviromnent for use in fabricating composites from prepregs containing air and/or volatiles such as reactive resin matrix composites or composites from solvent containing prepregs with non-reactive resins matrices. By using two vacuum environments during the curing process, a vacuum can be drawn during a B-stage of a two-step cycle without placing the composite under significant relative pressure. During the final cure stage, a significant pressure can be applied by releasing the vacuum in one of the two environments. Inner and outer bags are useful for creating the two vacuum environments with a perforated tool intermediate the two. The composite is placed intermediate a tool plate and a caul plate in the first environment with the inner bag and tool plate defining the first environment. The second environment is characterized by the outer bag which is placed over the inner bag and the tool plate.

  10. Mirror Fusion Test Facility-B (MFTF-B) axicell configuration: NbTi magnet system. Manufacturing/producibility final report. Volume 2

    SciTech Connect

    Ritschel, A.J.; White, W.L.

    1985-05-01

    This Final MFTF-B Manufacturing/Producibility Report covers facilities, tooling plan, manufacturing sequence, schedule and performance, producibility, and lessons learned for the solenoid, axicell, and transition coils, as well as a deactivation plan, conclusions, references, and appendices.

  11. ENVIRONMENTAL CONSIDERATIONS OF SELECTED ENERGY-CONSERVING MANUFACTURING PROCESS OPTIONS. VOLUME XVII. NITROGEN OXIDES SUMMARY REPORT

    EPA Science Inventory

    Arthur D. Little, Inc. undertook a study of the 'Environmental Consideration of Selected Energy-Conserving Manufacturing Process Options.' Some 80 industrial process options were examined in 13 industrial sectors. Results were published in 15 volumes, including a summary, industr...

  12. ENVIRONMENTAL CONSIDERATIONS OF SELECTED ENERGY-CONSERVING MANUFACTURING PROCESS OPTIONS. VOLUME XX: TOXICS/ORGANICS

    EPA Science Inventory

    Arthur D. Little, Inc. undertook a study of the 'Environmental Considerations of Selected Energy-Conserving Manufacturing Process Options.' Some 80 industrial process options were examined in13 industrial sectors. Results were published in 15 volumes, including a summary, industr...

  13. Environmentally Conscious Manufacturing Solvent Substitution Program/switch tube assemblies final report

    SciTech Connect

    Lopez, E.P.; Ohlhausen, J.A.; Peebles, D.E.; Benkovich, M.G.

    1995-06-01

    As part of an Environmentally Conscious Manufacturing (ECM) Program, a study was conducted at Sandia National Laboratories to identify an alternative cleaning process that would effectively replace trichloroethylene (TCE) for cleaning mechanical piece parts of Switch Tube assemblies. Eight aqueous alkaline cleaners, as well as an isopropyl alcohol and isopropyl alcohol/Cyclohexane cleaning process, were studied as potential replacements. Cleaning efficacy, materials compatibility, etch rate and corrosion studies were conducted and used to screen potential candidates. Cleaning efficacy was determined using visual examination, goniometer/contact angle measurements, Auger electron spectroscopy, X-ray Photoelectron spectroscopy and an evaporative rate analysis technique known as MESERAN Surface Analysis. Several cleaners were identified as potential replacements for TCE based solely on the cleaning efficacy results. Some of the cleaners, however, left undesirable residues studies were completed, Brulin 815GD (an aqueous alkaline cleaner) was selected as the replacement for TCE.

  14. Manufacturing process applications team (MATeam). [NASA/industry relations

    NASA Technical Reports Server (NTRS)

    Bangs, E. R.

    1978-01-01

    Forty additional statements were added to the list of 150 problem/opportunity statements identifying possibilities for transfer of NASA technology to various manufacturing industries. Selected statements that are considered to have a high potential for transfer in the 1978 program year are presented in the form of goals and milestones. The transfer of a flux used in the stud welding of aluminum is reported. Candidate RTOP programs are identified.

  15. Manufacturing technology for improved low-cost electroslag materials and components for application in fossil-energy systems. Final report

    SciTech Connect

    Bhat, G.K.

    1982-03-01

    Safe, reliable and long term service of critical components used in fossil energy systems are major objectives of DOE's materials research and fabrication technology programs. The use of electroslag refined materials and electroslag cast components in chemical processing, petrochemical, nuclear power generation and fossil energy conversion systems has become quite common in the USSR, Japan, Western and Eastern European countries. Elecroslag cast components as lower cost alternates to forged components have performed exceedingly well in such critical applications. The aim of this program is to broaden the technology base of the novel electroslag casting process for improving its application potential in the fossil energy systems construction industry. The specific objectives of this project were to determine (a) the economics and (b) the technical factors which determine the value of using electroslag casting process for the manufacture of components of various fossil energy systems. The castings of carbon steel so produced have exhibited mechanical properties equal to and in some instances superior to similar shapes produced by conventional forging method. The possibilities of attaining lower final cost of the electroslag cast component compared to similar shaped forging appear very promising. Specification approval based on current code standards is a deterrent to acceptability of electroslag cast materials and components for many industrial applications. These and other process aspects which need further investigations are outlined.

  16. [Data integration, data mining and visualization analysis of traditional Chinese medicine manufacturing process].

    PubMed

    Li, Zheng; Kang, Li-Yuan; Fan, Xiao-Hui

    2014-08-01

    Huge amount of data becomes available from the pharmaceutical manufacturing process with wide application of in- dustrial automatic control technology in traditional Chinese medicine (TCM) industry. The industrial big data thus provides golden op- portunities to better understand the manufacturing process and improve the process performance. Therefore it is important to implement data integration and management systems in TCM plants to easily collect, integrate, store, analyze, communicate and visulize the data with high efficiency. It could break the data island and discover useful information and knowledge to improve the manufacturing process performance. The key supporting technologies for TCM manufacturing and industrial big data management were introduced in this paper, with a specific focus on data mining and visualization technologies. Using historic data collected from a manufacturing plant of Shengmai injection of SZYY group, we illustrated the usefulness and discussed future prospects of data mining and visualization technologies. PMID:25423846

  17. [Data integration, data mining and visualization analysis of traditional Chinese medicine manufacturing process].

    PubMed

    Li, Zheng; Kang, Li-Yuan; Fan, Xiao-Hui

    2014-08-01

    Huge amount of data becomes available from the pharmaceutical manufacturing process with wide application of in- dustrial automatic control technology in traditional Chinese medicine (TCM) industry. The industrial big data thus provides golden op- portunities to better understand the manufacturing process and improve the process performance. Therefore it is important to implement data integration and management systems in TCM plants to easily collect, integrate, store, analyze, communicate and visulize the data with high efficiency. It could break the data island and discover useful information and knowledge to improve the manufacturing process performance. The key supporting technologies for TCM manufacturing and industrial big data management were introduced in this paper, with a specific focus on data mining and visualization technologies. Using historic data collected from a manufacturing plant of Shengmai injection of SZYY group, we illustrated the usefulness and discussed future prospects of data mining and visualization technologies. PMID:25507568

  18. Development of Integrated Programs for Aerospace-vehicle Design (IPAD): Product manufacture interactions with the design process

    NASA Technical Reports Server (NTRS)

    Crowell, H. A.

    1979-01-01

    The product manufacturing interactions with the design process and the IPAD requirements to support the interactions are described. The data requirements supplied to manufacturing by design are identified and quantified. Trends in computer-aided manufacturing are discussed and the manufacturing process of the 1980's is anticipated.

  19. Imaging-based optical caliper for objects in hot manufacturing processes

    SciTech Connect

    Huang, Howard

    2013-04-03

    OG Technologies, Inc. (OGT), in conjunction with its industrial and academic partners, proposes to develop an Imaging-Based Optical Caliper (hereafter referred to as OC) for Objects in Hot Manufacturing Processes. The goal is to develop and demonstrate the OC with the synergy of OGT's current technological pool and other innovations to provide a light weight, robust, safe and accurate portable dimensional measurement device for hot objects with integrated wireless communication capacity to enable real time process control. The technical areas of interest in this project are the combination of advanced imaging, Sensor Fusion, and process control. OGT believes that the synergistic interactions between its current set of technologies and other innovations could deliver products that are viable and have high impact in the hot manufacture processes, such as steel making, steel rolling, open die forging, and glass industries, resulting in a new energy efficient control paradigm in the operations through improved yield, prolonged tool life and improved quality. In-line dimension measurement and control is of interest to the steel makers, yet current industry focus is on the final product dimension only instead of whole process due to the limit of man power, system cost and operator safety concerns. As sensor technologies advances, the industry started to see the need to enforce better dimensional control throughout the process, but lack the proper tools to do so. OGT along with its industrial partners represent the indigenous effort of technological development to serve the US steel industry. The immediate market that can use and get benefited from the proposed OC is the Steel Industry. The deployment of the OC has the potential to provide benefits in reduction of energy waste, CO2 emission, waste water amount, toxic waste, and so forth. The potential market after further expended function includes Hot Forging and Freight Industries. The OC prototypes were fabricated, and

  20. Physical verification and manufacturing of contact/via layers using grapho-epitaxy DSA processes

    NASA Astrophysics Data System (ADS)

    Torres, J. Andres; Sakajiri, Kyohei; Fryer, David; Granik, Yuri; Ma, Yuansheng; Krasnova, Polina; Fenger, Germain; Nagahara, Seiji; Kawakami, Shinichiro; Rathsack, Benjamen; Khaira, Gurdaman; de Pablo, Juan; Ryckaert, Julien

    2014-03-01

    This paper extends the state of the art by describing the practical material's challenges, as well as approaches to minimize their impact in the manufacture of contact/via layers using a grapho-epitaxy directed self assembly (DSA) process. Three full designs have been analyzed from the point of view of layout constructs. A construct is an atomic and repetitive section of the layout which can be analyzed in isolation. Results indicate that DSA's main benefit is its ability to be resilient to the shape of the guiding pattern across process window. The results suggest that directed self assembly can still be guaranteed even with high distortion of the guiding patterns when the guiding patterns have been designed properly for the target process. Focusing on a 14nm process based on 193i lithography, we present evidence of the need of DSA compliance methods and mask synthesis tools which consider pattern dependencies of adjacent structures a few microns away. Finally, an outlook as to the guidelines and challenges to DSA copolymer mixtures and process are discussed highlighting the benefits of mixtures of homo polymer and diblock copolymer to reduce the number of defects of arbitrarily placed hole configurations.

  1. Process for the manufacture of carbon or graphite fibers

    NASA Technical Reports Server (NTRS)

    Overhoff, D.; Winkler, E.; Mueller, D.

    1979-01-01

    Carbon or graphite fibers are manufactured by heating polyacrylonitrile fiber materials in various solutions and gases. They are characterized in that the materials are heated to temperatures from 150 to 300 C in a solution containing one or more acids from the group of carbonic acids, sulfonic acids, and/or phenols. The original molecular orientation of the fibers is preserved by the cyclization that occurs before interlacing, which gives very strong and stiff carbon or graphite fibers without additional high temperature stretching treatments.

  2. An Introduction to Intelligent Processing Programs Developed by the Air Force Manufacturing Technology Directorate

    NASA Technical Reports Server (NTRS)

    Sampson, Paul G.; Sny, Linda C.

    1992-01-01

    The Air Force has numerous on-going manufacturing and integration development programs (machine tools, composites, metals, assembly, and electronics) which are instrumental in improving productivity in the aerospace industry, but more importantly, have identified strategies and technologies required for the integration of advanced processing equipment. An introduction to four current Air Force Manufacturing Technology Directorate (ManTech) manufacturing areas is provided. Research is being carried out in the following areas: (1) machining initiatives for aerospace subcontractors which provide for advanced technology and innovative manufacturing strategies to increase the capabilities of small shops; (2) innovative approaches to advance machine tool products and manufacturing processes; (3) innovative approaches to advance sensors for process control in machine tools; and (4) efforts currently underway to develop, with the support of industry, the Next Generation Workstation/Machine Controller (Low-End Controller Task).

  3. Using experimental design modules for process characterization in manufacturing/materials processes laboratories

    NASA Technical Reports Server (NTRS)

    Ankenman, Bruce; Ermer, Donald; Clum, James A.

    1994-01-01

    Modules dealing with statistical experimental design (SED), process modeling and improvement, and response surface methods have been developed and tested in two laboratory courses. One course was a manufacturing processes course in Mechanical Engineering and the other course was a materials processing course in Materials Science and Engineering. Each module is used as an 'experiment' in the course with the intent that subsequent course experiments will use SED methods for analysis and interpretation of data. Evaluation of the modules' effectiveness has been done by both survey questionnaires and inclusion of the module methodology in course examination questions. Results of the evaluation have been very positive. Those evaluation results and details of the modules' content and implementation are presented. The modules represent an important component for updating laboratory instruction and to provide training in quality for improved engineering practice.

  4. Closing the Competency Gap in Manufacturing Processes as It Applies to New Engineering Graduates

    ERIC Educational Resources Information Center

    Ssemakula, Mukasa; Liao, Gene; Ellis, Darin

    2010-01-01

    Industry has consistently identified lack of experience in manufacturing processes as one of the key competency gaps among new engineering graduates. This paper discusses a laboratory-based course that provides realistic hands-on manufacturing experiences to students. The course uses team-based projects that help students gain hands-on experience…

  5. Process optimization for the manufacture of angoori petha.

    PubMed

    Singh, Sudhir; Kumar, Umesh; Rai, Ashutosh

    2014-05-01

    Angoori petha (AP) is delicacy which is relished by large section of Indian population. Fully ripened ash gourd fruits were osmotically dehydrated at different lime water concentration, lime water treatment time and sugar concentration for the manufacture of AP. The response variables consisted of sensory parameter for flavour, body and texture, colour and appearance and overall acceptability and physico-chemical properties. A central composite rotatable design (CCRD) was used as experimental design to predict the optimum conditions for manufacture of petha. The interaction of lime water concentration and lime water treatment time had significant (P < 0.05) effect for flavour, body and texture, colour and appearance and overall acceptability score (OAA) score in AP. The colour and appearance score had declining trend with increase the lime water treatment time and lime water concentration. Reducing sugar varied from 1.0% to 2.0%. The mean values for total invert sugar, sucrose and total sugar were in the range of 31.6-68.3%, 30.6-66.9% and 31.6-68.4%, respectively in different runs of AP samples. The optimum osmotic diffusion treatment consisted of lime water concentration of 12.6%, lime water treatment time of 54.1 min and sugar concentration of 87.9% for maximum acceptability in AP. PMID:24803695

  6. Analytic network process model for sustainable lean and green manufacturing performance indicator

    NASA Astrophysics Data System (ADS)

    Aminuddin, Adam Shariff Adli; Nawawi, Mohd Kamal Mohd; Mohamed, Nik Mohd Zuki Nik

    2014-09-01

    Sustainable manufacturing is regarded as the most complex manufacturing paradigm to date as it holds the widest scope of requirements. In addition, its three major pillars of economic, environment and society though distinct, have some overlapping among each of its elements. Even though the concept of sustainability is not new, the development of the performance indicator still needs a lot of improvement due to its multifaceted nature, which requires integrated approach to solve the problem. This paper proposed the best combination of criteria en route a robust sustainable manufacturing performance indicator formation via Analytic Network Process (ANP). The integrated lean, green and sustainable ANP model can be used to comprehend the complex decision system of the sustainability assessment. The finding shows that green manufacturing is more sustainable than lean manufacturing. It also illustrates that procurement practice is the most important criteria in the sustainable manufacturing performance indicator.

  7. Extraterrestrial processing and manufacturing of large space systems. Volume 3: Executive summary

    NASA Technical Reports Server (NTRS)

    Miller, R. H.; Smith, D. B. S.

    1979-01-01

    Facilities and equipment are defined for refining processes to commercial grade of lunar material that is delivered to a 'space manufacturing facility' in beneficiated, primary processed quality. The manufacturing facilities and the equipment for producing elements of large space systems from these materials and providing programmatic assessments of the concepts are also defined. In-space production processes of solar cells (by vapor deposition) and arrays, structures and joints, conduits, waveguides, RF equipment radiators, wire cables, converters, and others are described.

  8. High Volume Manufacturing of Silicon-Film Solar Cells and Modules; Final Subcontract Report, 26 February 2003 - 30 September 2003

    SciTech Connect

    Rand, J. A.; Culik, J. S.

    2005-10-01

    The objective of the PV Manufacturing R&D subcontract was to continue to improve AstroPower's technology for manufacturing Silicon-Film* wafers, solar cells, and modules to reduce costs, and increase production yield, throughput, and capacity. As part of the effort, new technology such as the continuous back metallization screen-printing system and the laser scribing system were developed and implemented. Existing processes, such as the silicon nitride antireflection coating system and the fire-through process were optimized. Improvements were made to the statistical process control (SPC) systems of the major manufacturing processes: feedstock preparation, wafer growth, surface etch, diffusion, and the antireflection coating process. These process improvements and improved process control have led to an increase of 5% relative power, and nearly 15% relative improvement in mechanical and visual yield.

  9. 40 CFR 61.134 - Standard: Naphthalene processing, final coolers, and final-cooler cooling towers.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... POLLUTANTS National Emission Standard for Benzene Emissions from Coke By-Product Recovery Plants § 61.134... are allowed from naphthalene processing, final coolers and final-cooler cooling towers at coke...

  10. 40 CFR 61.134 - Standard: Naphthalene processing, final coolers, and final-cooler cooling towers.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... POLLUTANTS National Emission Standard for Benzene Emissions from Coke By-Product Recovery Plants § 61.134... are allowed from naphthalene processing, final coolers and final-cooler cooling towers at coke...

  11. 40 CFR 61.134 - Standard: Naphthalene processing, final coolers, and final-cooler cooling towers.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... POLLUTANTS National Emission Standard for Benzene Emissions from Coke By-Product Recovery Plants § 61.134... are allowed from naphthalene processing, final coolers and final-cooler cooling towers at coke...

  12. 40 CFR 61.134 - Standard: Naphthalene processing, final coolers, and final-cooler cooling towers.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... POLLUTANTS National Emission Standard for Benzene Emissions from Coke By-Product Recovery Plants § 61.134... are allowed from naphthalene processing, final coolers and final-cooler cooling towers at coke...

  13. 40 CFR 61.134 - Standard: Naphthalene processing, final coolers, and final-cooler cooling towers.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... POLLUTANTS National Emission Standard for Benzene Emissions from Coke By-Product Recovery Plants § 61.134... are allowed from naphthalene processing, final coolers and final-cooler cooling towers at coke...

  14. Development of Pulsed Processes for the Manufacture of Solar Cells

    NASA Technical Reports Server (NTRS)

    1979-01-01

    The development status of the process based upon ion implantation for the introduction of junctions and back surface fields is described. A process sequence is presented employing ion implantation and pulse processing. Efforts to improve throughout and descrease process element costs for furnace annealing are described. Design studies for a modular 3,000 wafer per hour pulse processor are discussed.

  15. Pathogen safety of intravenous Rh immunoglobulin liquid and other immune globulin products: enhanced nanofiltration and manufacturing process overview.

    PubMed

    Soluk, Lori; Price, Hugh; Sinclair, Chris; Atalla-Mikhail, Dina; Genereux, Maurice

    2008-01-01

    Plasma products for therapeutic use pose specific challenges in manufacturing to ensure products maintain biologic activity and are safe with respect to contamination and transmission of disease-causing agents. Various processes have demonstrated effectiveness in eliminating, reducing, or inactivating viral contaminants. Recently, the possibility of transmitting variant Creutzfeld-Jakob disease (vCJD) or transmissible spongiform encephalopathies (TSE) through blood-based products has become a concern. The present study involves the validation of a hyperimmune immunoglobulin manufacturing process incorporating a nanofiltration step with a nominal pore size of 20 nm for removal of viral contaminants and other adventitious agents. Processing intermediates during the manufacture of IV Rh IgG (WinRho SDF/WinRho SDF Liquid, Cangene Corporation, Manitoba, Canada) were spiked with model viruses and processed in scaled-down procedures to validate the viral reduction capacity of each step. Anion-exchange chromatography and solvent/detergent steps are known to contribute to virus removal and inactivation. The Planova 20 N nanofiltration step was effective in reducing model viruses representing a wide range of viral morphologies with varying degrees of resistance to physicochemical inactivation. All in-process and final batch testing met current standards for production of IV Rh IgG manufactured with the previously licensed filter, which had a larger nominal pore size of 35 nm. The manufacturing process, employing a Planova 35 N filtration step, has been proactively improved by the change to a smaller-pore 20 N filter. Replacement of the 35 N filter with the 20 N filter produces a similar product while enhancing the capability for removal of smaller viruses and prions. PMID:18806519

  16. 1995 national heat transfer conference: Proceedings. Volume 4: Transport phenomena in manufacturing and materials processing; Transport phenomena in materials joining processes; Transport phenomena in net shape manufacturing; HTD-Volume 306

    SciTech Connect

    Mahajan, R.L.

    1995-12-31

    This book is divided into three sections: (1) transport phenomena in manufacturing and materials processing; (2) transport phenomena in net shape manufacturing: and (3) transport phenomena in materials joining processes. Separate abstracts were prepared for most papers in this volume.

  17. Cast Polycrystalline Photovoltaic Module Manufacturing Technology Improvements; Final Subcontract Report, 8 December 199330 April 1998

    SciTech Connect

    J. Wohlgemuth.

    1999-06-16

    This report summarizes work performed by Solarex, A Business Unit of Amoco/Enron Solar, under this subcontract. Among the accomplishments during the program are the following: Converting all of the production casting stations to increase ingot size, operating them at equivalent yields and cell efficiencies, and thus doubling the casting capacity at a 20% lower cost than the cost of new equipment. Developing a wire-saw process and transferring the process to production; as a result, more than 80% of wafering is now done using wire saws, at higher yields and lower costs than achieved on the internal diameter saws. Developing an aluminum paste back-surface field (BSF) process to increase cell efficiency by 5%; researchers also designed, procured, and transferred to manufacturing a fully automated printing system to produce the BSF cells. Fabricating 15.2-cm by 15.2-cm polycrystalline silicon solar cells and building modules using these cells. Modifying the module assembly area to increase capacity by a factor of three. Implementing a single-layer Tedlar backsheet that reduced backsheet cost by $0.50/ft2. Selecting, testing, and qualifying a low-cost (< $1.00 per module) electrical termination system. Qualifying the structure and adhesive system for mounting frameless modules and using the system to build several large arrays.

  18. Microeconomics of yield learning and process control in semiconductor manufacturing

    NASA Astrophysics Data System (ADS)

    Monahan, Kevin M.

    2003-06-01

    Simple microeconomic models that directly link yield learning to profitability in semiconductor manufacturing have been rare or non-existent. In this work, we review such a model and provide links to inspection capability and cost. Using a small number of input parameters, we explain current yield management practices in 200mm factories. The model is then used to extrapolate requirements for 300mm factories, including the impact of technology transitions to 130nm design rules and below. We show that the dramatic increase in value per wafer at the 300mm transition becomes a driver for increasing metrology and inspection capability and sampling. These analyses correlate well wtih actual factory data and often identify millions of dollars in potential cost savings. We demonstrate this using the example of grating-based overlay metrology for the 65nm node.

  19. Thin film photovoltaic device and process of manufacture

    DOEpatents

    Albright, Scot P.; Chamberlin, Rhodes

    1997-10-07

    Provided is a thin film photovoltaic device and a method of manufacturing the device. The thin film photovoltaic device comprises a film layer having particles which are smaller than about 30 microns in size held in an electrically insulating matrix material to reduce the potential for electrical shorting through the film layer. The film layer may be provided by depositing preformed particles onto a surrogate substrate and binding the particles in a film-forming matrix material to form a flexible sheet with the film layer. The flexible sheet may be separated from the surrogate substrate and cut into flexible strips. A plurality of the flexible strips may be located adjacent to and supported by a common supporting substrate to form a photovoltaic module having a plurality of electrically interconnected photovoltaic cells.

  20. Thin film photovoltaic device and process of manufacture

    DOEpatents

    Albright, Scot P.; Chamberlin, Rhodes

    1999-02-09

    Provided is a thin film photovoltaic device and a method of manufacturing the device. The thin film photovoltaic device comprises a film layer having particles which are smaller than about 30 microns in size held in an electrically insulating matrix material to reduce the potential for electrical shorting through the film layer. The film layer may be provided by depositing preformed particles onto a surrogate substrate and binding the particles in a film-forming matrix material to form a flexible sheet with the film layer. The flexible sheet may be separated from the surrogate substrate and cut into flexible strips. A plurality of the flexible strips may be located adjacent to and supported by a common supporting substrate to form a photovoltaic module having a plurality of electrically interconnected photovoltaic cells.

  1. Thin film photovoltaic device and process of manufacture

    DOEpatents

    Albright, S.P.; Chamberlin, R.

    1997-10-07

    Provided is a thin film photovoltaic device and a method of manufacturing the device. The thin film photovoltaic device comprises a film layer having particles which are smaller than about 30 microns in size held in an electrically insulating matrix material to reduce the potential for electrical shorting through the film layer. The film layer may be provided by depositing preformed particles onto a surrogate substrate and binding the particles in a film-forming matrix material to form a flexible sheet with the film layer. The flexible sheet may be separated from the surrogate substrate and cut into flexible strips. A plurality of the flexible strips may be located adjacent to and supported by a common supporting substrate to form a photovoltaic module having a plurality of electrically interconnected photovoltaic cells. 13 figs.

  2. Thin film photovoltaic device and process of manufacture

    DOEpatents

    Albright, S.P.; Chamberlin, R.

    1999-02-09

    Provided is a thin film photovoltaic device and a method of manufacturing the device. The thin film photovoltaic device comprises a film layer having particles which are smaller than about 30 microns in size held in an electrically insulating matrix material to reduce the potential for electrical shorting through the film layer. The film layer may be provided by depositing preformed particles onto a surrogate substrate and binding the particles in a film-forming matrix material to form a flexible sheet with the film layer. The flexible sheet may be separated from the surrogate substrate and cut into flexible strips. A plurality of the flexible strips may be located adjacent to and supported by a common supporting substrate to form a photovoltaic module having a plurality of electrically interconnected photovoltaic cells. 13 figs.

  3. Study of process variables associated with manufacturing hermetically-sealed nickel-cadmium cells

    NASA Technical Reports Server (NTRS)

    Miller, L.

    1974-01-01

    A two year study of the major process variables associated with the manufacturing process for sealed, nickel-cadmium, areospace cells is summarized. Effort was directed toward identifying the major process variables associated with a manufacturing process, experimentally assessing each variable's effect, and imposing the necessary changes (optimization) and controls for the critical process variables to improve results and uniformity. A critical process variable associated with the sintered nickel plaque manufacturing process was identified as the manual forming operation. Critical process variables identified with the positive electrode impregnation/polarization process were impregnation solution temperature, free acid content, vacuum impregnation, and sintered plaque strength. Positive and negative electrodes were identified as a major source of carbonate contamination in sealed cells.

  4. Linking process, structure, property, and performance for metal-based additive manufacturing: computational approaches with experimental support

    NASA Astrophysics Data System (ADS)

    Smith, Jacob; Xiong, Wei; Yan, Wentao; Lin, Stephen; Cheng, Puikei; Kafka, Orion L.; Wagner, Gregory J.; Cao, Jian; Liu, Wing Kam

    2016-04-01

    Additive manufacturing (AM) methods for rapid prototyping of 3D materials (3D printing) have become increasingly popular with a particular recent emphasis on those methods used for metallic materials. These processes typically involve an accumulation of cyclic phase changes. The widespread interest in these methods is largely stimulated by their unique ability to create components of considerable complexity. However, modeling such processes is exceedingly difficult due to the highly localized and drastic material evolution that often occurs over the course of the manufacture time of each component. Final product characterization and validation are currently driven primarily by experimental means as a result of the lack of robust modeling procedures. In the present work, the authors discuss primary detrimental hurdles that have plagued effective modeling of AM methods for metallic materials while also providing logical speculation into preferable research directions for overcoming these hurdles. The primary focus of this work encompasses the specific areas of high-performance computing, multiscale modeling, materials characterization, process modeling, experimentation, and validation for final product performance of additively manufactured metallic components.

  5. Advanced Bio-Based Nanocomposites and Manufacturing Processes

    NASA Astrophysics Data System (ADS)

    Spinella, Stephen Matthew

    The aim of the PhD thesis concerns with the modification of cellulose nanocrystals (CNCs) via esterification or a radical grafting "from" approach to achieve polymeric nanocomposites of exceptional properties (Chapters 1 to 4). In addition to CNCs modification, other green routes have been introduced in this thesis in order to environmentally friendly polyester-based materials, i.e. Chapters five and six. The second chapter focuses on expanding on a one-pot cellulose acid hydrolysis/Fischer esterification to produce highly compatible CNCs without any organic solvent. It consists of modifying CNCs with acetic- and lactic- acid and exploring how such surface chemistry has an effect of dispersion in the case of polylactide (PLA)-based nanocomposites. The degree of substitution for AA-CNCs and LA-CNCs, determined by FTIR, are 0.12 and 0.13, respectively. PLA-based materials represent the best bioplastics relating to its high stiffness and biodegradability, but suffer from its poor thermal performances, namely its Heat Deflection Temperature (HDT). To improve the HDT of PLA, nanocomposites have been therefore prepared with modified cellulose nanocrystals (CNCs) by melt blending. After blending at 5 wt-% loading of CNCs, LA-CNCs gives superior reinforcement below and above the glass temperature of PLA. An increase in PLA's heat deflection temperature by 10°C and 20°C is achieved by melt-blending PLA with 5 and 20 wt-% LA-CNCs, respectively. Chapter three concerns with expanding this process to a series of hydrophilic and hydrophobic acids yielding functional CNCs for electronic and biomedical applications. Hydrophilic acids include citric-, malonic- and malic acid. Modification with the abovementioned organic acids allows for the introduction of free acids onto the surface of CNCs. Modification with citric-, malonic- and malic- acid is verified by Fourier Transform Infrared Spectroscopy and 13C solid state magic-angle spinning (MAS) NMR experiments. The degree of

  6. 78 FR 36786 - Linking Marketplace Heparin Product Attributes and Manufacturing Processes to Bioactivity and...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2013-06-19

    ... HUMAN SERVICES Food and Drug Administration Linking Marketplace Heparin Product Attributes and Manufacturing Processes to Bioactivity and Immunogenicity AGENCY: Food and Drug Administration, HHS. ACTION: Notice. SUMMARY: The Food and Drug Administration (FDA) is announcing the availability of grant funds...

  7. Towards a commercial process for the manufacture of genetically modified T cells for therapy

    PubMed Central

    Kaiser, A D; Assenmacher, M; Schröder, B; Meyer, M; Orentas, R; Bethke, U; Dropulic, B

    2015-01-01

    The recent successes of adoptive T-cell immunotherapy for the treatment of hematologic malignancies have highlighted the need for manufacturing processes that are robust and scalable for product commercialization. Here we review some of the more outstanding issues surrounding commercial scale manufacturing of personalized-adoptive T-cell medicinal products. These include closed system operations, improving process robustness and simplifying work flows, reducing labor intensity by implementing process automation, scalability and cost, as well as appropriate testing and tracking of products, all while maintaining strict adherence to Current Good Manufacturing Practices and regulatory guidelines. A decentralized manufacturing model is proposed, where in the future patients' cells could be processed at the point-of-care in the hospital. PMID:25613483

  8. Towards a commercial process for the manufacture of genetically modified T cells for therapy.

    PubMed

    Kaiser, A D; Assenmacher, M; Schröder, B; Meyer, M; Orentas, R; Bethke, U; Dropulic, B

    2015-03-01

    The recent successes of adoptive T-cell immunotherapy for the treatment of hematologic malignancies have highlighted the need for manufacturing processes that are robust and scalable for product commercialization. Here we review some of the more outstanding issues surrounding commercial scale manufacturing of personalized-adoptive T-cell medicinal products. These include closed system operations, improving process robustness and simplifying work flows, reducing labor intensity by implementing process automation, scalability and cost, as well as appropriate testing and tracking of products, all while maintaining strict adherence to Current Good Manufacturing Practices and regulatory guidelines. A decentralized manufacturing model is proposed, where in the future patients' cells could be processed at the point-of-care in the hospital. PMID:25613483

  9. Ultrasonic online monitoring of additive manufacturing processes based on selective laser melting

    NASA Astrophysics Data System (ADS)

    Rieder, Hans; Dillhöfer, Alexander; Spies, Martin; Bamberg, Joachim; Hess, Thomas

    2015-03-01

    Additive manufacturing processes have become commercially available and are particularly interesting for the production of free-formed parts. Selective laser melting allows to manufacture components by localized melting of successive layers of metal powder. In order to be able to describe and to understand the complex dynamics of selective laser melting processes more accurately, online measurements using ultrasound have been performed for the first time. In this contribution, we report on the integration of the measurement technique into the manufacturing facility and on a variety of promising monitoring results.

  10. Process for utilizing the waste heat content of condensate and/or vapor produced in the manufacture of sugar

    SciTech Connect

    Huber, H.; Schiweck, H.

    1981-09-22

    A process is provided for utilizing the waste heat content of condensate and/or vapor produced in the manufacture of sugar in which thin juice is cooled, subjected to one or more stages of flash evaporation to concentrate and further cool the juice, after which it is heated with condensate and/or vapor produced elsewhere in the sugar manufacturing process and with incoming thin juice thereby heating the outgoing juice to substantially its original temperature and providing the cooling of the incoming thin juice. In another embodiment completely purified thin juice is concentrated in a multiple effect evaporating plant wherein the vapor produced in the final evaporator is compressed and is returned selectively to one of the preceding evaporators of the evaporating plant for use in heating the juice.

  11. New Process for Grain Refinement of Aluminum. Final Report

    SciTech Connect

    Dr. Joseph A. Megy

    2000-09-22

    A new method of grain refining aluminum involving in-situ formation of boride nuclei in molten aluminum just prior to casting has been developed in the subject DOE program over the last thirty months by a team consisting of JDC, Inc., Alcoa Technical Center, GRAS, Inc., Touchstone Labs, and GKS Engineering Services. The Manufacturing process to make boron trichloride for grain refining is much simpler than preparing conventional grain refiners, with attendant environmental, capital, and energy savings. The manufacture of boride grain refining nuclei using the fy-Gem process avoids clusters, salt and oxide inclusions that cause quality problems in aluminum today.

  12. Quality-by-Design approach to monitor the operation of a batch bioreactor in an industrial avian vaccine manufacturing process.

    PubMed

    Largoni, Martina; Facco, Pierantonio; Bernini, Donatella; Bezzo, Fabrizio; Barolo, Massimiliano

    2015-10-10

    Monitoring batch bioreactors is a complex task, due to the fact that several sources of variability can affect a running batch and impact on the final product quality. Additionally, the product quality itself may not be measurable on line, but requires sampling and lab analysis taking several days to be completed. In this study we show that, by using appropriate process analytical technology tools, the operation of an industrial batch bioreactor used in avian vaccine manufacturing can be effectively monitored as the batch progresses. Multivariate statistical models are built from historical databases of batches already completed, and they are used to enable the real time identification of the variability sources, to reliably predict the final product quality, and to improve process understanding, paving the way to a reduction of final product rejections, as well as to a reduction of the product cycle time. It is also shown that the product quality "builds up" mainly during the first half of a batch, suggesting on the one side that reducing the variability during this period is crucial, and on the other side that the batch length can possibly be shortened. Overall, the study demonstrates that, by using a Quality-by-Design approach centered on the appropriate use of mathematical modeling, quality can indeed be built "by design" into the final product, whereas the role of end-point product testing can progressively reduce its importance in product manufacturing. PMID:26216182

  13. Freeform optical manufacturing and testing processes for IR conformal window and domes

    NASA Astrophysics Data System (ADS)

    Medicus, Kate; Nelson, Jessica D.; Lynch, Timothy; Brunelle, Matt; Brophy, Matthew

    2014-05-01

    Freeform optical shapes or optical surfaces that are designed with non-symmetric features are gaining popularity with lens designers and optical system integrators. This enabling technology allows for conformal sensor windows and domes that provide enhanced aerodynamic properties as well as environmental and ballistic protection. In order to provide ballistic and environmental protection, these conformal windows and domes are typically fabricated from hard ceramic materials which challenge the optical fabricator. The material hardness, polycrystalline nature and non-traditional shape demand creative optical fabrication techniques to produce these types of optics cost-effectively. This paper will overview a complete freeform optical fabrication process that includes ultrasonic generation of hard ceramic surfaces, high speed VIBE polishing, sub-aperture figure correction of polycrystalline materials, finishing and final testing of freeform surfaces. This paper will highlight the progress made to each of the processes as well as the challenges associated with each of them specifically focusing on the use of fiducials in the manufacturing and measurement process and the adaptation of stitching interferometry to the measurement of a freeform conformal window.

  14. Noninvasive sensors for in-situ process monitoring and control in advanced microelectronics manufacturing

    NASA Astrophysics Data System (ADS)

    Moslehi, Mehrdad M.

    1991-04-01

    The combination of noninvasive in-situ monitoring sensors single-wafer processing modules vacuum-integrated cluster tools and computer-integrated manufacturing (CIM) can provide a suitable fabrication environment for flexible and high-yield advanced semiconductor device manufacturing. The use of in-situ sensors for monitoring of equipment process and wafer parameters results in increased equipment/process up-time reduced process and device parameter spread improved cluster tool reliability and functionality and reduced overall device manufacturing cycle time. This paper will present an overview of the main features and impact of noninvasive in-situ monitoring sensors for semiconductor device manufacturing applications. Specific examples will be presented for the use of critical sensors in conjunction with cluster tools for advanced CMOS device processing. A noninvasive temperature sensor will be presented which can monitor true wafer temperature via infrared (5. 35 jtm) pyrometery and laser-assisted real-time spectral wafer emissivity measurements. This sensor design eliminates any. temperature measurement errors caused by the heating lamp radiation and wafer emissivity variations. 1. SENSORS: MOTIVATIONS AND IMPACT Semiconductor chip manufacturing factories usually employ well-established statistical process control (SPC) techniques to minimize the process parameter deviations and to increase the device fabrication yield. The conventional fabrication environments rely on controlling a limited set of critical equipment and process parameters (e. g. process pressure gas flow rates substrate temperature RF power etc. ) however most of the significant wafer process and equipment parameters of interest are not monitored in real

  15. Optimization of process parameters for the manufacturing of rocket casings: A study using processing maps

    NASA Astrophysics Data System (ADS)

    Avadhani, G. S.

    2003-12-01

    Maraging steels possess ultrahigh strength combined with ductility and toughness and could be easily fabricated and heat-treated. Bulk metalworking of maraging steels is an important step in the component manufacture. To optimize the hot-working parameters (temperature and strain rate) for the ring rolling process of maraging steel used for the manufacture of rocket casings, a systematic study was conducted to characterize the hot working behavior by developing processing maps for γ-iron and an indigenous 250 grade maraging steel. The hot deformation behavior of binary alloys of iron with Ni, Co, and Mo, which are major constituents of maraging steel, is also studied. Results from the investigation suggest that all the materials tested exhibit a domain of dynamic recrystallization (DRX). From the instability maps, it was revealed that strain rates above 10 s-1 are not suitable for hot working of these materials. An important result from the stress-strain behavior is that while Co strengthens γ-iron, Ni and Mo cause flow softening. Temperatures around 1125 °C and strain rate range between 0.001 and 0.1 s-1 are suitable for the hot working of maraging steel in the DRX domain. Also, higher strain rates may be used in the meta-dynamic recrystallization domain above 1075 °C for high strain rate applications such as ring rolling. The microstructural mechanisms identified from the processing maps along with grain size analyses and hot ductility measurements could be used to design hot-working schedules for maraging steel.

  16. From lab to industrial: PZT nanoparticles synthesis and process control for application in additive manufacturing

    NASA Astrophysics Data System (ADS)

    Huang, Hsien-Lin

    Lead Zirconate Titanate (PZT) nanoparticles hold many promising current and future applications, such as PZT ink for 3-D printing or seeds for PZT thick films. One common method is hydrothermal growth, in which temperature, duration time, or mineralizer concentrations are optimized to produce PZT nanoparticles with desired morphology, controlled size and size distribution. A modified hydrothermal process is used to fabricate PZT nanoparticles. The novelty is to employ a high ramping rate (e.g., 20 deg C/min) to generate abrupt supersaturation so as to promote burst nucleation of PZT nanoparticles as well as a fast cooling rate (e.g., 5 deg C/min) with a controlled termination of crystal growth. As a result, PZT nanoparticles with a size distribution ranging from 200 nm to 800 nm are obtained with cubic morphology and good crystallinity. The identification of nanoparticles is confirmed through use of X-ray diffractometer (XRD). XRD patterns are used to compare sample variations in their microstructures such as lattice parameter. A cubic morphology and particle size are also examined via SEM images. The hydrothermal process is further modified with excess lead (from 20% wt. to 80% wt.) to significantly reduce amorphous phase and agglomeration of the PZT nanoparticles. With a modified process, the particle size still remains within the 200 nm to 800 nm. Also, the crystal structures (microstructure) of the samples show little variations. Finally, a semi-continuous hydrothermal manufacturing process was developed to substantially reduce the fabrication time and maintained the same high quality as the nanoparticles prepared in an earlier stage. In this semi-continuous process, a furnace is maintained at the process temperature (200 deg C), whereas autoclaves containing PZT sol are placed in and out of the furnace to control the ramp-up and cooling rates. This setup eliminates an extremely time-consuming step of cooling down the furnace, thus saving tremendous amount of

  17. Changing Employment Patterns of Scientists, Engineers, and Technicians in Manufacturing Industries: 1977-80. Final Report.

    ERIC Educational Resources Information Center

    National Science Foundation, Washington, DC.

    This report presents an analysis of science, engineering, and technician (SET) employment within manufacturing industries based on data from the 1977 and 1980 Occupational Employment Statistics survey. The purposes of the report are to: (1) summarize employment data for detailed SET occupations in manufacturing to describe demand patterns; (2)…

  18. Workplace Literacy Partners for the Manufacturing Industry in Chicago and Cook County. Final Performance Report.

    ERIC Educational Resources Information Center

    Community Consolidated School District 54, Des Plaines, IL. Adult Learning Resource Center.

    A workplace literacy project had two goals: (1) to improve the productivity and efficiency of the manufacturing industry in Chicago and Cook County, Illinois, by providing workplace literacy instruction to workers who lack the basic skills required for their jobs; and (2) to improve educational programs to meet manufacturing industry needs by…

  19. Advanced Bio-Based Nanocomposites and Manufacturing Processes

    NASA Astrophysics Data System (ADS)

    Spinella, Stephen Matthew

    The aim of the PhD thesis concerns with the modification of cellulose nanocrystals (CNCs) via esterification or a radical grafting "from" approach to achieve polymeric nanocomposites of exceptional properties (Chapters 1 to 4). In addition to CNCs modification, other green routes have been introduced in this thesis in order to environmentally friendly polyester-based materials, i.e. Chapters five and six. The second chapter focuses on expanding on a one-pot cellulose acid hydrolysis/Fischer esterification to produce highly compatible CNCs without any organic solvent. It consists of modifying CNCs with acetic- and lactic- acid and exploring how such surface chemistry has an effect of dispersion in the case of polylactide (PLA)-based nanocomposites. The degree of substitution for AA-CNCs and LA-CNCs, determined by FTIR, are 0.12 and 0.13, respectively. PLA-based materials represent the best bioplastics relating to its high stiffness and biodegradability, but suffer from its poor thermal performances, namely its Heat Deflection Temperature (HDT). To improve the HDT of PLA, nanocomposites have been therefore prepared with modified cellulose nanocrystals (CNCs) by melt blending. After blending at 5 wt-% loading of CNCs, LA-CNCs gives superior reinforcement below and above the glass temperature of PLA. An increase in PLA's heat deflection temperature by 10°C and 20°C is achieved by melt-blending PLA with 5 and 20 wt-% LA-CNCs, respectively. Chapter three concerns with expanding this process to a series of hydrophilic and hydrophobic acids yielding functional CNCs for electronic and biomedical applications. Hydrophilic acids include citric-, malonic- and malic acid. Modification with the abovementioned organic acids allows for the introduction of free acids onto the surface of CNCs. Modification with citric-, malonic- and malic- acid is verified by Fourier Transform Infrared Spectroscopy and 13C solid state magic-angle spinning (MAS) NMR experiments. The degree of

  20. Due Process Hearings: An Update. Final Report.

    ERIC Educational Resources Information Center

    Ahearn, Eileen M.

    This report presents data from all 50 states on due process hearings concerning the education of students with disabilities for the years 1992, 1993, and 1994. Data were gathered from a 1996 survey conducted by the National Association of State Directors of Special Education. This survey updates due process statistics from a 1994 survey that…

  1. Low energy production processes in manufacturing of silicon solar cells

    NASA Technical Reports Server (NTRS)

    Kirkpatrick, A. R.

    1976-01-01

    Ion implantation and pulsed energy techniques are being combined for fabrication of silicon solar cells totally under vacuum and at room temperature. Simplified sequences allow very short processing times with small process energy consumption. Economic projections for fully automated production are excellent.

  2. Process Equipment Cost Estimation, Final Report

    SciTech Connect

    H.P. Loh; Jennifer Lyons; Charles W. White, III

    2002-01-01

    This report presents generic cost curves for several equipment types generated using ICARUS Process Evaluator. The curves give Purchased Equipment Cost as a function of a capacity variable. This work was performed to assist NETL engineers and scientists in performing rapid, order of magnitude level cost estimates or as an aid in evaluating the reasonableness of cost estimates submitted with proposed systems studies or proposals for new processes. The specific equipment types contained in this report were selected to represent a relatively comprehensive set of conventional chemical process equipment types.

  3. Development of pulsed processes for the manufacture of solar cells

    NASA Technical Reports Server (NTRS)

    Minnucci, J. A.

    1978-01-01

    The results of a 1-year program to develop the processes required for low-energy ion implantation for the automated production of silicon solar cells are described. The program included: (1) demonstrating state-of-the-art ion implantation equipment and designing an automated ion implanter, (2) making efforts to improve the performance of ion-implanted solar cells to 16.5 percent AM1, (3) developing a model of the pulse annealing process used in solar cell production, and (4) preparing an economic analysis of the process costs of ion implantation.

  4. Shared and service-oriented CNC machining system for intelligent manufacturing process

    NASA Astrophysics Data System (ADS)

    Li, Yao; Liu, Qiang; Tong, Ronglei; Cui, Xiaohong

    2015-11-01

    To improve efficiency, reduce cost, ensure quality effectively, researchers on CNC machining have focused on virtual machine tool, cloud manufacturing, wireless manufacturing. However, low level of information shared among different systems is a common disadvantage. In this paper, a machining database with data evaluation module is set up to ensure integrity and update. An online monitoring system based on internet of things and multi-sensors "feel" a variety of signal features to "percept" the state in CNC machining process. A high efficiency and green machining parameters optimization system "execute" service-oriented manufacturing, intelligent manufacturing and green manufacturing. The intelligent CNC machining system is applied in production. CNC machining database effectively shares and manages process data among different systems. The prediction accuracy of online monitoring system is up to 98.8% by acquiring acceleration and noise in real time. High efficiency and green machining parameters optimization system optimizes the original processing parameters, and the calculation indicates that optimized processing parameters not only improve production efficiency, but also reduce carbon emissions. The application proves that the shared and service-oriented CNC machining system is reliable and effective. This research presents a shared and service-oriented CNC machining system for intelligent manufacturing process.

  5. A manufacturable process integration approach for graphene devices

    NASA Astrophysics Data System (ADS)

    Vaziri, Sam; Lupina, Grzegorz; Paussa, Alan; Smith, Anderson D.; Henkel, Christoph; Lippert, Gunther; Dabrowski, Jarek; Mehr, Wolfgang; Östling, Mikael; Lemme, Max C.

    2013-06-01

    In this work, we propose an integration approach for double gate graphene field effect transistors. The approach includes a number of process steps that are key for future integration of graphene in microelectronics: bottom gates with ultra-thin (2 nm) high-quality thermally grown SiO2 dielectrics, shallow trench isolation between devices and atomic layer deposited Al2O3 top gate dielectrics. The complete process flow is demonstrated with fully functional GFET transistors and can be extended to wafer scale processing. We assess, through simulation, the effects of the quantum capacitance and band bending in the silicon substrate on the effective electric fields in the top and bottom gate oxide. The proposed process technology is suitable for other graphene-based devices such as graphene-based hot electron transistors and photodetectors.

  6. Automated defect spatial signature analysis for semiconductor manufacturing process

    DOEpatents

    Tobin, Jr., Kenneth W.; Gleason, Shaun S.; Karnowski, Thomas P.; Sari-Sarraf, Hamed

    1999-01-01

    An apparatus and method for performing automated defect spatial signature alysis on a data set representing defect coordinates and wafer processing information includes categorizing data from the data set into a plurality of high level categories, classifying the categorized data contained in each high level category into user-labeled signature events, and correlating the categorized, classified signature events to a present or incipient anomalous process condition.

  7. FY-2010 Process Monitoring Technology Final Report

    SciTech Connect

    Orton, Christopher R.; Bryan, Samuel A.; Casella, Amanda J.; Hines, Wes; Levitskaia, Tatiana G.; henkell, J.; Schwantes, Jon M.; Jordan, Elizabeth A.; Lines, Amanda M.; Fraga, Carlos G.; Peterson, James M.; Verdugo, Dawn E.; Christensen, Ronald N.; Peper, Shane M.

    2011-01-01

    During FY 2010, work under the Spectroscopy-Based Process Monitoring task included ordering and receiving four fluid flow meters and four flow visible-near infrared spectrometer cells to be instrumented within the centrifugal contactor system at Pacific Northwest National Laboratory (PNNL). Initial demonstrations of real-time spectroscopic measurements on cold-stream simulants were conducted using plutonium (Pu)/uranium (U) (PUREX) solvent extraction process conditions. The specific test case examined the extraction of neodymium nitrate (Nd(NO3)3) from an aqueous nitric acid (HNO3) feed into a tri-n-butyl phosphate (TBP)/ n-dodecane solvent. Demonstration testing of this system included diverting a sample from the aqueous feed meanwhile monitoring the process in every phase using the on-line spectroscopic process monitoring system. The purpose of this demonstration was to test whether spectroscopic monitoring is capable of determining the mass balance of metal nitrate species involved in a cross-current solvent extraction scheme while also diverting a sample from the system. The diversion scenario involved diverting a portion of the feed from a counter-current extraction system while a continuous extraction experiment was underway. A successful test would demonstrate the ability of the process monitoring system to detect and quantify the diversion of material from the system during a real-time continuous solvent extraction experiment. The system was designed to mimic a PUREX-type extraction process with a bank of four centrifugal contactors. The aqueous feed contained Nd(NO3)3 in HNO3, and the organic phase was composed of TBP/n-dodecane. The amount of sample observed to be diverted by on-line spectroscopic process monitoring was measured to be 3 mmol (3 x 10-3 mol) Nd3+. This value was in excellent agreement with the 2.9 mmol Nd3+ value based on the known mass of sample taken (i.e., diverted) directly from the system feed solution.

  8. Statistics to the Rescue!: Using Data to Evaluate a Manufacturing Process

    ERIC Educational Resources Information Center

    Keithley, Michael G.

    2009-01-01

    The use of statistics and process controls is too often overlooked in educating students. This article describes an activity appropriate for high school students who have a background in material processing. It gives them a chance to advance their knowledge by determining whether or not a manufacturing process works well. The activity follows a…

  9. 21 CFR 801.122 - Medical devices for processing, repacking, or manufacturing.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... HUMAN SERVICES (CONTINUED) MEDICAL DEVICES LABELING Exemptions From Adequate Directions for Use § 801.122 Medical devices for processing, repacking, or manufacturing. A device intended for processing... 21 Food and Drugs 8 2010-04-01 2010-04-01 false Medical devices for processing, repacking,...

  10. 21 CFR 801.122 - Medical devices for processing, repacking, or manufacturing.

    Code of Federal Regulations, 2011 CFR

    2011-04-01

    ... HUMAN SERVICES (CONTINUED) MEDICAL DEVICES LABELING Exemptions From Adequate Directions for Use § 801.122 Medical devices for processing, repacking, or manufacturing. A device intended for processing... 21 Food and Drugs 8 2011-04-01 2011-04-01 false Medical devices for processing, repacking,...

  11. Advanced computational research in materials processing for design and manufacturing

    SciTech Connect

    Zacharia, T.

    1995-04-01

    Advanced mathematical techniques and computer simulation play a major role in providing enhanced understanding of conventional and advanced materials processing operations. Development and application of mathematical models and computer simulation techniques can provide a quantitative understanding of materials processes and will minimize the need for expensive and time consuming trial- and error-based product development. As computer simulations and materials databases grow in complexity, high performance computing and simulation are expected to play a key role in supporting the improvements required in advanced material syntheses and processing by lessening the dependence on expensive prototyping and re-tooling. Many of these numerical models are highly compute-intensive. It is not unusual for an analysis to require several hours of computational time on current supercomputers despite the simplicity of the models being studied. For example, to accurately simulate the heat transfer in a 1-m{sup 3} block using a simple computational method requires 10`2 arithmetic operations per second of simulated time. For a computer to do the simulation in real time would require a sustained computation rate 1000 times faster than that achievable by current supercomputers. Massively parallel computer systems, which combine several thousand processors able to operate concurrently on a problem are expected to provide orders of magnitude increase in performance. This paper briefly describes advanced computational research in materials processing at ORNL. Continued development of computational techniques and algorithms utilizing the massively parallel computers will allow the simulation of conventional and advanced materials processes in sufficient generality.

  12. 10 CFR 710.29 - Final appeal process.

    Code of Federal Regulations, 2010 CFR

    2010-01-01

    ... 10 Energy 4 2010-01-01 2010-01-01 false Final appeal process. 710.29 Section 710.29 Energy... Classified Matter or Special Nuclear Material Administrative Review § 710.29 Final appeal process. (a) The Appeal Panel shall be convened by the Deputy Chief for Operations, Office of Health, Safety and...

  13. A Search Algorithm for Generating Alternative Process Plans in Flexible Manufacturing System

    NASA Astrophysics Data System (ADS)

    Tehrani, Hossein; Sugimura, Nobuhiro; Tanimizu, Yoshitaka; Iwamura, Koji

    Capabilities and complexity of manufacturing systems are increasing and striving for an integrated manufacturing environment. Availability of alternative process plans is a key factor for integration of design, process planning and scheduling. This paper describes an algorithm for generation of alternative process plans by extending the existing framework of the process plan networks. A class diagram is introduced for generating process plans and process plan networks from the viewpoint of the integrated process planning and scheduling systems. An incomplete search algorithm is developed for generating and searching the process plan networks. The benefit of this algorithm is that the whole process plan network does not have to be generated before the search algorithm starts. This algorithm is applicable to large and enormous process plan networks and also to search wide areas of the network based on the user requirement. The algorithm can generate alternative process plans and to select a suitable one based on the objective functions.

  14. Etchback smear removal process characterization. Final report

    SciTech Connect

    Richardson, J.H.

    1981-03-01

    A study evaluated variable limits for each chemical solution used in etchback smear removal on multilayer printed wiring boards (MLPWBs) to determine variables' influence on etchback behavior. Etchback smear removal is essential to fabricate about 40 different multilayer parts. However, erratic etchback behavior contributes to reduced yields among multilayer parts. The study, conducted on 172 multilayer printed wiring boards in 43 test runs, indicated that chemical interaction may not be a principal influence on etchback behavior. Study results also indicated that slight changes in process variables did not influence the presence of recessed conductors. The results verified the adequacy of existing tolerances on main process variables to produce uniformly etched holes.

  15. Development of superplastic steel processing. Final report

    SciTech Connect

    Goldberg, A.

    1995-04-01

    Objective was to provide basis for producing, processing, and forming UHCS (ultrahigh carbon steel) on a commercial scale. Business plans were developed for potential commercialization. Effort was directed at improving the combination of flow stress and forming rates in UHCS alloys in order to make near net shape superplastic forming competitive; the result was the development of a series of UHCS alloys and processing, the selection of which depends on the specific requirements of the commercial application. Useful ancillary properties of these materials include: improved mechanical properties, wear resistance, and oxidation resistance at elevated temperatures.

  16. Manufacturing of SiCp Reinforced Magnesium Composite Tubes by Hot Extrusion Processes

    NASA Astrophysics Data System (ADS)

    Hwang, Yeong-Maw; Huang, Song-Jeng; Huang, Yu-San

    2011-05-01

    Magnesium alloys have higher specific strength compared with other metals, such as aluminum, copper and steel. Nevertheless, their ductility is still not good for further metal forming and their strength is not large enough for real structure applications. The aim of this paper is to develop magnesium alloy composite tubes reinforced with SiC particulates by the stir-casting method and hot extrusion processes. At first, AZ61/SiCp composite ingots reinforced with 5 wt% SiC particulates are fabricated by the melt-stirring technique. Then, finite element simulations are conducted to analyze the plastic flow of magnesium alloy AZ61 within the die and the temperature distribution of the products. AZ61/SiCp composite tubes are manufactured by hot extrusion using a specially designed die-set for obtaining uniform thickness distribution tubes. Finally, the mechanical properties of the reinforced AZ61/SiCp composite and Mg alloy AZ61 tubes are compared with those of the billets to manifest the advantages of extrusion processes and reinforcement of SiC particulates. The microstructures of the billet and extruded tubes are also observed. Through the improvement of the strength of the tube product, its life cycle can be extended and the energy consumption can be reduced, and eventually the environmental sustainability is achieved.

  17. Manufacturing of SiCp Reinforced Magnesium Composite Tubes by Hot Extrusion Processes

    SciTech Connect

    Hwang, Yeong-Maw; Huang, Song-Jeng; Huang, Yu-San

    2011-05-04

    Magnesium alloys have higher specific strength compared with other metals, such as aluminum, copper and steel. Nevertheless, their ductility is still not good for further metal forming and their strength is not large enough for real structure applications. The aim of this paper is to develop magnesium alloy composite tubes reinforced with SiC particulates by the stir-casting method and hot extrusion processes. At first, AZ61/SiCp composite ingots reinforced with 5 wt% SiC particulates are fabricated by the melt-stirring technique. Then, finite element simulations are conducted to analyze the plastic flow of magnesium alloy AZ61 within the die and the temperature distribution of the products. AZ61/SiCp composite tubes are manufactured by hot extrusion using a specially designed die-set for obtaining uniform thickness distribution tubes. Finally, the mechanical properties of the reinforced AZ61/SiCp composite and Mg alloy AZ61 tubes are compared with those of the billets to manifest the advantages of extrusion processes and reinforcement of SiC particulates. The microstructures of the billet and extruded tubes are also observed. Through the improvement of the strength of the tube product, its life cycle can be extended and the energy consumption can be reduced, and eventually the environmental sustainability is achieved.

  18. Microstructure-controllable Laser Additive Manufacturing Process for Metal Products

    NASA Astrophysics Data System (ADS)

    Huang, Wei-Chin; Chuang, Chuan-Sheng; Lin, Ching-Chih; Wu, Chih-Hsien; Lin, De-Yau; Liu, Sung-Ho; Tseng, Wen-Peng; Horng, Ji-Bin

    Controlling the cooling rate of alloy during solidification is the most commonly used method for varying the material microstructure. However, the cooling rate of selective laser melting (SLM) production is constrained by the optimal parameter settings for a dense product. This study proposes a method for forming metal products via the SLM process with electromagnetic vibrations. The electromagnetic vibrations change the solidification process for a given set of SLM parameters, allowing the microstructure to be varied via magnetic flux density. This proposed method can be used for creating microstructure-controllable bio-implant products with complex shapes.

  19. Process for manufacture of thick film hydrogen sensors

    DOEpatents

    Perdieu, Louisa H.

    2000-09-09

    A thick film process for producing hydrogen sensors capable of sensing down to a one percent concentration of hydrogen in carrier gasses such as argon, nitrogen, and air. The sensor is also suitable to detect hydrogen gas while immersed in transformer oil. The sensor includes a palladium resistance network thick film printed on a substrate, a portion of which network is coated with a protective hydrogen barrier. The process utilizes a sequence of printing of the requisite materials on a non-conductive substrate with firing temperatures at each step which are less than or equal to the temperature at the previous step.

  20. Manufacturing processes for fabricating graphite/PMR 15 polyimide structural elements

    NASA Technical Reports Server (NTRS)

    Sheppard, C. H.; Hoggatt, J. T.; Symonds, W. A.

    1979-01-01

    Investigations were conducted to obtain commercially available graphite/PMR-15 polyimide prepreg, develop an autoclave manufacturing process, and demonstrate the process by manufacturing structural elements. Controls were established on polymer, prepreg, composite fabrication, and quality assurance, Successful material quality control and processes were demonstrated by fabricating major structural elements including flat laminates, hat sections, I beam sections, honeycomb sandwich structures, and molded graphite reinforced fittings. Successful fabrication of structural elements and simulated section of the space shuttle aft body flap shows that the graphite/PMR-15 polyimide system and the developed processes are ready for further evaluation in flight test hardware.

  1. Key technologies for manufacturing and processing sheet materials: A global perspective

    NASA Astrophysics Data System (ADS)

    Demeri, Mahmoud Y.

    2001-02-01

    Modern industrial technologies continue to seek new materials and processes to produce products that meet design and functional requirements. Sheet materials made from ferrous and non-ferrous metals, laminates, composites, and reinforced plastics constitute a large percentage of today’s products, components, and systems. Major manufacturers of sheet products include automotive, aerospace, appliance, and food-packaging industries. The Second Global Symposium on Innovations in Materials Processing & Manufacturing: Sheet Materials is organized to provide a forum for presenting advances in sheet processing and manufacturing by worldwide researchers and engineers from industrial, research, and academic centers. The symposium, sponsored by the TMS Materials Processing & Manufacturing Division (MPMD), was planned for the 2001 TMS Annual Meeting, New Orleans, Louisiana, February 11 15, 2001. This article is a review of key papers submitted for publication in the concurrent volume. The selected papers present significant developments in the rapidly expanding areas of advanced sheet materials, innovative forming methods, industrial applications, primary and secondary processing, composite processing, and numerical modeling of manufacturing processes.

  2. Urethane foam process improvements. Final report

    SciTech Connect

    Watson, D.R.

    1995-03-01

    A study was completed to evaluate the foam molding process for environmental and technical improvements. The investigation led to a replacement for chlorinated solvent usage, a potential permanent mold release coating, improved tooling design, and shrinkage characterization of foams filled with varying levels of aluminum oxide.

  3. Tubeless evaporation process development: Final report

    SciTech Connect

    Not Available

    1987-12-01

    A tubeless evaporation process which has the potential to combine the advantage of both evaporation and freezing processes, without their disadvantages is being developed. The TEP is capable of concentrating process solutions of such things as sugar, caustic soda, salt, sodium sulfate, black liquor from the pulp and paper industry, cooling tower blowdown, ''spent'' pickling liquor (sulfuric acid) from the steel industry, and nitric acid with potential energy savings of half to three-quarters of the energy required by conventional evaporators, with about half of the capital and maintenance cost. It has similar potential for the production of fresh water from seawater. The process uses working fluids (WF's) at their freezing point to effect direct contact heat exchange. The purpose of this project was to find additional and lower cost WF's in the laboratory, to obtain sizing information for the major equipment for an economic evaluation and a pilot plant design in a bench scale plant, and to perform the economic evaluation, and the pilot plant design and cost estimate. 6 refs., 37 figs., 7 tabs.

  4. Part height control of laser metal additive manufacturing process

    NASA Astrophysics Data System (ADS)

    Pan, Yu-Herng

    Laser Metal Deposition (LMD) has been used to not only make but also repair damaged parts in a layer-by-layer fashion. Parts made in this manner may produce less waste than those made through conventional machining processes. However, a common issue of LMD involves controlling the deposition's layer thickness. Accuracy is important, and as it increases, both the time required to produce the part and the material wasted during the material removal process (e.g., milling, lathe) decrease. The deposition rate is affected by multiple parameters, such as the powder feed rate, laser input power, axis feed rate, material type, and part design, the values of each of which may change during the LMD process. Using a mathematical model to build a generic equation that predicts the deposition's layer thickness is difficult due to these complex parameters. In this thesis, we propose a simple method that utilizes a single device. This device uses a pyrometer to monitor the current build height, thereby allowing the layer thickness to be controlled during the LMD process. This method also helps the LMD system to build parts even with complex parameters and to increase material efficiency.

  5. CLOSED PROCESS WATER LOOP IN NSSC CORRUGATING MEDIUM MANUFACTURE

    EPA Science Inventory

    Over the last 5 years, the Green Bay Packaging corrugating medium mill has converted to an essentially closed process water system. The mill is a net consumer of water. This is due to the greater amount of water carried out of the system with the sheet compared to the lower water...

  6. The relation between the shop floor energy system and the manufacturing process optimality

    NASA Astrophysics Data System (ADS)

    Badea, N.; Frumuşanu, G.; Epureanu, A.

    2015-11-01

    Nowadays, the overhead expenses are a significant component of the manufacturing cost. The expenditures occasioned by running the shop floor energy system are one of the most important among the overhead expenses. However, the manufacturing process optimization actually does not take into account these expenses. More than that, the expenses for running the shop floor energy system are not constant, varying after the external environment seasonal conditions, and they are depending on several issues, like the building's energetic exchange with its environment, or the loading degree of the machine tools from the shop floor. This paper approaches the relation between the shop floor energy system expenditures, on one hand, and the manufacturing process optimality, on the other hand. A case study, revealing the influence of the shop floor energy system on the manufacturing cost-optimal solution is also included.

  7. High temperature metallic diffraction gratings and process of manufacturing same

    SciTech Connect

    Deason, V.A.; Hsu, Karen M.; Miller, R.L.

    1993-12-31

    This invention is comprised of a method of applying diffraction gratings or images directly to the surface of a substrate wherein the gratings or images are capable of withstanding high temperatures, pressures, humidity and other such conditions related to materials testing. The method includes coating the surface of the substrate with an uniform layer of metal which is then overlaid with a layer of photo-resist material. Next, after contacting the photo-resist material with a master image containing regions of opacity and transparency, electromagnetic radiation is directed through the master image to expose the photo-resist material such that a contact print of the master image is produced on the photo-resist material. Then, after removing the master image, the photo-resist material is developed so as to remove unhardened portions thereof and leave corresponding portions of the metal layer uncovered. Finally, after removing or etching the uncovered portions of the metal layer, the remaining photo-resist material is removed to produce a metallic diffraction grating or image of predetermined size and pattern on the surface of the substrate.

  8. Tracking the course of the manufacturing process in selective laser melting

    NASA Astrophysics Data System (ADS)

    Thombansen, U.; Gatej, A.; Pereira, M.

    2014-02-01

    An innovative optical train for a selective laser melting based manufacturing system (SLM) has been designed under the objective to track the course of the SLM process. In this, the thermal emission from the melt pool and the geometric properties of the interaction zone are addressed by applying a pyrometer and a camera system respectively. The optical system is designed such that all three radiations from processing laser, thermal emission and camera image are coupled coaxially and that they propagate on the same optical axis. As standard f-theta lenses for high power applications inevitably lead to aberrations and divergent optical axes for increasing deflection angles in combination with multiple wavelengths, a pre-focus system is used to implement a focusing unit which shapes the beam prior to passing the scanner. The sensor system records synchronously the current position of the laser beam, the current emission from the melt pool and an image of the interaction zone. Acquired data of the thermal emission is being visualized after processing which allows an instant evaluation of the course of the process at any position of each layer. As such, it provides a fully detailed history of the product This basic work realizes a first step towards self-optimization of the manufacturing process by providing information about quality relevant events during manufacture. The deviation from the planned course of the manufacturing process to the actual course of the manufacturing process can be used to adapt the manufacturing strategy from one layer to the next. In the current state, the system can be used to facilitate the setup of the manufacturing system as it allows identification of false machine settings without having to analyze the work piece.

  9. Method of manufacturing aluminide sheet by thermomechanical processing of aluminide powders

    SciTech Connect

    Hajaligol, M.R.; Scorey, C.; Sikka, V.K.; Deevi, S.C.; Fleischhauer, G.; Lilly, A.C. Jr.; German, R.M.

    2000-02-29

    A powder metallurgical process is disclosed of preparing a sheet from a powder having an intermetallic alloy composition such as an iron, nickel or titanium aluminide. The sheet can be manufactured into electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 4 to 32% Al, and optional additions such as {<=}1% Cr, {>=}0.05% Zr{<=}2% Ti, {<=}2% Mo, {<=}1% Ni, {<=}0.75% C, {<=}0.1% B, {<=}1% submicron oxide particles and/or electrically insulating or electrically conductive covalent ceramic particles, {<=}1% rare earth metal, and/or {<=}3% Cu. The process includes forming a non-densified metal sheet by consolidating a powder having an intermetallic alloy composition such as by roll compaction, tape casting or plasma spraying, forming a cold rolled sheet by cold rolling the non-densified metal sheet so as to increase the density and reduce the thickness thereof and annealing the cold rolled sheet. The powder can be a water, polymer or gas atomized powder which is subjecting to sieving and/or blending with a binder prior to the consolidation step. After the consolidation step, the sheet can be partially sintered. The cold rolling and/or annealing steps can be repeated to achieve the desired sheet thickness and properties. The annealing can be carried out in a vacuum furnace with a vacuum or inert atmosphere. During final annealing, the cold rolled sheet recrystallizes to an average grain size of about 10 to 30 {mu}m. Final stress relief annealing can be carried out in the B2 phase temperature range.

  10. Method of manufacturing aluminide sheet by thermomechanical processing of aluminide powders

    DOEpatents

    Hajaligol, Mohammad R.; Scorey, Clive; Sikka, Vinod K.; Deevi, Seetharama C.; Fleishhauer, Grier; Lilly, Jr., A. Clifton; German, Randall M.

    2003-12-09

    A powder metallurgical process of preparing a sheet from a powder having an intermetallic alloy composition such as an iron, nickel or titanium aluminide. The sheet can be manufactured into electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 4 to 32% Al, and optional additions such as .ltoreq.1% Cr, .gtoreq.0.05% Zr .ltoreq.2% Ti, .ltoreq.2% Mo, .ltoreq.1% Ni, .ltoreq.0.75% C, .ltoreq.0.1% B, .ltoreq.1% submicron oxide particles and/or electrically insulating or electrically conductive covalent ceramic particles, .ltoreq.1% rare earth metal, and/or .ltoreq.3% Cu. The process includes forming a non-densified metal sheet by consolidating a powder having an intermetallic alloy composition such as by roll compaction, tape casting or plasma spraying, forming a cold rolled sheet by cold rolling the non-densified metal sheet so as to increase the density and reduce the thickness thereof and annealing the cold rolled sheet. The powder can be a water, polymer or gas atomized powder which is subjecting to sieving and/or blending with a binder prior to the consolidation step. After the consolidation step, the sheet can be partially sintered. The cold rolling and/or annealing steps can be repeated to achieve the desired sheet thickness and properties. The annealing can be carried out in a vacuum furnace with a vacuum or inert atmosphere. During final annealing, the cold rolled sheet recrystallizes to an average grain size of about 10 to 30 .mu.m. Final stress relief annealing can be carried out in the B2 phase temperature range.

  11. Method of manufacturing aluminide sheet by thermomechanical processing of aluminide powders

    DOEpatents

    Hajaligol, Mohammad R.; Scorey, Clive; Sikka, Vinod K.; Deevi, Seetharama C.; Fleischhauer, Grier; Lilly, Jr., A. Clifton; German, Randall M.

    2000-01-01

    A powder metallurgical process of preparing a sheet from a powder having an intermetallic alloy composition such as an iron, nickel or titanium aluminide. The sheet can be manufactured into electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 4 to 32% Al, and optional additions such as .ltoreq.1% Cr, .gtoreq.0.05% Zr.ltoreq.2% Ti, .ltoreq.2% Mo, .ltoreq.1% Ni, .ltoreq.0.75% C, .ltoreq.0.1% B, .ltoreq.1% submicron oxide particles and/or electrically insulating or electrically conductive covalent ceramic particles, .ltoreq.1% rare earth metal, and/or .ltoreq.3% Cu. The process includes forming a non-densified metal sheet by consolidating a powder having an intermetallic alloy composition such as by roll compaction, tape casting or plasma spraying, forming a cold rolled sheet by cold rolling the non-densified metal sheet so as to increase the density and reduce the thickness thereof and annealing the cold rolled sheet. The powder can be a water, polymer or gas atomized powder which is subjecting to sieving and/or blending with a binder prior to the consolidation step. After the consolidation step, the sheet can be partially sintered. The cold rolling and/or annealing steps can be repeated to achieve the desired sheet thickness and properties. The annealing can be carried out in a vacuum furnace with a vacuum or inert atmosphere. During final annealing, the cold rolled sheet recrystallizes to an average grain size of about 10 to 30 .mu.m. Final stress relief annealing can be carried out in the B2 phase temperature range.

  12. Additive manufacturing of Inconel 718 using electron beam melting: Processing, post-processing, & mechanical properties

    NASA Astrophysics Data System (ADS)

    Sames, William James, V.

    Additive Manufacturing (AM) process parameters were studied for production of the high temperature alloy Inconel 718 using Electron Beam Melting (EBM) to better understand the relationship between processing, microstructure, and mechanical properties. Processing parameters were analyzed for impact on process time, process temperature, and the amount of applied energy. The applied electron beam energy was shown to be integral to the formation of swelling defects. Standard features in the microstructure were identified, including previously unidentified solidification features such as shrinkage porosity and non-equilibrium phases. The as-solidified structure does not persist in the bulk of EBM parts due to a high process hold temperature (˜1000°C), which causes in situ homogenization. The most significant variability in as-fabricated microstructure is the formation of intragranular delta-phase needles, which can form in samples produced with lower process temperatures (< 960°C). A novel approach was developed and demonstrated for controlling the temperature of cool down, thus providing a technique for in situ heat treatment of material. This technique was used to produce material with hardness of 478+/-7 HV with no post-processing, which exceeds the hardness of peak-aged Inconel 718. Traditional post-processing methods of hot isostatic pressing (HIP) and solution treatment and aging (STA) were found to result in variability in grain growth and phase solution. Recrystallization and grain structure are identified as possible mechanisms to promote grain growth. These results led to the conclusion that the first step in thermal post-processing of EBM Inconel 718 should be an optimized solution treatment to reset phase variation in the as-fabricated microstructure without incurring significant grain growth. Such an optimized solution treatment was developed (1120°C, 2hr) for application prior to aging or HIP. The majority of as-fabricated tensile properties met ASTM

  13. Microwave processing of materials. Final report

    SciTech Connect

    McMillan, A.D.; Lauf, R.J.; Garard, R.S.

    1997-11-01

    A Cooperative Research and Development Agreement (CRADA) between Lockheed Martin Energy Systems, Inc. (LMES) and Lambda Technologies, Inc. (Lambda) of Raleigh, N.C., was initiated in May 1995. [Lockheed Martin Energy Research, Corp. (LMER) has replaced LMES]. The completion data for the Agreement was December 31, 1996. The purpose of this work is to explore the feasibility of several advanced microwave processing concepts to develop new energy-efficient materials and processes. The project includes two tasks: (1) commercialization of the variable-frequency microwave furnace (VFMF); and (2) microwave curing of polymer composites. The VFMF, whose initial conception and design was funded by the Advanced Industrial Concepts (AIC) Materials Program, will allow us, for the first time, to conduct microwave processing studies over a wide frequency range. This novel design uses a high-power traveling wave tube (TWT) originally developed for electronic warfare. By using this microwave source, one can not only select individual microwave frequencies for particular experiments, but also achieve uniform power densities over a large area by the superposition of many different frequencies.

  14. Ultrasound assisted manufacturing of paraffin wax nanoemulsions: process optimization.

    PubMed

    Jadhav, A J; Holkar, C R; Karekar, S E; Pinjari, D V; Pandit, A B

    2015-03-01

    This work reports on the process optimization of ultrasound-assisted, paraffin wax in water nanoemulsions, stabilized by modified sodium dodecyl sulfate (SDS). This work focuses on the optimization of major emulsification process variables including sonication time, applied power and surfactant concentration. The effects of these variables were investigated on the basis of mean droplet diameter and stability of the prepared emulsion. It was found that the stable emulsion with droplet diameters about 160.9 nm could be formed with the surfactant concentration of 10 mg/ml and treated at 40% of applied power (power density: 0.61 W/ml) for 15 min. Scanning electron microscopy (SEM) was used to study the morphology of the emulsion droplets. The droplets were solid at room temperature, showing bright spots under polarized light and a spherical shape under SEM. The electrophoretic properties of emulsion droplets showed a negative zeta potential due to the adsorption of head sulfate groups of the SDS surfactant. For the sake of comparison, paraffin wax emulsion was prepared via emulsion inversion point method and was checked its intrinsic stability. Visually, it was found that the emulsion get separated/creamed within 30 min. while the emulsion prepared via ultrasonically is stable for more than 3 months. From this study, it was found that the ultrasound-assisted emulsification process could be successfully used for the preparation of stable paraffin wax nanoemulsions. PMID:25465097

  15. A Statistical Process Control Method for Semiconductor Manufacturing

    NASA Astrophysics Data System (ADS)

    Kubo, Tomoaki; Ino, Tomomi; Minami, Kazuhiro; Minami, Masateru; Homma, Tetsuya

    To maintain stable operation of semiconductor fabrication lines, statistical process control (SPC) methods are recognized to be effective. However, in semiconductor fabrication lines, there exist a huge number of process state signals to be monitored, and these signals contain both normally and non-normally distributed data. Therefore, if we try to apply SPC methods to those signals, we need one which satisfies three requirements: 1) It can deal with both normally distributed data, and non-normally distributed data, 2) It can be set up automatically, 3) It can be easily understood by engineers and technicians. In this paper, we propose a new SPC method which satisfies these three requirements at the same time. This method uses similar rules to the Shewhart chart, but can deal with non-normally distributed data by introducing “effective standard deviations”. Usefulness of this method is demonstrated by comparing false alarm ratios to that of the Shewhart chart method. In the demonstration, we use various kinds of artificially generated data, and real data observed in a chemical vapor deposition (CVD) process tool in a semiconductor fabrication line.

  16. Transesterification process to manufacture ethyl ester of rape oil

    SciTech Connect

    Korus, R.A.; Hoffman, D.S.; Bam, N.; Peterson, C.L.; Drown, D.C.

    1993-12-31

    A process for the production of the ethyl ester of winter rape [EEWR] for use as a biodiesel fuel has been studied. The essential part of the process is the transesterification of rape oil with ethanol, in the presence of a catalyst, to yield the ethyl ester of rape oil as a product and glycerin as a by-product. Experiments have been performed to determine the optimum conditions for the preparation of EEWR. The process variables were: (1) temperature, (2) catalyst, (3) rate of agitation, (4) water content of the alcohol used, and (5) the amount of excess alcohol used. The optimum conditions were: (1) room temperature, (2) 0.5% sodium methoxide or 1% potassium hydroxide catalyst by weight of rapeseed oil, (3) extremely vigorous agitation with some splashing during the initial phase of the reaction and agitation was not necessary after the reaction mixture became homogeneous, (4) absolute ethanol was necessary for high conversion, and (5) 50% excess ethanol with NaOCH{sub 3} or 100% excess with KOH gave a maximum conversion. Viscosity, cloud point and pour point of the EEWR were measured. A preliminary break-even cost for the commercial production of EEWR was found to be $0.55/liter [$2.08/US gallon].

  17. Extraterrestrial processing and manufacturing of large space systems, volume 1, chapters 1-6

    NASA Technical Reports Server (NTRS)

    Miller, R. H.; Smith, D. B. S.

    1979-01-01

    Space program scenarios for production of large space structures from lunar materials are defined. The concept of the space manufacturing facility (SMF) is presented. The manufacturing processes and equipment for the SMF are defined and the conceptual layouts are described for the production of solar cells and arrays, structures and joints, conduits, waveguides, RF equipment radiators, wire cables, and converters. A 'reference' SMF was designed and its operation requirements are described.

  18. Thermographic process monitoring in powderbed based additive manufacturing

    SciTech Connect

    Krauss, Harald Zaeh, Michael F.; Zeugner, Thomas

    2015-03-31

    Selective Laser Melting is utilized to build metallic parts directly from CAD-Data by solidification of thin powder layers through application of a fast scanning laser beam. In this study layerwise monitoring of the temperature distribution is used to gather information about the process stability and the resulting part quality. The heat distribution varies with different kinds of parameters including scan vector length, laser power, layer thickness and inter-part distance in the job layout which in turn influence the resulting part quality. By integration of an off-axis mounted uncooled thermal detector the solidification as well as the layer deposition are monitored and evaluated. Errors in the generation of new powder layers usually result in a locally varying layer thickness that may cause poor part quality. For effect quantification, the locally applied layer thickness is determined by evaluating the heat-up of the newly deposited powder. During the solidification process space and time-resolved data is used to characterize the zone of elevated temperatures and to derive locally varying heat dissipation properties. Potential quality indicators are evaluated and correlated to the resulting part quality: Thermal diffusivity is derived from a simplified heat dissipation model and evaluated for every pixel and cool-down phase of a layer. This allows the quantification of expected material homogeneity properties. Maximum temperature and time above certain temperatures are measured in order to detect hot spots or delamination issues that may cause a process breakdown. Furthermore, a method for quantification of sputter activity is presented. Since high sputter activity indicates unstable melt dynamics this can be used to identify parameter drifts, improper atmospheric conditions or material binding errors. The resulting surface structure after solidification complicates temperature determination on the one hand but enables the detection of potential surface defects

  19. Thermographic process monitoring in powderbed based additive manufacturing

    NASA Astrophysics Data System (ADS)

    Krauss, Harald; Zeugner, Thomas; Zaeh, Michael F.

    2015-03-01

    Selective Laser Melting is utilized to build metallic parts directly from CAD-Data by solidification of thin powder layers through application of a fast scanning laser beam. In this study layerwise monitoring of the temperature distribution is used to gather information about the process stability and the resulting part quality. The heat distribution varies with different kinds of parameters including scan vector length, laser power, layer thickness and inter-part distance in the job layout which in turn influence the resulting part quality. By integration of an off-axis mounted uncooled thermal detector the solidification as well as the layer deposition are monitored and evaluated. Errors in the generation of new powder layers usually result in a locally varying layer thickness that may cause poor part quality. For effect quantification, the locally applied layer thickness is determined by evaluating the heat-up of the newly deposited powder. During the solidification process space and time-resolved data is used to characterize the zone of elevated temperatures and to derive locally varying heat dissipation properties. Potential quality indicators are evaluated and correlated to the resulting part quality: Thermal diffusivity is derived from a simplified heat dissipation model and evaluated for every pixel and cool-down phase of a layer. This allows the quantification of expected material homogeneity properties. Maximum temperature and time above certain temperatures are measured in order to detect hot spots or delamination issues that may cause a process breakdown. Furthermore, a method for quantification of sputter activity is presented. Since high sputter activity indicates unstable melt dynamics this can be used to identify parameter drifts, improper atmospheric conditions or material binding errors. The resulting surface structure after solidification complicates temperature determination on the one hand but enables the detection of potential surface defects

  20. A Process Analytical Technology (PAT) approach to control a new API manufacturing process: development, validation and implementation.

    PubMed

    Schaefer, Cédric; Clicq, David; Lecomte, Clémence; Merschaert, Alain; Norrant, Edith; Fotiadu, Frédéric

    2014-03-01

    Pharmaceutical companies are progressively adopting and introducing Process Analytical Technology (PAT) and Quality-by-Design (QbD) concepts promoted by the regulatory agencies, aiming the building of the quality directly into the product by combining thorough scientific understanding and quality risk management. An analytical method based on near infrared (NIR) spectroscopy was developed as a PAT tool to control on-line an API (active pharmaceutical ingredient) manufacturing crystallization step during which the API and residual solvent contents need to be precisely determined to reach the predefined seeding point. An original methodology based on the QbD principles was designed to conduct the development and validation of the NIR method and to ensure that it is fitted for its intended use. On this basis, Partial least squares (PLS) models were developed and optimized using chemometrics methods. The method was fully validated according to the ICH Q2(R1) guideline and using the accuracy profile approach. The dosing ranges were evaluated to 9.0-12.0% w/w for the API and 0.18-1.50% w/w for the residual methanol. As by nature the variability of the sampling method and the reference method are included in the variability obtained for the NIR method during the validation phase, a real-time process monitoring exercise was performed to prove its fit for purpose. The implementation of this in-process control (IPC) method on the industrial plant from the launch of the new API synthesis process will enable automatic control of the final crystallization step in order to ensure a predefined quality level of the API. In addition, several valuable benefits are expected including reduction of the process time, suppression of a rather difficult sampling and tedious off-line analyses. PMID:24468350

  1. New Electrode Manufacturing Process Equipment: Novel High Energy Density Lithium-Ion Cell Designs via Innovative Manufacturing Process Modules for Cathode and Integrated Separator

    SciTech Connect

    2010-07-01

    BEEST Project: Applied Materials is developing new tools for manufacturing Li-Ion batteries that could dramatically increase their performance. Traditionally, the positive and negative terminals of Li-Ion batteries are mixed with glue-like materials called binders, pressed onto electrodes, and then physically kept apart by winding a polymer mesh material between them called a separator. With the Applied Materials system, many of these manually intensive processes will be replaced by next generation coating technology to apply each component. This process will improve product reliability and performance of the cells at a fraction of the current cost. These novel manufacturing techniques will also increase the energy density of the battery and reduce the size of several of the battery’s components to free up more space within the cell for storage.

  2. Manufacturing process modeling for composite materials and structures, Sandia blade reliability collaborative

    SciTech Connect

    Guest, Daniel A.; Cairns, Douglas S.

    2014-02-01

    The increased use and interest in wind energy over the last few years has necessitated an increase in the manufacturing of wind turbine blades. This increase in manufacturing has in many ways out stepped the current understanding of not only the materials used but also the manufacturing methods used to construct composite laminates. The goal of this study is to develop a list of process parameters which influence the quality of composite laminates manufactured using vacuum assisted resin transfer molding and to evaluate how they influence laminate quality. Known to be primary factors for the manufacturing process are resin flow rate and vacuum pressure. An incorrect balance of these parameters will often cause porosity or voids in laminates that ultimately degrade the strength of the composite. Fiber waviness has also been seen as a major contributor to failures in wind turbine blades and is often the effect of mishandling during the lay-up process. Based on laboratory tests conducted, a relationship between these parameters and laminate quality has been established which will be a valuable tool in developing best practices and standard procedures for the manufacture of wind turbine blade composites.

  3. Control of formaldehyde and TVOC emission from wood-based flooring composites at various manufacturing processes by surface finishing.

    PubMed

    Kim, Sumin

    2010-04-15

    This paper assesses the reproducibility of testing formaldehyde and TVOC emission behavior from wood flooring composites bonded by urea-formaldehyde resin at various manufacturing steps for surface finishing materials. The surface adhesion step of laminate flooring for this research was divided into two steps; HDF only and HDF with LPMs. In the case of engineered flooring, the manufacturing steps were divided into three steps; plywood only, fancy veneer bonded on plywood and UV coated on fancy veneer with plywood. Formaldehyde and VOCs emission decreased at the process of final surface finishing materials; LPMs were applied on the surface of HDF for laminate flooring. Although emissions increased when fancy veneer was bonded onto plywood in the case of engineered flooring, emission was dramatically reduced up to similar level with plywood only when final surface finishing; UV-curable coating was applied on fancy veneer. This study suggests that formaldehyde and VOCs emission from floorings can be controlled at manufacturing steps for surface finishing. PMID:19467783

  4. Process for manufacturing gasoline with upgrading of hydrocarbon oils

    SciTech Connect

    Juguin, B.; Franck, Jp.; Jacquin, Y.; Marcilly, C.; Martino, G.

    1984-03-06

    Residual oils from steam-cracking or catalytic cracking, oils from coal liquefaction and oils from bituminous sands and shales are converted to gasoline by a process comprising the fractionation of the feed charge to a naphtha and a middle distillate: the naphtha, admixed with a gasoline cut ''E'', is hydrotreated and then dehydrogenated to gasoline; the middle distillate is hydrotreated and fractionated to gasoline and a heavier fraction, the heavier fraction is hydrocracked and fractionated, thus producing a gasoline cut which constitutes the above cut ''E''.

  5. Development of pulsed processes for the manufacture of solar cells

    NASA Technical Reports Server (NTRS)

    Minnucci, J. A.

    1979-01-01

    Low-energy ion implantation processes for the automated production of silicon solar cells were investigated. Phosphorus ions at an energy of 10 keV and dose of 2 x 10 to the 15th power/sq cm were implanted in silicon solar cells to produce junctions, while boron ions at 25 keV and 5 x 10 to the 15th power were implanted in the cells to produce effective back surface fields. An ion implantation facility with a beam current up to 4 mA and a production throughput of 300 wafers per hour was designed and installed. A design was prepared for a 100 mA, automated implanter with a production capacity of 100 MW sub e/sq cm per year. Two process sequences were developed which employ ion implantation and furnace or pulse annealing. A computer program was used to determine costs for junction formation by ion implantation and various furnace annealing cycles to demonstrate cost effectiveness of these methods.

  6. Infrared thermography for laser-based powder bed fusion additive manufacturing processes

    SciTech Connect

    Moylan, Shawn; Whitenton, Eric; Lane, Brandon; Slotwinski, John

    2014-02-18

    Additive manufacturing (AM) has the potential to revolutionize discrete part manufacturing, but improvements in processing of metallic materials are necessary before AM will see widespread adoption. A better understanding of AM processes, resulting from physics-based modeling as well as direct process metrology, will form the basis for these improvements. Infrared (IR) thermography of AM processes can provide direct process metrology, as well as data necessary for the verification of physics-based models. We review selected works examining how IR thermography was implemented and used in various powder-bed AM processes. This previous work, as well as significant experience at the National Institute of Standards and Technology in temperature measurement and IR thermography for machining processes, shapes our own research in AM process metrology with IR thermography. We discuss our experimental design, as well as plans for future IR measurements of a laser-based powder bed fusion AM process.

  7. Infrared thermography for laser-based powder bed fusion additive manufacturing processes

    NASA Astrophysics Data System (ADS)

    Moylan, Shawn; Whitenton, Eric; Lane, Brandon; Slotwinski, John

    2014-02-01

    Additive manufacturing (AM) has the potential to revolutionize discrete part manufacturing, but improvements in processing of metallic materials are necessary before AM will see widespread adoption. A better understanding of AM processes, resulting from physics-based modeling as well as direct process metrology, will form the basis for these improvements. Infrared (IR) thermography of AM processes can provide direct process metrology, as well as data necessary for the verification of physics-based models. We review selected works examining how IR thermography was implemented and used in various powder-bed AM processes. This previous work, as well as significant experience at the National Institute of Standards and Technology in temperature measurement and IR thermography for machining processes, shapes our own research in AM process metrology with IR thermography. We discuss our experimental design, as well as plans for future IR measurements of a laser-based powder bed fusion AM process.

  8. Adaptive Process Controls and Ultrasonics for High Temperature PEM MEA Manufacture

    SciTech Connect

    Walczyk, Daniel F.

    2015-08-26

    The purpose of this 5-year DOE-sponsored project was to address major process bottlenecks associated with fuel cell manufacturing. New technologies were developed to significantly reduce pressing cycle time for high temperature PEM membrane electrode assembly (MEA) through the use of novel, robust ultrasonic (U/S) bonding processes along with low temperature (<100°C) PEM MEAs. In addition, greater manufacturing uniformity and performance was achieved through (a) an investigation into the causes of excessive variation in ultrasonically and thermally bonded MEAs using more diagnostics applied during the entire fabrication and cell build process, and (b) development of rapid, yet simple quality control measurement techniques for use by industry.

  9. The Manufacturing of Niobium Powder by Hunter Process

    NASA Astrophysics Data System (ADS)

    Yoon, Jae-Sik

    Niobium powder was fabricated by metallothermic reduction process using K2NbF7 as the raw material, KCl and KF as the diluents and Na as the reducing agent. The apparatus for the experiment was designed and built specifically for the present study. Varying properties of niobium powder depending on reaction temperature and excess of reducing agent were analyzed. The niobium particle size increased significantly as the reduction temperature increased from 993 to 1093 K. The particle size was fairly uniform at a given reaction temperature, varying from 0.2 μ m to 50 nm depending on the reaction temperature. The yield of niobium powder increased from 58 to 83% with an increase in reaction temperature. The average particle size of niobium powder was improved from 70 nm to 0.2 μ m with the increase in the amount of Na excess. In addition, the yield rate of Nb powder was 82% in the 5% excess sodium.

  10. Porous tooling process for manufacture of graphite/polyimide composites

    NASA Technical Reports Server (NTRS)

    Smiser, L. W.; Orr, K. K.; Araujo, S. M.

    1981-01-01

    A porous tooling system was selected for the processing of Graphite/PMR-15 Polyimide laminates in thickness up to 3.2 mm. (0.125 inch). This tool system must have a reasonable strength, permeability dimensional stability, and thermal conductivity to accomplish curing at 600 F and 200 psi and 200 psi autoclave temperature and pressure. A permeability measuring apparatus was constructed and permeability vs. casting water level determined to produce tools at three different permeability levels. On these tools, laminates of 5, 11, and 22 plies (.027, .060, and 0.121 inch) were produced and evaluated by ultrasonic, mechanical, and thermal tests to determine the effect of the tool permeability on the cured laminates. All tools produced acceptable laminates at 5 and 11 plies but only the highest permeability produced acceptable clear ultrasonic C-Scans. Recommendations are made for future investigations of design geometry, and strengthening techniques for porous ceramic tooling.

  11. 78 FR 5496 - Certain Paper Shredders, Certain Processes for Manufacturing or Relating to Same and Certain...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2013-01-25

    ... COMMISSION Certain Paper Shredders, Certain Processes for Manufacturing or Relating to Same and Certain... sale within the United States after importation of certain paper shredders, certain processes for... for importation, and the sale within the United States after importation of certain paper...

  12. Simulation of Powder Layer Deposition in Additive Manufacturing Processes Using the Discrete Element Method

    SciTech Connect

    Herbold, E. B.; Walton, O.; Homel, M. A.

    2015-10-26

    This document serves as a final report to a small effort where several improvements were added to a LLNL code GEODYN-­L to develop Discrete Element Method (DEM) algorithms coupled to Lagrangian Finite Element (FE) solvers to investigate powder-­bed formation problems for additive manufacturing. The results from these simulations will be assessed for inclusion as the initial conditions for Direct Metal Laser Sintering (DMLS) simulations performed with ALE3D. The algorithms were written and performed on parallel computing platforms at LLNL. The total funding level was 3-­4 weeks of an FTE split amongst two staff scientists and one post-­doc. The DEM simulations emulated, as much as was feasible, the physical process of depositing a new layer of powder over a bed of existing powder. The DEM simulations utilized truncated size distributions spanning realistic size ranges with a size distribution profile consistent with realistic sample set. A minimum simulation sample size on the order of 40-­particles square by 10-­particles deep was utilized in these scoping studies in order to evaluate the potential effects of size segregation variation with distance displaced in front of a screed blade. A reasonable method for evaluating the problem was developed and validated. Several simulations were performed to show the viability of the approach. Future investigations will focus on running various simulations investigating powder particle sizing and screen geometries.

  13. Development of a Low-Cost Process for Manufacturing of Ti-Metal Matrix Composite by Roll-Diffusion Bonding

    NASA Astrophysics Data System (ADS)

    Testani, C.; Ferraro, F.

    2010-06-01

    Composite materials with titanium-alloy matrix are currently the class of material with the highest specific resistance at temperatures up to 800 °C. The main hurdle to their application is their final cost. Even if it is clear that the costs of constituent materials are decreasing due to volume production effects, the production processing costs remain high due to the batch production approach. Centro Sviluppo Materiali’s (CSM) efforts have focused on the manufacturing process in order to obtain an innovative solution to reduce the manufacturing costs with respect to the hot isostatic pressing (HIP) process that represents the standard production process for this class of materials. The new approach can allow a cost reduction of about 40%; this result was obtained by developing an experimental “diffusion bonding” plant for co-rolling at high temperature in a superplastic rolling regime, sheets of titanium alloy and monofilament silicon carbide fabrics. The experimental pilot plant was proposed for patent with RM2006A000261 in May 2006. This paper describes the manufacturing phases and process results. Moreover, has been shown that the diffusion in the solid state was obtained in a process window that was at least 100 times faster than that of HIP. High-temperature tensile tests were carried out on specimens machined from metallic matrix composite materials produced with the roll-diffusion bonding (RDB) process. The samples produced were also submitted to electrochemical dissolution tests of the metallic matrix in order to verify the geometric integrity of the fibers inside the matrix after the bonding phase. The results achieved as well as the process knowledge acquired with the CSM pilot plant are the base for further development of industrial application of the titanium roll-diffusion bonding.

  14. Manufacturing work and organizational stresses in export processing zones.

    PubMed

    Lu, Jinky Leilanie

    2009-10-01

    In the light of global industrialization, much attention has been focused on occupational factors and their influence on the health and welfare of workers. This was a cross sectional study using stratified sampling technique based on industry sizes. The study sampled 24 industries, 6 were small scale industries and 9 each for medium and large scale industries. From the 24 industries, a total of 500 respondents for the questionnaire was taken. For occupational health and safety standards that industries have to comply with, there was low compliance among small-scale industries relative to the medium and large scale industries. Only one industry had an air cleaning device for cleaning contaminated air prior to emission into the external community. Among the 500 respondents, majority were female (88.8%), single (69.6%) and worked in the production or assembly-line station (87.4%). Sickness absenteeism was relative high among the workers in this study accounting for almost 54% among females and 48% among males. Many of the workers also reported of poor performance at work, boredom, tardiness and absenteeism. For association between work factors and personal factors, the following were found to be statistically significant at p=0.05. Boredom was associated with lack of skills training, lack of promotion, disincentives for sick leaves, poor relationship with boss and poor relationships with employers. On the other hand, poor performance was also associated with lack of skills training, lack of promotions, job insecurity, and poor relationship with employers. From the data generated, important issues that must be dealt with in work organizations include the quality of work life, and health and safety issues. Based on these findings, we can conclude that there are still issues on occupational health and safety (OHS) in the target site of export processing zones in the Philippines. There must be an active campaign for OHS in industries that are produce for the global market

  15. Development of a Manufacturing Process for High-Precision Cu EOS Targets

    SciTech Connect

    Bono, M J; Castro, C; Hibbard, R L

    2006-01-12

    This document describes the development of a manufacturing process and the production of Cu EOS targets. The development of a manufacturing process for these targets required a great deal of research, because the specifications for the targets required a level of precision an order of magnitude beyond Target Fabrication's capabilities at the time. Strict limitations on the dimensions of the components and the interfaces between them required research efforts to develop bonding and deposition processes consistent with a manufacturing plan with a dimensional precision on the order of 0.1 {micro}m. Several months into this effort, the specifications for the targets were relaxed slightly as a result of discussions between the Target Fabrication Group and the physicists. The level of precision required for these targets remained an order of magnitude beyond previous capabilities, but the changes made it possible to manufacture targets to the specifications. The development efforts and manufacturing processes described in this document successfully produced a complete Cu EOS target that satisfied all of the fabrication and metrology specifications.

  16. Metal and Glass Manufactures Reduce Costs by Increasing Energy Efficiency in Process Heating Systems

    SciTech Connect

    2004-05-01

    Process heating plays a key role in producing steel, aluminum, and glass and in manufacturing products made from these materials. Faced with regulatory and competitive pressures to control emissions and reduce operating costs, metal and glass manufacturers are considering a variety of options for reducing overall energy consumption. As 38% of the energy used in U.S. industrial plants is consumed for process heating applications, metal and glass manufacturers are discovering that process heating technologies provide significant opportunities for improving industrial productivity, energy efficiency, and global competitiveness. This fact sheet is the first in a series to describe such opportunities that can be realized in industrial systems by conducting plant-wide assessments (PWA).

  17. Method for distributed agent-based non-expert simulation of manufacturing process behavior

    DOEpatents

    Ivezic, Nenad; Potok, Thomas E.

    2004-11-30

    A method for distributed agent based non-expert simulation of manufacturing process behavior on a single-processor computer comprises the steps of: object modeling a manufacturing technique having a plurality of processes; associating a distributed agent with each the process; and, programming each the agent to respond to discrete events corresponding to the manufacturing technique, wherein each discrete event triggers a programmed response. The method can further comprise the step of transmitting the discrete events to each agent in a message loop. In addition, the programming step comprises the step of conditioning each agent to respond to a discrete event selected from the group consisting of a clock tick message, a resources received message, and a request for output production message.

  18. PVMaT Cost Reductions in the EFG High Volume PV Manufacturing Line: Final Subcontract Report, 5 August 1998 -- 4 February 2001

    SciTech Connect

    Kalejs, J.; Bathey, B.; Brown, B.; Cao, J.; Doedderlein, J.; Ebers, S.; Gonsiorawski, R.; Heath, B.; Kardauskas, M.; Mackintosh, B.; Ouellette, M.; Piwczyk, B.; Rosenblum, M.; Southimath, B.

    2002-03-01

    This report describes the three major task areas: manufacturing systems development, low-cost processing technology, and flexible manufacturing methods. In Manufacturing Systems, we have worked on implementing and utilizing SPC on a larger scale by developing support systems for computer-aided data bases and equipment and process-tracking methodology; developing and implementing new diagnostic techniques; reducing acid use and waste products by introducing a new dry-etch process; and formalizing documentation and training procedures for manufacturing processes (ISO 9000) and for waste product and safety management (ISO 14000) to assist in handling the larger manufacturing organization. Low-Cost Processes, we report on progress in demonstrating low-damage, high-throughput laser technology; studies on Rapid Thermal Processing approaches to improving cell efficiency; evaluating new thin-wafer technology using EFG cylinders; and developing a large EFG octagon and laser-cutting technology for producing 12.5 cm x 12.5 cm wafers. For Flexible Manufacturing, we completed introduction of manufacturing data bases for wafer and cell manufacturing; process modifications to accommodate manufacture of 10 cm x 15 cm wafers; and module field-performance studies and defect tracking to be used to improve manufacturing processes, new encapsulant qualification and introduction into manufacturing, and progress in developing designs for low-cost modules.

  19. The Boeing Company's Manufacturing Technology Student Internship. Final Evaluation Report for 1996.

    ERIC Educational Resources Information Center

    Owens, Tom

    A study evaluated The Boeing Company's Student Internship Program for students enrolled in a manufacturing technology program. The programs in the Seattle (Washington) and Portland (Oregon) areas provided students with three progressive internship levels offered in the summers of grades 11, 12, and 13 (the first year of community college). The…

  20. Job Cluster for Manufacturing Occupations at the High School Level. Final Report.

    ERIC Educational Resources Information Center

    New Jersey State Dept. of Education, Trenton. Div. of Vocational Education.

    A project was designed to develop curricula in manufacturing occupations for grades 9 through 12, and to test, modify, reproduce, and disseminate the results. To enhance the dimensions of the operation a committee from Fairleigh Dickinson University and the New Jersey State Department of Education staff was formed to ensure effective achievement…

  1. (Development of industrial processes for manufacturing of silicon sampling hadron calorimeters)

    SciTech Connect

    Plasil, F.; Walter, J.

    1991-01-04

    The travelers attended meetings in Dubna and in Zelenograd. Discussions in Dubna centered on (1) obtaining information on USSR capabilities in silicon detector manufacture and testing and on (2) strategy regarding the development of an industrial process and the manufacture of a large quantity of silicon detectors for the SSC L* collaboration. The ELMA plant in Zelenograd was inspected, and discussions were held on production process development and on a possible detector supply time line. In addition, J. Walter participated in technical and cost estimate forecast discussions with representatives of Wacker-Chemitronic Factory (Germany) about silicon crystals for possible use in the SSC.

  2. Design and development of a layer-based additive manufacturing process for the realization of metal parts of designed mesostructure

    NASA Astrophysics Data System (ADS)

    Williams, Christopher Bryant

    Low-density cellular materials, metallic bodies with gaseous voids, are a unique class of materials that are characterized by their high strength, low mass, good energy absorption characteristics, and good thermal and acoustic insulation properties. In an effort to take advantage of this entire suite of positive mechanical traits, designers are tailoring the cellular mesostructure for multiple design objectives. Unfortunately, existing cellular material manufacturing technologies limit the design space as they are limited to certain part mesostructure, material type, and macrostructure. The opportunity that exists to improve the design of existing products, and the ability to reap the benefits of cellular materials in new applications is the driving force behind this research. As such, the primary research goal of this work is to design, embody, and analyze a manufacturing process that provides a designer the ability to specify the material type, material composition, void morphology, and mesostructure topology for any conceivable part geometry. The accomplishment of this goal is achieved in three phases of research: (1) Design---Following a systematic design process and a rigorous selection exercise, a layer-based additive manufacturing process is designed that is capable of meeting the unique requirements of fabricating cellular material geometry. Specifically, metal parts of designed mesostructure are fabricated via three-dimensional printing of metal oxide ceramic powder followed by post-processing in a reducing atmosphere. (2) Embodiment ---The primary research hypothesis is verified through the use of the designed manufacturing process chain to successfully realize metal parts of designed mesostructure. (3) Modeling & Evaluation ---The designed manufacturing process is modeled in this final research phase so as to increase understanding of experimental results and to establish a foundation for future analytical modeling research. In addition to an analysis of

  3. Manufacturing and Process-based Property Analysis of Textile-Reinforced Thermoplastic Spacer Composites

    NASA Astrophysics Data System (ADS)

    Hufenbach, Werner; Adam, Frank; Füßel, René; Krahl, Michael; Weck, Daniel

    2012-12-01

    Novel woven spacer fabrics based on hybrid yarns are suitable for an efficient fabrication of three-dimensional composite structures in high volume production. In this paper, an innovative manufacturing process with short cycle times and high automatisation is introduced for textile-reinforced thermoplastic spacer structures suited for bending load cases. The different process steps hybrid yarn fabrication, weaving technology for three-dimensional textile preforms and consolidation with unique kinematics and hot pressing technology are described in detail. The bending properties of the manufactured spacer structures are evaluated by means of experiments as well as finite element simulations. Numerical parametric studies are performed in order to validate the influence of manufacturing tolerances on the bending stiffness of the spacer structures.

  4. Development of Remote Laboratory for Understanding the Processes from Design to Manufacture

    NASA Astrophysics Data System (ADS)

    Hayashi, Kazumasa; Fukuda, Shuichi

    Faculties at the Department of Production, Information and Systems Engineering at Tokyo Metropolitan Institute of Technology faces a problem how they can motivate their students who lack in substantial hands on experience of design and manufacture and let them understand the processes from design to manufacture. To overcome this difficulty, a Remote Laboratory system was developed using a Stirling engine by noting its simple structure and principle, with the aim of providing a student hands on experience. A student designs a connecting rod, and it is machined by a milling machine in the lab at a distance. The on-site lab attendant installs the connecting rod on the engine and conducts a trial run, which is viewed by the student via internet video at the remote location. Experiments demonstrated that the Remote Lab system will facilitate a student to understand the processes from design to manufacture.

  5. Self-made silver-bromide-based emulsions for users in holography: manufacturing, processing, and application

    NASA Astrophysics Data System (ADS)

    Duenkel, Lothar; Eichler, Juergen; Ackermann, Gerhard; Schneeweiss, Claudia

    2004-06-01

    Holography is the most fascinating technology for three-dimensional imaging. But despite of many decades of research, the seek for an ideal recording material has never been given up. From all ultra-fine materials, silver bromide emulsions with very small grain sizes have the highest sensitivity. In recent years however, many traditional manufacturers discontinued their production. Meanwhile, newcomers succeeded in manufacturing emulsions which are very suitable for holography, concerning extremely high resolution, brigthness and sensitivity1. But two problems may still linger: First, the deficient market situation for production and application on this field. Second, the reputation of the system of being extremely complicated for laboratory preparation. In such a crucial situation, the authors have succeeded in presenting a laboratory procedure for making do-it-yourself materials available to any expert who is well versed in holography, and who disposes of normal darkroom equipment2. The methodology is based on precipitation using the traditional double-jet method according to Thiry and predecessors3. But sensitization is carried out by a diffusion process according to the procedure as proposed by Blyth et al.4 Thus, precipitation and coating on one side and sensitization on the other one are separated strictly from one another. Efficient desaltation is an important process too, warranting the high opto-mechanical quality of the layer. The material has been sensitzed for HeNe-Laser radiation (632,8 nm) only up to now. The mean diameter of the silver bromide grains is about 15 nm, as determined by transmission electron microscopy (TEM). Phillips-Bjelkhagen Ultimate (PBU) or Fe3+ rehalogenation bleach are applied successfully5-6. In final result, a new generation of holograms with ultra-high resolution, proper contrast, excellent sharpness and light brightness has been obtained. Holography belongs to an advancing technology where the search for an ideal recording

  6. Manufacturing Processes for TiO x -Based Thermoelectric Modules: from Suboxide Synthesis to Module Testing

    NASA Astrophysics Data System (ADS)

    Conze, S.; Poenicke, A.; Martin, H.-P.; Rost, A.; Kinski, I.; Schilm, J.; Michaelis, A.

    2014-10-01

    An overview of different TiO x synthesis methods with regard to enhancement of thermoelectric properties and transfer of the synthesis process to cost-efficient methods as well as joining techniques for module manufacture is presented. Different synthesis routes were applied and investigated, namely synthesis of TiO x via reduction with less gas formation by mixing TiO2 and TiC [powder-derived (PD)-TiO x ], a bottom-up approach via a precursor route for synthesizing TiO x directly [precursor-derived (PDC)-TiO x ], and the combination by mixing TiO2 with precursor (PDC-TiO x /TiO2). All the approaches resulted in adjustable phase composition with different oxygen contents and, therefore, adjustable electrical properties as well as different microstructures to enhance the physical and thermoelectric properties. The electrical resistivity could be adjusted from 1 mΩ cm to 1000 mΩ cm through the oxygen content of TiO x . The research included investigations of cost-efficient production processes for thermoelectric material such as spray-drying, spark plasma sintering, hot pressing or pressureless sintering in terms of shaping, sintering, and machining, as well as joining techniques to build a complete thermoelectric module. To realize thermal and electrical connections, technologies for joining and packaging were developed. For a first demonstration of the feasibility of TiO x -based thermoelectric modules for use at high temperatures, a unileg n-type module with footprint of 30 mm × 30 mm was designed. Low-volume fabrication yielded more than 20 single modules. Finally, the modules were successfully tested under conditions close to those of the desired applications with hot-side temperature up to 600°C.

  7. Reclaimed manufacturer asphalt roofing shingles in asphalt mixtures. Final research report

    SciTech Connect

    Reed, A.B.

    1999-04-23

    The purpose of this project was to pave a test section using hot mix asphalt with roofing shingle pieces in the wearing and binder courses and to evaluate. The test project near Allentown, PA plus two other test projects in 1998 provide evidence of very good pavement performance. The bituminous concrete mix was modified with shredded shingles with a maximum size of 1/2 inch which added 1% of the asphalt content. The Department issued a statewide Provisional Specification titled Reclaimed Manufacturer Asphalt Roofing Shingles in Plant-Mixed Bituminous Concrete Courses'' on March 15, 1999. New manufacturer asphalt roofing shingle scrap including tab punch-outs can be successfully incorporated in bituminous concrete pavements if the shingles are shredded to 100% passing the 3/4 inch sieve. To take full advantage of the potential to replace a portion of the asphalt and therefore, reduce mix costs, shingles should be shredded to 100% passing minus 1/2 inch sieve.

  8. Airborne Windshear Detection and Warning Systems. Fifth and Final Combined Manufacturers' and Technologists' Conference, part 2

    NASA Technical Reports Server (NTRS)

    Delnore, Victor E. (Compiler)

    1994-01-01

    The Fifth Combined Manufacturers' and Technologists' Airborne Windshear Review Meeting was hosted by the NASA Langley Research Center and the Federal Aviation Administration in Hampton, Virginia, on September 28-30, 1993. The purpose was to report on the highly successful windshear experiments conducted by government, academic institutions, and industry; to transfer the results to regulators, manufacturers, and users; and to set initiatives for future aeronautics technology research. The formal sessions covered recent developments in windshear flight testing, windshear modeling, flight management, and ground-based systems, airborne windshear detection systems, certification and regulatory issues, and development and applications of sensors for wake vortices and for synthetic and enhanced vision systems. This report was compiled to record and make available the technology updates and materials from the conference.

  9. On-Line Texture Diagnostics for Coated Conductor Manufacture. Final Report

    SciTech Connect

    White, M. K.

    2002-12-30

    This Phase I project was undertaken to assess the feasibility of implementing a particular diagnostic method for characterizing the crystallographic texture of high temperature superconductor (HTS) coated conductors on-line during their reel-to-reel continuous manufacture. Key factors in this technique were the use of an area detector to greatly reduce scan time, an x-ray mirror to enhance incident beam brightness, and an automation scheme for diffractometer control, tape motion control, and calculation and output of texture characterizations.

  10. Chemical profiling and gene expression profiling during the manufacturing process of Taiwan oolong tea "Oriental Beauty".

    PubMed

    Cho, Jeong-Yong; Mizutani, Masaharu; Shimizu, Bun-ichi; Kinoshita, Tomomi; Ogura, Miharu; Tokoro, Kazuhiko; Lin, Mu-Lien; Sakata, Kanzo

    2007-06-01

    Oriental Beauty, which is made from tea leaves infested by the tea green leafhopper (Jacobiasca formosana) in Taiwan, has a unique aroma like ripe fruits and honey. To determine what occurs in the tea leaves during the oolong tea manufacturing process, the gene expression profiles and the chemical profiles were investigated. Tea samples were prepared from Camellia sinensis var. sinensis cv. Chin-shin Dah-pang while the tea leaves were attacked by the insect. The main volatile compounds, such as linalool-oxides, benzyl alcohol, 2-phenylethanol, and 2,6-dimethylocta-3,7-diene-2,6-diol, increased during manufacture. The gene expression profiles during manufacture were analyzed by differential screening between fresh leaves and tea leaves of the first turn over. Many up-regulated transcripts were found to encode various proteins homologous to stress response proteins. Accordingly, the endogenous contents of abscisic acid and raffinose increased during manufacture. Thus the traditional manufacturing method is a unique process that utilizes plant defense responses to elevate the production of volatile compounds and other metabolites. PMID:17587678

  11. Laser processing of organic photovoltaic cells with a roll-to-roll manufacturing process

    NASA Astrophysics Data System (ADS)

    Petsch, Tino; Haenel, Jens; Clair, Maurice; Keiper, Bernd; Scholz, Christian

    2011-03-01

    Flexible large area organic photovoltaic (OPV) is currently one of the fastest developing areas of organic electronics. New light absorbing polymer blends combined with new transparent conductive materials provide higher power conversion efficiencies while new and improved production methods are developed to achieve higher throughput at reduced cost. A typical OPV is formed by TCO layers as the transparent front contact and polymers as active layer as well as interface layer between active layer and front contact. The several materials have to be patterned in order to allow for a row connection of the solar cell. 3D-Micromac used ultra-short pulsed lasers to evaluate the applicability of various wavelengths for the selective ablation of the indium tin oxide (ITO) layer and the selective ablation of the bulk hetero junction (BHJ) consisting of poly(3-hexylthiophene):phenyl-C61-butyric acid methyl ester (P3HT:PCBM) on top of a Poly(3,4-ethylenedioxythiophene) poly(styrenesulfonate) (PEDOT:PSS) without damaging the ITO. These lasers in combination with high performance galvanometer scanning systems achieve superior scribing quality without damaging the substrate. With scribing speeds of 10 m/s and up it is possible to integrate this technology into a roll-to-roll manufacturing tool. The functionality of an OPV usually also requires an annealing step, especially when using a BHJ for the active layer consisting of P3HT:PCBM, to optimize the layers structure and therewith the efficiency of the solar cell (typically by thermal treatment, e.g. oven). The process of laser annealing was investigated using a short-pulsed laser with a wavelength close to the absorption maximum of the BHJ.

  12. Silicon-Film(TM) Solar Cells by a Flexible Manufacturing System: Final Report, 16 April 1998 -- 31 March 2001

    SciTech Connect

    Rand, J.

    2002-02-01

    This report describes the overall goal to engineer and develop flexible manufacturing methods and equipment to process Silicon-Film solar cells and modules. Three major thrusts of this three-year effort were to: develop a new larger-area (208 mm x 208 mm) Silicon-Film solar cell, the APx-8; construct and operate a new high-throughput wafer-making system; and develop a 15-MW single-thread manufacturing process. Specific technical accomplishments from this period are: Increase solar cell area by 80%, increase the generation capacity of a Silicon-Film wafer-making system by 350%, use a new in-line HF etch system in solar cell production, design and develop an in-line NaOH etch system, eliminate cassettes in solar cell processing, and design a new family of module products.

  13. Studies in process modeling, design, monitoring, and control, with applications to polymer composites manufacturing

    NASA Astrophysics Data System (ADS)

    Srinivasagupta, Deepak

    2002-01-01

    High material and manufacturing costs have hindered the introduction of advanced polymer composite materials into mainstream civilian applications such as automotive. Even though high-fidelity models for several polymer composite manufacturing processes have become available over the past several years and offer significant benefits in manufacturing cost reduction, concerns about their inflexibility and maintenance has adversely affected their widespread usage. This research seeks to advance process modeling and design in polymer composites manufacturing to address these concerns. Other more general issues in measurement validation and distributed control are also addressed. Using a rigorous 3-D model of the injected pultrusion (IP) process validated recently, an algorithm was developed for process and equipment design with integrated economic, operability and environmental considerations. The optimum design promised enhanced throughput as well as reduction in the time and expenses of the current purely experimental approaches. Scale-up issues in IP were analyzed, and refinements to overcome some drawbacks in the model were suggested. The process model was then extended to simulate the co-injection resin transfer molding (CIRTM) process used for manufacture of foam-core sandwich composites. A 1-D isothermal model for real-time control was also developed. Process optimization using these models and experimental parametric studies increased the debond fracture toughness of sandwiches by 78% over current technology. To ensure the availability of validated measurements from process instrumentation, a novel in-situ sensor modeling approach to sensor validation was proposed. Both active and passive, time and frequency domain techniques were developed, and experimentally verified using temperature and flow sensors. A model-based dynamic estimator to predict the true measurement online was also validated. The effect of network communication delay on stability and control

  14. Integration of computer-aided design and manufacturing through artificial-intelligence-based process planning

    SciTech Connect

    Arunthavanathan, V.

    1988-01-01

    The research effort reported in this thesis is directed towards the integration of design, process planning, and manufacturing. The principal notion used in system integration through information integration. The main outcome of this research effort is an artificial-intelligence-based computer-aided generative process planning system, which would use a feature-based symbolic geometry as its input. The feature-based symbolic data structure is used as the common data between design, process planning, and manufacturing. As the commercial computer-aided design systems would not generate a feature-based data base, special interfaces are designed and used. As part of the solution strategy, a module to analyze the symbolic geometry from a global perspective is developed. This module imitates a human process planner and derives some overall assertions. The enhanced geometry data is then used by a rule-based expert system to develop the process plan.

  15. Competitive position of natural gas: Manufacturing automation and process controls: Topical report, April 1989

    SciTech Connect

    Karamchetty, S.D.; Kothari, V.S.; Holmes, J.G.; Minsker, B.S.

    1989-04-01

    In the study of manufacturing automation, three interacting areas were examined: industrial process, process components, and automation components. Taxonomies were developed for each of these areas to focus the analysis. The interactions between automation developments and gas use were studied in detail for five processes: metal heat treating, steel reheating, forging, glass making, and paper drying. Recent developments reported in the literature were reviewed and within each industry, areas of gas and automation systems, vendors of manufacturing automation systems, and systems designs and integrators were interviewed. Through this approach, current and future developments in automation and their impacts were identified. R D opportunities for the five specific processes studied and generic areas were also identified. Automation trends in industrial process heat applications will continue, with continued reduction in energy and gas use.

  16. General Tips Concerning What Has Been Learned About Cotton Processing in Traditional Textile Manufacturing

    Technology Transfer Automated Retrieval System (TEKTRAN)

    This article, under the following sub-headings, briefly describes a few important practical tips involving processing of cotton in traditional textile manufacturing: (1)Bale Selection and Fiber Mixing, (2) Fiber Opening and Cleaning, (3) Carding, (4) Drawing, (5) Combing (if necessary), (6) Roving, ...

  17. Manufacturing Processes: New Methods for the "Materials Age." Resources in Technology.

    ERIC Educational Resources Information Center

    Technology Teacher, 1990

    1990-01-01

    To make the best use of new materials developed for everything from computers to artificial hearts to more fuel-efficient cars, improved materials syntheses and manufacturing processes are needed. This instructional module includes teacher materials, a student quiz, and possible student outcomes. (JOW)

  18. Nanomanufacturing Portfolio: Manufacturing Processes and Applications to Accelerate Commercial Use of Nanomaterials

    SciTech Connect

    Industrial Technologies Program

    2011-01-05

    This brochure describes the 31 R&D projects that AMO supports to accelerate the commercial manufacture and use of nanomaterials for enhanced energy efficiency. These cost-shared projects seek to exploit the unique properties of nanomaterials to improve the functionality of industrial processes and products.

  19. 75 FR 13766 - Food and Drug Administration and Process Analytical Technology for Pharma Manufacturing: Food and...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2010-03-23

    ... From the Federal Register Online via the Government Publishing Office DEPARTMENT OF HEALTH AND HUMAN SERVICES Food and Drug Administration Food and Drug Administration and Process Analytical Technology for Pharma Manufacturing: Food and Drug Administration--Partnering With Industry; Public Conference AGENCY: Food and Drug Administration,...

  20. Materials, Processes and Manufacturing in Ares 1 Upper Stage: Integration with Systems Design and Development

    NASA Technical Reports Server (NTRS)

    Bhat, Biliyar N.

    2008-01-01

    Ares I Crew Launch Vehicle Upper Stage is designed and developed based on sound systems engineering principles. Systems Engineering starts with Concept of Operations and Mission requirements, which in turn determine the launch system architecture and its performance requirements. The Ares I-Upper Stage is designed and developed to meet these requirements. Designers depend on the support from materials, processes and manufacturing during the design, development and verification of subsystems and components. The requirements relative to reliability, safety, operability and availability are also dependent on materials availability, characterization, process maturation and vendor support. This paper discusses the roles and responsibilities of materials and manufacturing engineering during the various phases of Ares IUS development, including design and analysis, hardware development, test and verification. Emphasis is placed how materials, processes and manufacturing support is integrated over the Upper Stage Project, both horizontally and vertically. In addition, the paper describes the approach used to ensure compliance with materials, processes, and manufacturing requirements during the project cycle, with focus on hardware systems design and development.

  1. 15 CFR 400.32 - Procedure for review of request for approval of manufacturing or processing.

    Code of Federal Regulations, 2010 CFR

    2010-01-01

    ... sought do not involve the election of non-privileged foreign status (19 CFR 146.42) on items involving... 15 Commerce and Foreign Trade 2 2010-01-01 2010-01-01 false Procedure for review of request for approval of manufacturing or processing. 400.32 Section 400.32 Commerce and Foreign Trade...

  2. 15 CFR 400.32 - Procedure for review of request for approval of manufacturing or processing.

    Code of Federal Regulations, 2011 CFR

    2011-01-01

    ... sought do not involve the election of non-privileged foreign status (19 CFR 146.42) on items involving... 15 Commerce and Foreign Trade 2 2011-01-01 2011-01-01 false Procedure for review of request for approval of manufacturing or processing. 400.32 Section 400.32 Commerce and Foreign Trade...

  3. 15 CFR 400.32 - Procedure for review of request for approval of manufacturing or processing.

    Code of Federal Regulations, 2012 CFR

    2012-01-01

    ... sought do not involve the election of non-privileged foreign status (19 CFR 146.42) on items involving... 15 Commerce and Foreign Trade 2 2012-01-01 2012-01-01 false Procedure for review of request for approval of manufacturing or processing. 400.32 Section 400.32 Commerce and Foreign Trade...

  4. 27 CFR 19.57 - Recovery and reuse of denatured spirits in manufacturing processes.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... 27 Alcohol, Tobacco Products and Firearms 1 2010-04-01 2010-04-01 false Recovery and reuse of denatured spirits in manufacturing processes. 19.57 Section 19.57 Alcohol, Tobacco Products and Firearms... Administrative and Miscellaneous Provisions Activities Not Subject to This Part § 19.57 Recovery and reuse...

  5. Apparatus and method for converting biomass to feedstock for biofuel and biochemical manufacturing processes

    SciTech Connect

    Kania, John; Qiao, Ming; Woods, Elizabeth M.; Cortright, Randy D.; Myren, Paul

    2015-12-15

    The present invention includes improved systems and methods for producing biomass-derived feedstocks for biofuel and biochemical manufacturing processes. The systems and methods use components that are capable of transferring relatively high concentrations of solid biomass utilizing pressure variations between vessels, and allows for the recovery and recycling of heterogeneous catalyst materials.

  6. 16 CFR 303.33 - Country where textile fiber products are processed or manufactured.

    Code of Federal Regulations, 2010 CFR

    2010-01-01

    ... 16 Commercial Practices 1 2010-01-01 2010-01-01 false Country where textile fiber products are... UNDER SPECIFIC ACTS OF CONGRESS RULES AND REGULATIONS UNDER THE TEXTILE FIBER PRODUCTS IDENTIFICATION ACT § 303.33 Country where textile fiber products are processed or manufactured. (a) In addition...

  7. ENABLING COMMERCIALIZATION OF A LEAD-FREE COATING MANUFACTURING PROCESS - PHASE I

    EPA Science Inventory

    This Phase I SBIR program addresses the need for a manufacturing process that enables high reliability Pb-free tin coatings. Pb-free tin solders used in electronics applications have demonstrated whisker growth, due in part to compressive stresses within the deposit, causing ...

  8. General Tips of What Little This Author has Learned of Cotton Processing in Traditional Textile Manufacturing

    Technology Transfer Automated Retrieval System (TEKTRAN)

    This article, under the following sub-headings, only lists a few very important tips that the author has experienced in his career involving processing of cotton in the traditional textile manufacturing: (1) Fiber Opening and Cleaning (2) Carding (3) Drawing (4) Combing, if necessary (5) Roving (6)...

  9. Basic Education in the Workplace Exploratory Project. Canadian Manufacturers' Association. Perceptions of Workplace Literacy Skills in Manitoba's Manufacturing Sector. Final Report.

    ERIC Educational Resources Information Center

    McKeag, Janis

    A project assessed perceptions of manufacturing employers regarding the workplace literacy skills of occupational groups in their industry in Manitoba. A mailed survey was sent to 125 members of the Canadian Manufacturers' Association; 41 completed it. The first part of the survey obtained information about the occupations in manufacturing and…

  10. Real time intelligent process control system for thin film solar cell manufacturing

    SciTech Connect

    George Atanasoff

    2010-10-29

    This project addresses the problem of lower solar conversion efficiency and waste in the typical solar cell manufacturing process. The work from the proposed development will lead toward developing a system which should be able to increase solar panel conversion efficiency by an additional 12-15% resulting in lower cost panels, increased solar technology adoption, reduced carbon emissions and reduced dependency on foreign oil. All solar cell manufacturing processes today suffer from manufacturing inefficiencies that currently lead to lower product quality and lower conversion efficiency, increased product cost and greater material and energy consumption. This results in slower solar energy adoption and extends the time solar cells will reach grid parity with traditional energy sources. The thin film solar panel manufacturers struggle on a daily basis with the problem of thin film thickness non-uniformity and other parameters variances over the deposited substrates, which significantly degrade their manufacturing yield and quality. Optical monitoring of the thin films during the process of the film deposition is widely perceived as a necessary step towards resolving the non-uniformity and non-homogeneity problem. In order to enable the development of an optical control system for solar cell manufacturing, a new type of low cost optical sensor is needed, able to acquire local information about the panel under deposition and measure its local characteristics, including the light scattering in very close proximity to the surface of the film. This information cannot be obtained by monitoring from outside the deposition chamber (as traditional monitoring systems do) due to the significant signal attenuation and loss of its scattering component before the reflected beam reaches the detector. In addition, it would be too costly to install traditional external in-situ monitoring systems to perform any real-time monitoring over large solar panels, since it would require

  11. DEVELOPMENT OF LOW-COST MANUFACTURING PROCESSES FOR PLANAR, MULTILAYER SOLID OXIDE FUEL CELL ELEMENTS

    SciTech Connect

    Scott Swartz; Matthew Seabaugh; William Dawson; Harlan Anderson; Tim Armstrong; Michael Cobb; Kirby Meacham; James Stephan; Russell Bennett; Bob Remick; Chuck Sishtla; Scott Barnett; John Lannutti

    2004-06-12

    This report summarizes the results of a four-year project, entitled, ''Low-Cost Manufacturing Of Multilayer Ceramic Fuel Cells'', jointly funded by the U.S. Department of Energy, the State of Ohio, and by project participants. The project was led by NexTech Materials, Ltd., with subcontracting support provided by University of Missouri-Rolla, Michael A. Cobb & Co., Advanced Materials Technologies, Inc., Edison Materials Technology Center, Gas Technology Institute, Northwestern University, and The Ohio State University. Oak Ridge National Laboratory, though not formally a subcontractor on the program, supported the effort with separate DOE funding. The objective of the program was to develop advanced manufacturing technologies for making solid oxide fuel cell components that are more economical and reliable for a variety of applications. The program was carried out in three phases. In the Phase I effort, several manufacturing approaches were considered and subjected to detailed assessments of manufacturability and development risk. Estimated manufacturing costs for 5-kW stacks were in the range of $139/kW to $179/kW. The risk assessment identified a number of technical issues that would need to be considered during development. Phase II development work focused on development of planar solid oxide fuel cell elements, using a number of ceramic manufacturing methods, including tape casting, colloidal-spray deposition, screen printing, spin-coating, and sintering. Several processes were successfully established for fabrication of anode-supported, thin-film electrolyte cells, with performance levels at or near the state-of-the-art. The work in Phase III involved scale-up of cell manufacturing methods, development of non-destructive evaluation methods, and comprehensive electrical and electrochemical testing of solid oxide fuel cell materials and components.

  12. Hot Isostatic Press Manufacturing Process Development for Fabrication of RERTR Monolithic Fuel Plates

    SciTech Connect

    Crapps, Justin M.; Clarke, Kester D.; Katz, Joel D.; Alexander, David J.; Aikin, Beverly; Vargas, Victor D.; Montalvo, Joel D.; Dombrowski, David E.; Mihaila, Bogdan

    2012-06-06

    We use experimentation and finite element modeling to study a Hot Isostatic Press (HIP) manufacturing process for U-10Mo Monolithic Fuel Plates. Finite element simulations are used to identify the material properties affecting the process and improve the process geometry. Accounting for the high temperature material properties and plasticity is important to obtain qualitative agreement between model and experimental results. The model allows us to improve the process geometry and provide guidance on selection of material and finish conditions for the process strongbacks. We conclude that the HIP can must be fully filled to provide uniform normal stress across the bonding interface.

  13. Evaluation and qualification of environmentally conscious manufacturing processes for commercial and military applications

    SciTech Connect

    Anderson, D.J.; Cranwell, R.M.; Iman, R.; Van Buren, P.D.

    1995-03-01

    Environmental regulations are encouraging the development of new environmentally conscious manufacturing (ECNP processes. However, the quality and reliability of these processes and hardware produced must be understood prior to implementing these new technologies in factories. Furthermore, military hardware fabrication is governed by standards and specifications that frequently mandate the use of older, less environmentally friendly processes or materials, or prohibit the use of new ECM processes without advance military approvaL Sandia National Laboratories, with industrial and military partners, have developed methodologies for evaluating and qualifying new ECM processes for military and commercial applications, and have piloted these methodologies in qualifying new, low-residue soldering technologies and materials.

  14. Development and demonstration of manufacturing processes for fabricating graphite/LARC 160 polyimide structural elements

    NASA Technical Reports Server (NTRS)

    Frost, R. K.; Jones, J. S.; Dynes, P. J.; Wykes, D. H.

    1981-01-01

    The development and demonstration of manufacturing technologies for the structural application of Celion graphite/LARC-160 polyimide composite material is discussed. Process development and fabrication of demonstration components are discussed. Process development included establishing quality assurance of the basic composite material and processing, nondestructive inspection of fabricated components, developing processes for specific structural forms, and qualification of processes through mechanical testing. Demonstration components were fabricated. The demonstration components consisted of flat laminates, skin/stringer panels, honeycomb panels, chopped fiber compression moldings, and a technology demonstrator segment (TDS) representative of the space shuttle aft body flap.

  15. Fracture strength of GaAs solar cells as a function of manufacturing process steps

    NASA Technical Reports Server (NTRS)

    Chen, C. P.; Leipold, M. H.

    1985-01-01

    Fracture of single crystal GaAs substrate during the solar cell processing is an important factor in solar cell yield and cost. Fracture mechanics technique was utilized to evaluate cell cracking characteristics and changes in fracture strength of GaAs solar cells in a present state-of-the-art of manufacturing process for GaAs solar cells from wafer to complete cell of a typical production line. Considerable change in the fracture strength of GaAs solar cells as a function of cell processing was found. The strength data were described by Weibull statistical analysis and can be interpreted with the change of flaw distribution of each of the manufacturing process steps.

  16. Hollow microcoils made possible with external support structures manufactured with a two-solvent process

    NASA Astrophysics Data System (ADS)

    Kamberger, R.; Moazenzadeh, A.; Korvink, J. G.; Gruschke, O. G.

    2016-06-01

    We present a process to manufacture solenoidal microcoils with external support structures, which leaves the space within the coil windings free. The manufacturing procedure is based on a two solvent approach (water and acetone), for selectively etching polyvinyl alcohol and polymethyl methacrylate. Two sets of microcoils were manufactured with an inner diameter of 1.5 mm, an interwinding pitch of 100 μm and five or eight coil windings respectively. The coils were designed for application in magnetic resonance imaging and spectroscopy, and characterised in a 9.4 T MR scanner. An NMR spectrum of water and MR images in receive only and transceive mode were acquired as proof of concept.

  17. Effect of manufacturing process sequence on the corrosion resistance characteristics of coated metallic bipolar plates

    NASA Astrophysics Data System (ADS)

    Dur, Ender; Cora, Ömer Necati; Koç, Muammer

    2014-01-01

    Metallic bipolar plate (BPP) with high corrosion and low contact resistance, durability, strength, low cost, volume, and weight requirements is one of the critical parts of the PEMFC. This study is dedicated to understand the effect of the process sequence (manufacturing then coating vs. coating then manufacturing) on the corrosion resistance of coated metallic bipolar plates. To this goal, three different PVD coatings (titanium nitride (TiN), chromium nitride (CrN), zirconium nitride (ZrN)), with three thicknesses, (0.1, 0.5, 1 μm) were applied on BPPs made of 316L stainless steel alloy before and after two types of manufacturing (i.e., stamping or hydroforming). Corrosion test results indicated that ZrN coating exhibited the best corrosion protection while the performance of TiN coating was the lowest among the tested coatings and thicknesses. For most of the cases tested, in which coating was applied before manufacturing, occurrence of corrosion was found to be more profound than the case where coating was applied after manufacturing. Increasing the coating thickness was found to improve the corrosion resistance. It was also revealed that hydroformed BPPs performed slightly better than stamped BPPs in terms of the corrosion behavior.

  18. Using artificial neural networks to model extrusion processes for the manufacturing of polymeric micro-tubes

    NASA Astrophysics Data System (ADS)

    Mekras, N.; Artemakis, I.

    2012-09-01

    In this paper a methodology and an application example are presented aiming to show how Artificial Neural Networks (ANNs) can be used to model manufacturing processes when mathematical models are missing or are not applicable e.g. due to the micro- & nano-scaling, due to non-conventional processes, etc. Besides the ANNs methodology, the results of a Software System developed will be presented, which was used to create ANNs models for micro & nano manufacturing processes. More specifically results of a specific application example will be presented, concerning the modeling of extrusion processes for polymeric micro-tubes. ANNs models are capable for modeling manufacturing processes as far as adequate experimental and/or historical data of processes' inputs & outputs are available for their training. The POLYTUBES ANNs models have been trained and tested with experimental data records of process' inputs and outputs concerning a micro-extrusion process of polymeric micro-tubes for several materials such as: COC, PC, PET, PETG, PP and PVDF. The main ANN model of the extrusion application example has 3 inputs and 9 outputs. The inputs are: tube's inner & outer diameters, and the material density. The model outputs are 9 process parameters, which correspond to the specific inputs e.g. process temperature, die inner & outer diameters, extrusion pressure, draw speed etc. The training of the ANN model was completed, when the errors for the model's outputs, which expressed the difference between the training target values and the ANNs outputs, were minimized to acceptable levels. After the training, the micro-extrusion ANN is capable to simulate the process and can be used to calculate model's outputs, which are the process parameters for any new set of inputs. By this way a satisfactory functional approximation of the whole process is achieved. This research work has been supported by the EU FP7 NMP project POLYTUBES.

  19. Risks and reliability of manufacturing processes as related to composite materials for spacecraft structures

    NASA Technical Reports Server (NTRS)

    Bao, Han P.

    1995-01-01

    Fabricating primary aircraft and spacecraft structures using advanced composite materials entail both benefits and risks. The benefits come from much improved strength-to-weight ratios and stiffness-to-weight ratios, potential for less part count, ability to tailor properties, chemical and solvent resistance, and superior thermal properties. On the other hand, the risks involved include high material costs, lack of processing experience, expensive labor, poor reproducibility, high toxicity for some composites, and a variety of space induced risks. The purpose of this project is to generate a manufacturing database for a selected number of materials with potential for space applications, and to rely on this database to develop quantitative approaches to screen candidate materials and processes for space applications on the basis of their manufacturing risks including costs. So far, the following materials have been included in the database: epoxies, polycyanates, bismalemides, PMR-15, polyphenylene sulfides, polyetherimides, polyetheretherketone, and aluminum lithium. The first four materials are thermoset composites; the next three are thermoplastic composites, and the last one is is a metal. The emphasis of this database is on factors affecting manufacturing such as cost of raw material, handling aspects which include working life and shelf life of resins, process temperature, chemical/solvent resistance, moisture resistance, damage tolerance, toxicity, outgassing, thermal cycling, and void content, nature or type of process, associate tooling, and in-process quality assurance. Based on industry experience and published literature, a relative ranking was established for each of the factors affecting manufacturing as listed above. Potential applications of this database include the determination of a delta cost factor for specific structures with a given process plan and a general methodology to screen materials and processes for incorporation into the current

  20. Low-cost manufacturing of the point focus concentrating module and its key component, the Fresnel lens. Final subcontract report, 31 January 1991--6 May 1991

    SciTech Connect

    Saifee, T.; Konnerth, A. III

    1991-11-01

    Solar Kinetics, Inc. (SKI) has been developing point-focus concentrating PV modules since 1986. SKI is currently in position to manufacture between 200 to 600 kilowatts annually of the current design by a combination of manual and semi-automated methods. This report reviews the current status of module manufacture and specifies the required approach to achieve a high-volume manufacturing capability and low cost. The approach taken will include process development concurrent with module design for automated manufacturing. The current effort reviews the major manufacturing costs and identifies components and processes whose improvements would produce the greatest effect on manufacturability and cost reduction. The Fresnel lens is one such key component. Investigating specific alternative manufacturing methods and sources has substantially reduced the lens costs and has exceeded the DOE cost-reduction goals. 15 refs.

  1. Study of process variables associated with manufacturing hermetically-sealed nickel-cadmium cells

    NASA Technical Reports Server (NTRS)

    Miller, L.; Doan, D. J.; Carr, E. S.

    1971-01-01

    A program to determine and study the critical process variables associated with the manufacture of aerospace, hermetically-sealed, nickel-cadmium cells is described. The determination and study of the process variables associated with the positive and negative plaque impregnation/polarization process are emphasized. The experimental data resulting from the implementation of fractional factorial design experiments are analyzed by means of a linear multiple regression analysis technique. This analysis permits the selection of preferred levels for certain process variables to achieve desirable impregnated plaque characteristics.

  2. The space shuttle payload planning working groups: Volume 9: Materials processing and space manufacturing

    NASA Technical Reports Server (NTRS)

    1973-01-01

    The findings and recommendations of the Materials Processing and Space Manufacturing group of the space shuttle payload planning activity are presented. The effects of weightlessness on the levitation processes, mixture stability, and control over heat and mass transport in fluids are considered for investigation. The research and development projects include: (1) metallurgical processes, (2) electronic materials, (3) biological applications, and (4)nonmetallic materials and processes. Additional recommendations are provided concerning the allocation of payload space, acceptance of experiments for flight, flight qualification, and private use of the space shuttle.

  3. Rationalization of Microstructure Heterogeneity in INCONEL 718 Builds Made by the Direct Laser Additive Manufacturing Process

    NASA Astrophysics Data System (ADS)

    Tian, Yuan; McAllister, Donald; Colijn, Hendrik; Mills, Michael; Farson, Dave; Nordin, Mark; Babu, Sudarsanam

    2014-09-01

    Simulative builds, typical of the tip-repair procedure, with matching compositions were deposited on an INCONEL 718 substrate using the laser additive manufacturing process. In the as-processed condition, these builds exhibit spatial heterogeneity in microstructure. Electron backscattering diffraction analyses showed highly misoriented grains in the top region of the builds compared to those of the lower region. Hardness maps indicated a 30 pct hardness increase in build regions close to the substrate over those of the top regions. Detailed multiscale characterizations, through scanning electron microscopy, electron backscattered diffraction imaging, high-resolution transmission electron microscopy, and ChemiSTEM, also showed microstructure heterogeneities within the builds in different length scales including interdendritic and interprecipitate regions. These multiscale heterogeneities were correlated to primary solidification, remelting, and solid-state precipitation kinetics of γ″ induced by solute segregation, as well as multiple heating and cooling cycles induced by the laser additive manufacturing process.

  4. [Emission characteristics and safety evaluation of volatile organic compounds in manufacturing processes of automotive coatings].

    PubMed

    Zeng, Pei-Yuan; Li, Jian-Jun; Liao, Dong-Qi; Tu, Xiang; Xu, Mei-Ying; Sun, Guo-Ping

    2013-12-01

    Emission characteristics of volatile organic compounds (VOCs) were investigated in an automotive coating manufacturing enterprise. Air samples were taken from eight different manufacturing areas in three workshops, and the species of VOCs and their concentrations were measured by gas chromatography-mass spectrometry (GC-MS). Safety evaluation was also conducted by comparing the concentration of VOCs with the permissible concentration-short term exposure limit (PC-STEL) regulated by the Ministry of Health. The results showed that fifteen VOCs were detected in the indoor air of the automotive coatings workshop, including benzene, toluene, ethylbenzene, xylene, ethyl acetate, butyl acetate, methyl isobutyl ketone, propylene glycol monomethyl ether acetate, trimethylbenzene and ethylene glycol monobutyl ether, Their concentrations widely ranged from 0.51 to 593.14 mg x m(-3). The concentrations of TVOCs were significantly different among different manufacturing processes. Even in the same manufacturing process, the concentrations of each component measured at different times were also greatly different. The predominant VOCs of indoor air in the workshop were identified to be ethylbenzene and butyl acetate. The concentrations of most VOCs exceeded the occupational exposure limits, so the corresponding control measures should be taken to protect the health of the workers. PMID:24640895

  5. Statistical process control in the hybrid microelectronics manufacturing industry: A Navy view point

    NASA Astrophysics Data System (ADS)

    Azu, Charles C., Jr.

    1993-04-01

    The U.S. Navy is concerned with receiving high quality hybrid microelectronic circuits. The Navy recognizes that in order to obtain high quality circuits a manufacturer must have an effective statistical process control (SPC) program implemented. The implementation of effective SPC programs is an objective of the military hybrid microelectronics industry. Often the smaller sized manufacturers in the industry have little SPC implementation, while the larger manufacturers have practices originally developed for the control of other product lines outside the hybrid technology area. The industry recognizes that SPC programs will result in high quality hybrid microcircuits which the U.S. Navy requires. In the past, the goal of the industry had not been to put in effective process control methods, but to merely meet the government military standards on the quality of the hybrids they produce. This practice, at best, resulted in a 'hit or miss' situation when it comes to hybrid microcircuit assemblies meeting military standards. The U.S. Navy through its MicroCIM program has been challenging and working with the industry in the area of SPC practice methods. The major limitations so far have been a lack of available sensors for the real-time collection of effective SPC data on the factory floor. This paper will discuss the Navy's efforts in bringing about effective SPC programs in the military hybrid manufacturing industry.

  6. Manufacturing process scale-up of optical grade transparent spinel ceramic at ArmorLine Corporation

    NASA Astrophysics Data System (ADS)

    Spilman, Joseph; Voyles, John; Nick, Joseph; Shaffer, Lawrence

    2013-06-01

    While transparent Spinel ceramic's mechanical and optical characteristics are ideal for many Ultraviolet (UV), visible, Short-Wave Infrared (SWIR), Mid-Wave Infrared (MWIR), and multispectral sensor window applications, commercial adoption of the material has been hampered because the material has historically been available in relatively small sizes (one square foot per window or less), low volumes, unreliable supply, and with unreliable quality. Recent efforts, most notably by Technology Assessment and Transfer (TA and T), have scaled-up manufacturing processes and demonstrated the capability to produce larger windows on the order of two square feet, but with limited output not suitable for production type programs. ArmorLine Corporation licensed the hot-pressed Spinel manufacturing know-how of TA and T in 2009 with the goal of building the world's first dedicated full-scale Spinel production facility, enabling the supply of a reliable and sufficient volume of large Transparent Armor and Optical Grade Spinel plates. With over $20 million of private investment by J.F. Lehman and Company, ArmorLine has installed and commissioned the largest vacuum hot press in the world, the largest high-temperature/high-pressure hot isostatic press in the world, and supporting manufacturing processes within 75,000 square feet of manufacturing space. ArmorLine's equipment is capable of producing window blanks as large as 50" x 30" and the facility is capable of producing substantial volumes of material with its Lean configuration and 24/7 operation. Initial production capability was achieved in 2012. ArmorLine will discuss the challenges that were encountered during scale-up of the manufacturing processes, ArmorLine Optical Grade Spinel optical performance, and provide an overview of the facility and its capabilities.

  7. Survey of the US materials processing and manufacturing in space program

    NASA Technical Reports Server (NTRS)

    Mckannan, E. C.

    1981-01-01

    To promote potential commercial applications of low-g technology, the materials processing and manufacturing in space program is structured to: (1) analyze the scientific principles of gravitational effects on processes used in producing materials; (2) apply the research toward the technology used to control production process (on Earth or in space, as appropriate); and (3) establish the legal and managerial framework for commercial ventures. Presently federally funded NASA research is described as well as agreements for privately funded commercial activity, and a proposed academic participation process. The future scope of the program and related capabilities using ground based facilities, aircraft, sounding rockets, and space shuttles are discussed. Areas of interest described include crystal growth; solidification of metals and alloys; containerless processing; fluids and chemical processes (including biological separation processes); and processing extraterrestrial materials.

  8. Experimental analysis of selective laser melting process for Ti-6Al-4V turbine blade manufacturing

    NASA Astrophysics Data System (ADS)

    Caiazzo, Fabrizia; Cardaropoli, Francesco; Alfieri, Vittorio; Sergi, Vincenzo; Cuccaro, Luigi

    2012-01-01

    The present work focuses on the use of Selective Laser Melting (SLM) technique for manufacturing of near-net-shape aircraft component prototypes with Ti-6Al-4V titanium alloy, which has already successfully employed for the production of turbine blades since it combines mechanical properties with excellent wear resistance. The main characteristic of SLM is layer manufacturing which allows to obtain complex shaped elements using three dimensional computer aided design data, with the addition of particular features like channels or cavities which can not been easily obtained with traditional technologies. The other key aspect in comparison with investment casting is shorter post-processing. The feasibility of manufacturing turbine blades with mentioned process using a laser sintered machine EOSINT M 270 (Titanium version) is analysed. The first experimental phase has dealt with the definition of processing parameters which would guarantee laser sintered part maximum density. Preliminary specimens have been manufactured to define any material-dependent scaling value to control dimensional shrinkage. Afterwards a prototype of a turbine blade has been produced using optimal process parameter set. The element positioning and support definition are discussed as they influence the overall job time and the need of post processing operations. Further analyses have been carried out to check the whole structure of the prototype using X-rays and Fluorescent Penetrant Inspection, aiming to point out possible imperfections; no defects have been detected. Furthermore, laser sintered part dimensional inspection has been successively performed via coordinate measuring machine. Eventually, the microstructure of the prototype has been examined.

  9. TAPE CALENDERING MANUFACTURING PROCESS FOR MULTILAYER THIN-FILM SOLID OXIDE FUEL CELLS

    SciTech Connect

    Nguyen Minh; Kurt Montgomery

    2004-10-01

    This report summarizes the work performed by Hybrid Power Generation Systems, LLC during the Phases I and II under Contract DE-AC26-00NT40705 for the U. S. Department of Energy, National Energy Technology Laboratory (DOE/NETL) entitled ''Tape Calendering Manufacturing Process For Multilayer Thin-Film Solid Oxide Fuel Cells''. The main objective of this project was to develop the manufacturing process based on tape calendering for multilayer solid oxide fuel cells (SOFC's) using the unitized cell design concept and to demonstrate cell performance under specified operating conditions. Summarized in this report is the development and improvements to multilayer SOFC cells and the unitized cell design. Improvements to the multilayer SOFC cell were made in electrochemical performance, in both the anode and cathode, with cells demonstrating power densities of nearly 0.9 W/cm{sup 2} for 650 C operation and other cell configurations showing greater than 1.0 W/cm{sup 2} at 75% fuel utilization and 800 C. The unitized cell design was matured through design, analysis and development testing to a point that cell operation at greater than 70% fuel utilization was demonstrated at 800 C. The manufacturing process for both the multilayer cell and unitized cell design were assessed and refined, process maps were developed, forming approaches explored, and nondestructive evaluation (NDE) techniques examined.

  10. Manufacturing Materials and Processes. Grade 11-12. Course #8165 (Semester). Technology Education Course Guide. Industrial Arts/Technology Education.

    ERIC Educational Resources Information Center

    North Carolina State Dept. of Public Instruction, Raleigh. Div. of Vocational Education.

    This guide is intended for use in teaching an introductory course in manufacturing materials and processes. The course centers around four basic materials--metallics, polymers, ceramics, and composites--and seven manufacturing processes--casting, forming, molding, separating, conditioning, assembling, and finishing. Concepts and classifications of…

  11. 21 CFR 108.12 - Manufacturing, processing, or packing without a permit, or in violation of a permit.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... 21 Food and Drugs 2 2010-04-01 2010-04-01 false Manufacturing, processing, or packing without a... General Provisions § 108.12 Manufacturing, processing, or packing without a permit, or in violation of a... commerce without the advance written approval of the Food and Drug Administration. Such approval may...

  12. Development of Inorganic Precursors for Manufacturing of Photovoltaic Devices: Cooperative Research and Development Final Report, CRADA Number CRD-08-308

    SciTech Connect

    van Hest, M.; Ginley, D.

    2013-06-01

    Both NREL and Rohm and Haas Electronic Materials are interested in the development of solution phase metal and semiconductive precursors for the manufacturing of photovoltaic devices. In particular, we intend to develop material sets for atmospheric deposition processes. The cooperation between these two parties will enable high value materials and processing solutions for the manufacturing of low cost, roll-to-roll photovoltaics.

  13. Manufacturing technologies

    NASA Astrophysics Data System (ADS)

    The Manufacturing Technologies Center is at the core of Sandia National Laboratories' advanced manufacturing effort which spans the entire product realization process. The center's capabilities in product and process development are summarized in the following disciplines: (1) mechanical - rapid prototyping, manufacturing engineering, machining and computer-aided manufacturing, measurement and calibration, and mechanical and electronic manufacturing liaison; (2) electronics - advanced packaging for microelectronics, printed circuits, and electronic fabrication; and (3) materials - ceramics, glass, thin films, vacuum technology, brazing, polymers, adhesives, composite materials, and process analysis.

  14. Digital-Computer Processing of Graphical Data. Final Report.

    ERIC Educational Resources Information Center

    Freeman, Herbert

    The final report of a two-year study concerned with the digital-computer processing of graphical data. Five separate investigations carried out under this study are described briefly, and a detailed bibliography, complete with abstracts, is included in which are listed the technical papers and reports published during the period of this program.…

  15. Process for the manufacture of catalysts for the production of maleic anhydride

    SciTech Connect

    Edwards, R.C.

    1987-10-13

    A process is described for the manufacture of a phosphorus-vanadium oxide catalyst suitable for use in the manufacture of maleic anhydride from butane. The process comprises reacting at a temperature of about 0/sup 0/C to about 200/sup 0/C a vanadium compound in an organic ether solvent having from about 2 to about 10 carbon atoms, with a phosphoryl halide in the presence of water or an aliphatic alcohol having from about 1 to about 8 carbon atoms, eliminating the solvent and activating the catalyst by the addition of butane, benzene or another C/sub 4/ hydrocarbon feedstock and water and a phosphorus compound at a temperature of about 300/sup 0/C to about 500/sup 0/C wherein the amount of water added is about 1000 parts per million to about 40,000 parts per million by weight of the reactor feed gas stream.

  16. Experiment to Learn Statistical Characteristics of Dispersion Occurred in a Manufacturing Process

    NASA Astrophysics Data System (ADS)

    Hiraoka, Kazunori

    Statistical quality control (SQC) is widely applied to manufacturing process control. Although engineers graduated a college of technology are required to master SQC, they had not sufficiently taken lesson of statistics in a college. To teach statistics practically, lesson of experiment using Pb free solder is created in our college. Experiments are performed with various parameters as solder metals and soldering temperature. Results are analyzed using Hayashi‧s quantification methods which are a kind of multivariable analysis. The conditions on which standard deviations of solder amount per a connected point are minimum and maximum are estimated analytically and verified experimentally. Students learn that dispersion occurred in a manufacturing process is unavoidable but able to be reduced. They are expected to be more familiar to statistics from this lesson.

  17. Modular industrial robots as the tool of process automation in robotized manufacturing cells

    NASA Astrophysics Data System (ADS)

    Gwiazda, A.; Banas, W.; Sekala, A.; Foit, K.; Hryniewicz, P.; Kost, G.

    2015-11-01

    Recently the number of designed modular machine was increased. The term modular machine is used to denote different types of machinery, equipment and production lines, which are created using modular elements. Modular could be both mechanic elements, and drives, as well as control systems. This method of machine design is more and more popular because it allows obtaining flexible and relatively cheap solutions. So it is worth to develop the concept of modularity in next areas of application. The advantages of modular solutions are: simplification of the structure, standardization of components, and faster assembly process of the complete machine Additional advantages, which is particularly important for manufacturers, are shorter manufacturing times, longer production series and reduced manufacturing costs. Modular designing is also the challenge for designers and the need for a new approach to the design process, to the starting process and to the exploitation process. The purpose for many manufacturers is the standardization of the components used for creating the finished products. This purpose could be realized by the application of standard modules which could be combined together in different ways to create the desired particular construction as much as possible in accordance with the order. This solution is for the producer more favorable than the construction of a large machine whose configuration must be matched to each individual order. In the ideal case each module has its own control system and the full functionality of the modular machine is obtained due to the mutual cooperation of all modules. Such a solution also requires the modular components which create the modular machine are equipped with interfaces compatible one with another to facilitate their communication. The individual components of the machine could be designed, manufactured and used independently and production management task could be divided into subtasks. They could be also

  18. Optimisation of the manufacturing process of tritide and deuteride targets used for neutron production

    NASA Astrophysics Data System (ADS)

    Monnin, Carole; Bach, Pierre; Tulle, Pierre Alain; van Rompay, Marc; Ballanger, Anne

    2002-03-01

    As a neutron tube manufacturer, SODERN is now in charge of manufacturing tritium targets for accelerators, in cooperation with CEA/DAM/DTMN in Valduc. Specific deuterium and tritium targets are manufactured on request, according to the requirements of the users, starting from titanium targets on copper substrates, and going to more sophisticated devices. The range of possible uses is wide, including thin targets for neutron calibration, thick targets with controlled loading of deuterium and tritium, rotating targets or large size rotating targets for higher lifetimes. The activity of the targets ranges from 3.7×10 10 to 3.7×10 13 Bq (1-1000 Ci), the diameter being up to 30 cm. Sodern and the CEA/Valduc centre have developed different technologies for tritium target manufacture, allowing the selection of the best configuration for each kind of use. In order to optimize the production of high energy neutrons, the performance of tritide and deuteride titanium targets made by different processes has been studied experimentally by bombardment with 120 and 350 kV deuterons provided by electrostatic accelerators. It is then possible to optimize either neutron output or lifetime and stability or thermal behaviour. The importance of the deposit evaporation conditions on the efficiency of neutron emission is clearly demonstrated, as well as the thermomechanical stability of the Ti thin film under deuteron bombardment. The main parameters involved in the target performance are discussed from a thermodynamical approach.

  19. SETEC/Semiconductor Manufacturing Technologies Program: 1999 Annual and Final Report

    SciTech Connect

    MCBRAYER,JOHN D.

    2000-12-01

    This report summarizes the results of work conducted by the Semiconductor Manufacturing Technologies Program at Sandia National Laboratories (Sandia) during 1999. This work was performed by one working group: the Semiconductor Equipment Technology Center (SETEC). The group's projects included Numerical/Experimental Characterization of the Growth of Single-Crystal Calcium Fluoride (CaF{sub 2}); The Use of High-Resolution Transmission Electron Microscopy (HRTEM) Imaging for Certifying Critical-Dimension Reference Materials Fabricated with Silicon Micromachining; Assembly Test Chip for Flip Chip on Board; Plasma Mechanism Validation: Modeling and Experimentation; and Model-Based Reduction of Contamination in Gate-Quality Nitride Reactor. During 1999, all projects focused on meeting customer needs in a timely manner and ensuring that projects were aligned with the goals of the National Technology Roadmap for Semiconductors sponsored by the Semiconductor Industry Association and with Sandia's defense mission. This report also provides a short history of the Sandia/SEMATECH relationship and a brief on all projects completed during the seven years of the program.

  20. The establishment of a production-ready manufacturing process utilizing thin silicon substrates for solar cells

    NASA Technical Reports Server (NTRS)

    Pryor, R. A.

    1980-01-01

    Three inch diameter Czochralski silicon substrates sliced directly to 5 mil, 8 mil, and 27 mil thicknesses with wire saw techniques were procured. Processing sequences incorporating either diffusion or ion implantation technologies were employed to produce n+p or n+pp+ solar cell structures. These cells were evaluated for performance, ease of fabrication, and cost effectiveness. It was determined that the use of 7 mil or even 4 mil wafers would provide near term cost reductions for solar cell manufacturers.

  1. Development of Functionally Graded Materials for Manufacturing Tools and Dies and Industrial Processing Equipment

    SciTech Connect

    Lherbier, Louis, W.; Novotnak, David, J.; Herling, Darrell, R.; Sears, James, W.

    2009-03-23

    Hot forming processes such as forging, die casting and glass forming require tooling that is subjected to high temperatures during the manufacturing of components. Current tooling is adversely affected by prolonged exposure at high temperatures. Initial studies were conducted to determine the root cause of tool failures in a number of applications. Results show that tool failures vary and depend on the operating environment under which they are used. Major root cause failures include (1) thermal softening, (2) fatigue and (3) tool erosion, all of which are affected by process boundary conditions such as lubrication, cooling, process speed, etc. While thermal management is a key to addressing tooling failures, it was clear that new tooling materials with superior high temperature strength could provide improved manufacturing efficiencies. These efficiencies are based on the use of functionally graded materials (FGM), a new subset of hybrid tools with customizable properties that can be fabricated using advanced powder metallurgy manufacturing technologies. Modeling studies of the various hot forming processes helped identify the effect of key variables such as stress, temperature and cooling rate and aid in the selection of tooling materials for specific applications. To address the problem of high temperature strength, several advanced powder metallurgy nickel and cobalt based alloys were selected for evaluation. These materials were manufactured into tooling using two relatively new consolidation processes. One process involved laser powder deposition (LPD) and the second involved a solid state dynamic powder consolidation (SSDPC) process. These processes made possible functionally graded materials (FGM) that resulted in shaped tooling that was monolithic, bi-metallic or substrate coated. Manufacturing of tooling with these processes was determined to be robust and consistent for a variety of materials. Prototype and production testing of FGM tooling showed the

  2. Cost model relationships between textile manufacturing processes and design details for transport fuselage elements

    NASA Technical Reports Server (NTRS)

    Metschan, Stephen L.; Wilden, Kurtis S.; Sharpless, Garrett C.; Andelman, Rich M.

    1993-01-01

    Textile manufacturing processes offer potential cost and weight advantages over traditional composite materials and processes for transport fuselage elements. In the current study, design cost modeling relationships between textile processes and element design details were developed. Such relationships are expected to help future aircraft designers to make timely decisions on the effect of design details and overall configurations on textile fabrication costs. The fundamental advantage of a design cost model is to insure that the element design is cost effective for the intended process. Trade studies on the effects of processing parameters also help to optimize the manufacturing steps for a particular structural element. Two methods of analyzing design detail/process cost relationships developed for the design cost model were pursued in the current study. The first makes use of existing databases and alternative cost modeling methods (e.g. detailed estimating). The second compares design cost model predictions with data collected during the fabrication of seven foot circumferential frames for ATCAS crown test panels. The process used in this case involves 2D dry braiding and resin transfer molding of curved 'J' cross section frame members having design details characteristic of the baseline ATCAS crown design.

  3. An experimental analysis of process parameters to manufacture micro-channels in AISI H13 tempered steel by laser micro-milling

    NASA Astrophysics Data System (ADS)

    Teixidor, D.; Ferrer, I.; Ciurana, J.

    2012-04-01

    This paper reports the characterization of laser machining (milling) process to manufacture micro-channels in order to understand the incidence of process parameters on the final features. Selection of process operational parameters is highly critical for successful laser micromachining. A set of designed experiments is carried out in a pulsed Nd:YAG laser system using AISI H13 hardened tool steel as work material. Several micro-channels have been manufactured as micro-mold cavities varying parameters such as scanning speed (SS), pulse intensity (PI) and pulse frequency (PF). Results are obtained by evaluating the dimensions and the surface finish of the micro-channel. The dimensions and shape of the micro-channels produced with laser-micro-milling process exhibit variations. In general the use of low scanning speeds increases the quality of the feature in both surface finishing and dimensional.

  4. Photovoltaic manufacturing technology monolithic amorphous silicon modules on continuous polymer substrates: Final technical report, July 5, 1995--December 31, 1999

    SciTech Connect

    Jeffrey, F.

    2000-03-28

    Iowa Thin Film Technologies is completing a three-phase program that has increased throughput and decreased costs in nearly all aspects of its thin-film photovoltaic manufacturing process. The overall manufacturing costs have been reduced by 61 percent through implementation of the improvements developed under this program. Development of the ability to use a 1-mil substrate, rather than the standard 2-mil substrate, results in a 50 percent cost-saving for this material. Process development on a single-pass amorphous silicon deposition system has resulted in a 37 percent throughput improvement. A wide range of process and machine improvements have been implemented on the transparent conducting oxide deposition system. These include detailed parameter optimization of deposition temperatures, process gas flows, carrier gas flows, and web speeds. An overall process throughput improvement of 275 percent was achieved based on this work. The new alignment technique was developed for the laser scriber and printer systems, which improved registration accuracy from 100 microns to 10 microns. The new technique also reduced alignment time for these registration systems significantly. This resulted in a throughput increase of 75 percent on the scriber and 600 percent on the printer. Automated techniques were designed and implemented for the module assembly processes. These include automated busbar attachment, roll-based lamination, and automated die cutting of finished modules. These processes were previously done by hand labor. Throughput improvements ranged from 200 percent to 1200 percent, relative to hand labor rates. A wide range of potential encapsulation materials were evaluated for suitability in a roll lamination process and for cost-effectiveness. A combination material was found that has a cost that is only 10 percent of the standard EVA/Tefzel cost and is suitable for medium-lifetime applications. The 20-year lifetime applications still require the more expensive

  5. Changes in physico-chemical properties and volatile compounds throughout the manufacturing process of dry-cured foal loin.

    PubMed

    Lorenzo, José M; Carballo, J

    2015-01-01

    Physico-chemical, textural, lipolytic and volatile compound changes that occur during the manufacture of dry-cured foal loin were studied. Hardness and chewiness increased significantly (P<0.001) from 1.67 kg and 0.48 kg ∗ mm to 18.33 kg and 5.01 kg∗mm, respectively during ripening process. The total average content of free fatty acid increased significantly (P<0.001), from 768.8 mg/100g of fat in the loins immediately after the seasoning period to 1271.1mg/100g of fat at the end of the drying-ripening period. In the final product, aldehydes became the dominant volatile compounds. PMID:25280362

  6. The Manufacturing Process for the NASA Composite Crew Module Demonstration Structure

    NASA Technical Reports Server (NTRS)

    Pelham, Larry; Higgins, John E.

    2008-01-01

    lower tooling cost and less manufacturing risk. Assembly of the top and bottom halves of the pressure shell will allow access to the interior of the shell throughout remaining fabrication sequence and can also potentially permit extensive installation of equipment and .crew facilities prior to final assembly of the two shell halves. A Pi pre-form is a woven carbon composite material which is provided in pre-impregnated form and frozen for long term storage. The cross-section shape allows the top of the pi to be bonded to a flat or curved surface with a second flat plate composite section bonded between two upstanding legs of the Pi. One of the regions relying on the merits of the Pi pre-form is the backbone. All connections among plates of the backbone structure, including the upper flanges, and to the lobe base of the pressure shell are currently joined by Pi pre-forms. The intersection of backbone composite plates is formed by application of two Pi pre-forms, top flanges and lobed surfaces are bonded with one Pi pre-form. The process of applying the pre-impregnated pi-preform will be demonstrated to include important steps like surface preparation, forming, application of pressure dams, vacuum bagging for consolidation, and curing techniques. Chopped carbon fiber tooling was selected over other traditional metallic and carbon fiber tooling. The requirement of schedule and cost economy for a moderate reuse cure tool warranted composite tooling options. Composite tooling schedule duration of 18 weeks compared favorably against other metallic tooling including invar tooling. Composite tooling also shows significant cost savings over low CTE metallic options. The composite tooling options were divided into two groups and the final decision was based on the cost, schedule, tolerance, temperature, and reuse requirements.

  7. Cryogenic methane separation/catalytic hydrogasification process analysis. Final report

    SciTech Connect

    Cassano, A.A.; Hilton, M.F.; Li, T.C.; Tsao, T.R.

    1980-02-14

    The objective of this program was to recommend the most attractive combinations of acid gas removal methane separation systems for the Exxon Catalytic Coal Gasification (CCG) and the Rockwell Hydrogasification process currently undergoing development supported by DOE. The program was comprised of the following tasks. Screening to define the most promising integration scheme for each gasification process; development of a process flowsheet, heat and material balance, P and ID, equipment specification, utility summary, and plot plan for the process combination selected; and preparation of detailed economic and final report. The results of the study are documented in this report. The evaluations were performed using data supplied by the prime coal gasification contractors and the vendors of proprietary acid gas removal processes. This information, combined with Air Products' in-house capabilities in acid gas and cryogenic separation processses, was used to develop process designs and cost estimates for each integrated system. The design based and economic criteria employed in the study are described.

  8. Thermographic In-Situ Process Monitoring of the Electron Beam Melting Technology used in Additive Manufacturing

    SciTech Connect

    Dinwiddie, Ralph Barton; Dehoff, Ryan R; Lloyd, Peter D; Lowe, Larry E; Ulrich, Joseph B

    2013-01-01

    Oak Ridge National Laboratory (ORNL) has been utilizing the ARCAM electron beam melting technology to additively manufacture complex geometric structures directly from powder. Although the technology has demonstrated the ability to decrease costs, decrease manufacturing lead-time and fabricate complex structures that are impossible to fabricate through conventional processing techniques, certification of the component quality can be challenging. Because the process involves the continuous deposition of successive layers of material, each layer can be examined without destructively testing the component. However, in-situ process monitoring is difficult due to metallization on inside surfaces caused by evaporation and condensation of metal from the melt pool. This work describes a solution to one of the challenges to continuously imaging inside of the chamber during the EBM process. Here, the utilization of a continuously moving Mylar film canister is described. Results will be presented related to in-situ process monitoring and how this technique results in improved mechanical properties and reliability of the process.

  9. Formation of Volatile Tea Constituent Indole During the Oolong Tea Manufacturing Process.

    PubMed

    Zeng, Lanting; Zhou, Ying; Gui, Jiadong; Fu, Xiumin; Mei, Xin; Zhen, Yunpeng; Ye, Tingxiang; Du, Bing; Dong, Fang; Watanabe, Naoharu; Yang, Ziyin

    2016-06-22

    Indole is a characteristic volatile constituent in oolong tea. Our previous study indicated that indole was mostly accumulated at the turn over stage of oolong tea manufacturing process. However, formation of indole in tea leaves remains unknown. In this study, one tryptophan synthase α-subunit (TSA) and three tryptophan synthase β-subunits (TSBs) from tea leaves were isolated, cloned, sequenced, and functionally characterized. Combination of CsTSA and CsTSB2 recombinant protein produced in Escherichia coli exhibited the ability of transformation from indole-3-glycerol phosphate to indole. CsTSB2 was highly expressed during the turn over process of oolong tea. Continuous mechanical damage, simulating the turn over process, significantly enhanced the expression level of CsTSB2 and amount of indole. These suggested that accumulation of indole in oolong tea was due to the activation of CsTSB2 by continuous wounding stress from the turn over process. Black teas contain much less indole, although wounding stress is also involved in the manufacturing process. Stable isotope labeling indicated that tea leaf cell disruption from the rolling process of black tea did not lead to the conversion of indole, but terminated the synthesis of indole. Our study provided evidence concerning formation of indole in tea leaves for the first time. PMID:27263428

  10. Power of experimental design studies for the validation of pharmaceutical processes: case study of a multilayer tablet manufacturing process.

    PubMed

    Goutte, F; Guemguem, F; Dragan, C; Vergnault, G; Wehrlé, P

    2002-08-01

    Experimental design studies (EDS) are already widely used in the pharmaceutical industry for drug formulation or process optimization. Rare are the situations in which this methodology is applied for validation purposes. The power of this statistical tool, key element of a global validation strategy, is demonstrated for a multilayer tablet manufacturing process. Applied to the Geomatrix system generally composed of one compression and three granulation processes, time and strictness gains are non-negligible. Experimental design studies are not used in this work for modeling. Introduced at each important step of the process development, they allow for the evaluation of process ruggedness at pilot scale and specifications for full production. A demonstration of the complete control of key process parameters is given, identified throughout preliminary studies. PMID:12236070

  11. A digital process for additive manufacturing of occlusal splints: a clinical pilot study.

    PubMed

    Salmi, Mika; Paloheimo, Kaija-Stiina; Tuomi, Jukka; Ingman, Tuula; Mäkitie, Antti

    2013-07-01

    The aim of this study was to develop and evaluate a digital process for manufacturing of occlusal splints. An alginate impression was taken from the upper and lower jaws of a patient with temporomandibular disorder owing to cross bite and wear of the teeth, and then digitized using a table laser scanner. The scanned model was repaired using the 3Data Expert software, and a splint was designed with the Viscam RP software. A splint was manufactured from a biocompatible liquid photopolymer by stereolithography. The system employed in the process was SLA 350. The splint was worn nightly for six months. The patient adapted to the splint well and found it comfortable to use. The splint relieved tension in the patient's bite muscles. No sign of tooth wear or significant splint wear was detected after six months of testing. Modern digital technology enables us to manufacture clinically functional occlusal splints, which might reduce costs, dental technician working time and chair-side time. Maximum-dimensional errors of approximately 1 mm were found at thin walls and sharp corners of the splint when compared with the digital model. PMID:23614943

  12. A digital process for additive manufacturing of occlusal splints: a clinical pilot study

    PubMed Central

    Salmi, Mika; Paloheimo, Kaija-Stiina; Tuomi, Jukka; Ingman, Tuula; Mäkitie, Antti

    2013-01-01

    The aim of this study was to develop and evaluate a digital process for manufacturing of occlusal splints. An alginate impression was taken from the upper and lower jaws of a patient with temporomandibular disorder owing to cross bite and wear of the teeth, and then digitized using a table laser scanner. The scanned model was repaired using the 3Data Expert software, and a splint was designed with the Viscam RP software. A splint was manufactured from a biocompatible liquid photopolymer by stereolithography. The system employed in the process was SLA 350. The splint was worn nightly for six months. The patient adapted to the splint well and found it comfortable to use. The splint relieved tension in the patient's bite muscles. No sign of tooth wear or significant splint wear was detected after six months of testing. Modern digital technology enables us to manufacture clinically functional occlusal splints, which might reduce costs, dental technician working time and chair-side time. Maximum-dimensional errors of approximately 1 mm were found at thin walls and sharp corners of the splint when compared with the digital model. PMID:23614943

  13. Potential for on-orbit manufacture of large space structures using the pultrusion process

    NASA Technical Reports Server (NTRS)

    Wilson, Maywood L.; Macconochie, Ian O.; Johnson, Gary S.

    1987-01-01

    On-orbit manufacture of lightweight, high-strength, advanced-composite structures using the pultrusion process is proposed. This process is adaptable to a zero-gravity environment by using preimpregnated graphite-fiber reinforcement systems. The reinforcement material is preimpregnated with a high-performance thermoplastic resin at a ground station, is coiled on spools for compact storage, and is transported into Earth orbit. A pultrusion machine is installed in the Shuttle cargo bay from which very long lengths of the desired structure is fabricated on-orbit. Potential structural profiles include rods, angles, channels, hat sections, tubes, honeycomb-cored panels, and T, H, and I beams. A potential pultrudable thermoplastic/graphite composite material is presented as a model for determining the effect on Earth-to-orbit package density of an on-orbit manufacture, the package density is increased by 132 percent, and payload volume requirement is decreased by 56.3 percent. The fabrication method has the potential for on-orbit manufacture of structural members for space platforms, large space antennas, and long tethers.

  14. A neural manufacturing a novel concept for processing modeling, monitoring and control

    SciTech Connect

    Law, B.; Fu, C.Y.; Petrich, L.

    1995-10-01

    Semiconductor fabrication lines have become extremely costly, and achieving a good return from such a high capital investment requires efficient utilization of these expensive facilities. It is highly desirable to shorten processing development time, increase fabrication yield, enhance flexibility, improve quality, and minimize downtime. We propose that these ends can be achieved by applying recent advances in the areas of artificial neural networks, fuzzy logic, machine learning, and genetic algorithms. We use the term neural manufacturing to describe such applications. This paper describes our use of artificial neural networks to improve the monitoring and control of semiconductor process.

  15. Electric poling-assisted additive manufacturing process for PVDF polymer-based piezoelectric device applications

    NASA Astrophysics Data System (ADS)

    Lee, ChaBum; Tarbutton, Joshua A.

    2014-09-01

    This paper presents a new additive manufacturing (AM) process to directly and continuously print piezoelectric devices from polyvinylidene fluoride (PVDF) polymeric filament rods under a strong electric field. This process, called ‘electric poling-assisted additive manufacturing or EPAM, combines AM and electric poling processes and is able to fabricate free-form shape piezoelectric devices continuously. In this process, the PVDF polymer dipoles remain well-aligned and uniform over a large area in a single design, production and fabrication step. During EPAM process, molten PVDF polymer is simultaneously mechanically stresses in-situ by the leading nozzle and electrically poled by applying high electric field under high temperature. The EPAM system was constructed to directly print piezoelectric structures from PVDF polymeric filament while applying high electric field between nozzle tip and printing bed in AM machine. Piezoelectric devices were successfully fabricated using the EPAM process. The crystalline phase transitions that occurred from the process were identified by using the Fourier transform infrared spectroscope. The results indicate that devices printed under a strong electric field become piezoelectric during the EPAM process and that stronger electric fields result in greater piezoelectricity as marked by the electrical response and the formation of sharper peaks at the polar β crystalline wavenumber of the PVDF polymer. Performing this process in the absence of an electric field does not result in dipole alignment of PVDF polymer. The EPAM process is expected to lead to the widespread use of AM to fabricate a variety of piezoelectric PVDF polymer-based devices for sensing, actuation and energy harvesting applications with simple, low cost, single processing and fabrication step.

  16. Processing of New Materials by Additive Manufacturing: Iron-Based Alloys Containing Silver for Biomedical Applications

    NASA Astrophysics Data System (ADS)

    Niendorf, Thomas; Brenne, Florian; Hoyer, Peter; Schwarze, Dieter; Schaper, Mirko; Grothe, Richard; Wiesener, Markus; Grundmeier, Guido; Maier, Hans Jürgen

    2015-07-01

    In the biomedical sector, production of bioresorbable implants remains challenging due to improper dissolution rates or deficient strength of many candidate alloys. Promising materials for overcoming the prevalent drawbacks are iron-based alloys containing silver. However, due to immiscibility of iron and silver these alloys cannot be manufactured based on conventional processing routes. In this study, iron-manganese-silver alloys were for the first time synthesized by means of additive manufacturing. Based on combined mechanical, microscopic, and electrochemical studies, it is shown that silver particles well distributed in the matrix can be obtained, leading to cathodic sites in the composite material. Eventually, this results in an increased dissolution rate of the alloy. Stress-strain curves showed that the incorporation of silver barely affects the mechanical properties.

  17. Presence of airborne fibers in tungsten refining and manufacturing processes: preliminary characterization.

    PubMed

    McKernan, John L; Toraason, Mark A; Fernback, Joseph E

    2008-07-01

    In tungsten refining and manufacturing processes, a series of tungsten oxides (WO(X)) are typically formed as intermediates in the production of tungsten powder. Studies in the Swedish tungsten refining and manufacturing industry have shown that intermediate tungsten refining processes can create WO(X) fibers. The purpose of the present study was to identify and provide a preliminary characterization of airborne tungsten-containing fiber dimensions, elemental composition, and concentrations in the U.S. tungsten refining and manufacturing industry. To provide the preliminary characterization, 10 static air samples were collected during the course of normal employee work activities and analyzed using standard fiber sampling and counting methods. Results from transmission electron microscopy analyses conducted indicate that airborne fibers with length > 0.5 microm, diameter > 0.01 microm, and aspect ratio > or = 3:1, with a geometric mean (GM) length of approximately 2.0 microm and GM diameter of approximately 0.25 microm, were present on 9 of the 10 air samples collected. Energy dispersive X-ray spectrometry results indicate that airborne fibers prior to the carburization process consisted primarily of tungsten and oxygen, with other elements being detected in trace quantities. Results from an air sample collected at the carburization process indicated the presence of fibers composed primarily of tungsten with oxygen and carbon, and traces of other elements. Based on National Institute for Occupational Safety and Health standard fiber counting rules, airborne fiber concentrations ranged from below the limit of detection to 0.14 f/cm(3). The calcining process was associated with the highest airborne fiber concentrations. More than 99% (574/578) of the airborne fibers identified had an aerodynamic diameter

  18. Investigation of the Application of Process Analytical Technology for a Laser Welding Process in Medical Device Manufacturing

    NASA Astrophysics Data System (ADS)

    Moore, Sean; Conneely, Alan; Stenzel, Eric; Murphy, Eamonn

    In FDA regulated medical device manufacturing, real time inspection of manufactured product is limited by the requirement to destructively test random samples of the product post production. Infra Red thermography offers the ability to non-destructively test, key critical to quality attributes of medical devices during laser welding and facilitates real time statistical process control for enhanced product quality and yield. This paper will present results of research work focused on non-destructive methods using Infra Red Thermography to potentially replace destructive methods of assessment for laser welded joints in stent delivery catheters. The approach utilizes designed experiments in conjunction with IR assessment and also identifies some limitations of the proposed method.

  19. Affordable Design: A Methodolgy to Implement Process-Based Manufacturing Cost into the Traditional Performance-Focused Multidisciplinary Design Optimization

    NASA Technical Reports Server (NTRS)

    Bao, Han P.; Samareh, J. A.

    2000-01-01

    The primary objective of this paper is to demonstrate the use of process-based manufacturing and assembly cost models in a traditional performance-focused multidisciplinary design and optimization process. The use of automated cost-performance analysis is an enabling technology that could bring realistic processbased manufacturing and assembly cost into multidisciplinary design and optimization. In this paper, we present a new methodology for incorporating process costing into a standard multidisciplinary design optimization process. Material, manufacturing processes, and assembly processes costs then could be used as the objective function for the optimization method. A case study involving forty-six different configurations of a simple wing is presented, indicating that a design based on performance criteria alone may not necessarily be the most affordable as far as manufacturing and assembly cost is concerned.

  20. 21 CFR 111.530 - When must an investigation be conducted of your manufacturing processes and other batches?

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... PRACTICE IN MANUFACTURING, PACKAGING, LABELING, OR HOLDING OPERATIONS FOR DIETARY SUPPLEMENTS Returned Dietary Supplements § 111.530 When must an investigation be conducted of your manufacturing processes and other batches? If the reason for a dietary supplement being returned implicates other batches, you...

  1. 21 CFR 111.530 - When must an investigation be conducted of your manufacturing processes and other batches?

    Code of Federal Regulations, 2013 CFR

    2013-04-01

    ... PRACTICE IN MANUFACTURING, PACKAGING, LABELING, OR HOLDING OPERATIONS FOR DIETARY SUPPLEMENTS Returned Dietary Supplements § 111.530 When must an investigation be conducted of your manufacturing processes and other batches? If the reason for a dietary supplement being returned implicates other batches, you...

  2. 21 CFR 111.530 - When must an investigation be conducted of your manufacturing processes and other batches?

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... PRACTICE IN MANUFACTURING, PACKAGING, LABELING, OR HOLDING OPERATIONS FOR DIETARY SUPPLEMENTS Returned Dietary Supplements § 111.530 When must an investigation be conducted of your manufacturing processes and other batches? If the reason for a dietary supplement being returned implicates other batches, you...

  3. 21 CFR 111.530 - When must an investigation be conducted of your manufacturing processes and other batches?

    Code of Federal Regulations, 2011 CFR

    2011-04-01

    ... PRACTICE IN MANUFACTURING, PACKAGING, LABELING, OR HOLDING OPERATIONS FOR DIETARY SUPPLEMENTS Returned Dietary Supplements § 111.530 When must an investigation be conducted of your manufacturing processes and other batches? If the reason for a dietary supplement being returned implicates other batches, you...

  4. Control technology overview report: CFC (chlorofluorocarbon) emissions from rigid foam manufacturing. Final report, March-November 1986

    SciTech Connect

    Wert, K.P.; Nelson, T.P.; Quass, J.D.

    1988-01-01

    The report estimates total chlorofluorocarbon (CFC) emissions from the various rigid foam manufacturing processes and from the foam products themselves, and examines potential methods for reducing these emissions. Options studied include replacement of CFC-blown products with alternative products not requiring CFCs, replacement of ozone-depleting CFCs with other chemicals less likely to destroy stratospheric ozone, and recovery/recycle of CFCs released during manufacturing processes. In the production of rigid cellular foams, CFCs are used as physical blowing agents to reduce foam density and impart thermal insulating properties. Such rigid foams include polyurethane, polystyrene, polyethylene, polypropylene, polyvinyl chloride, and phenolic foams. Uses of these foams include building insulation, packaging materials, and single-service dinnerware. Depletion of stratospheric ozone through action of halocarbons, particularly CFCs, has been the subject of extensive study and wide debate. Although many uncertainties remain, current scientific evidence strongly suggests that anthropogenic CFCs could contribute to depletion of the stratospheric ozone layer as was first postulated in 1974.

  5. Challenges and Recent Developments in Hearing Aids: Part II. Feedback and Occlusion Effect Reduction Strategies, Laser Shell Manufacturing Processes, and Other Signal Processing Technologies

    PubMed Central

    Chung, King

    2004-01-01

    This is the second part of a review on the challenges and recent developments in hearing aids. Feedback and the occlusion effect pose great challenges in hearing aid design and usage. Yet, conventional solutions to feedback and the occlusion effect often create a dilemma: the solution to one often leads to the other. This review discusses the advanced signal processing strategies to reduce feedback and some new approaches to reduce the occlusion effect. Specifically, the causes of three types of feedback (acoustic, mechanical, and electromagnetic) are discussed. The strategies currently used to reduce acoustic feedback (i.e., adaptive feedback reduction algorithms using adaptive gain reduction, notch filtering, and phase cancellation strategies) and the design of new receivers that are built to reduce mechanical and electromagnetic feedback are explained. In addition, various new strategies (i.e., redesigned sound delivery devices and receiver-in-the-ear-canal hearing aid configuration) to reduce the occlusion effect are reviewed. Many manufacturers have recently adopted laser shell-manufacturing technologies to overcome problems associated with manufacturing custom hearing aid shells. The mechanisms of selected laser sintering and stereo lithographic apparatus and the properties of custom shells produced by these two processes are reviewed. Further, various new developments in hearing aid transducers, telecoils, channel-free amplification, open-platform programming options, rechargeable hearing aids, ear-level frequency modulated (FM) receivers, wireless Bluetooth FM systems, and wireless programming options are briefly explained and discussed. Finally, the applications of advanced hearing aid technologies to enhance other devices such as cochlear implants, hearing protectors, and cellular phones are discussed. PMID:15735871

  6. Risk management for moisture related effects in dry manufacturing processes: a statistical approach.

    PubMed

    Quiroz, Jorge; Strong, John; Zhang, Lanju

    2016-03-01

    A risk- and science-based approach to control the quality in pharmaceutical manufacturing includes a full understanding of how product attributes and process parameters relate to product performance through a proactive approach in formulation and process development. For dry manufacturing, where moisture content is not directly manipulated within the process, the variability in moisture of the incoming raw materials can impact both the processability and drug product quality attributes. A statistical approach is developed using individual raw material historical lots as a basis for the calculation of tolerance intervals for drug product moisture content so that risks associated with excursions in moisture content can be mitigated. The proposed method is based on a model-independent approach that uses available data to estimate parameters of interest that describe the population of blend moisture content values and which do not require knowledge of the individual blend moisture content values. Another advantage of the proposed tolerance intervals is that, it does not require the use of tabulated values for tolerance factors. This facilitates the implementation on any spreadsheet program like Microsoft Excel. A computational example is used to demonstrate the proposed method. PMID:25384711

  7. Controlled Thermal-Mechanical Processing of Tubes and Pipes for Enhanced Manufacturing and Performance

    SciTech Connect

    Kolarik, Robert V.

    2005-11-11

    The Alloy Steel Business of The Timken Company won an award for the controlled thermo-mechanical processing (CTMP) project and assembled a strong international public/private partnership to execute the project. The premise of the CTMP work was to combine Timken's product understanding with its process expertise and knowledge of metallurgical and deformation fundamentals developed during the project to build a predictive process design capability. The CTMP effort succeeded in delivering a pc-based capability in the tube optimization model, with a virtual pilot plant (VPP) feature to represent the desired tube making process to predict the resultant microstructure tailored for the desired application. Additional tasks included a system for direct, online measurement of grain size and demonstration of application of CTMP via robotically enhanced manufacturing.

  8. Rapid Intelligent Inspection Process Definition for dimensional measurement in advanced manufacturing

    SciTech Connect

    Brown, C.W.

    1993-03-01

    The Rapid Intelligent Inspection Process Definition (RIIPD) project is an industry-led effort to advance computer integrated manufacturing (CIM) systems for the creation and modification of inspection process definitions. The RIIPD project will define, design, develop, and demonstrate an automated tool (i.e., software) to generate inspection process plans and coordinate measuring machine (CMM) inspection programs, as well as produce support information for the dimensional measurement of piece parts. The goal of this project is to make the inspection and part verification function, specifically CMM measurements, a more effective production support tool by reducing inspection process definition flowtime, creating consistent and standard inspections, increasing confidence of measurement results, and capturing inspection expertise. This objective is accomplished through importing STEP geometry definitions, applying solid modeling, incorporating explicit tolerance representations, establishing dimensional inspection,techniques, embedding artificial intelligence techniques, and adhering to the Dimensional Measuring Interface Standard (DMIS) national standard.

  9. Sensor-based atomic layer deposition for rapid process learning and enhanced manufacturability

    NASA Astrophysics Data System (ADS)

    Lei, Wei

    In the search for sensor based atomic layer deposition (ALD) process to accelerate process learning and enhance manufacturability, we have explored new reactor designs and applied in-situ process sensing to W and HfO 2 ALD processes. A novel wafer scale ALD reactor, which features fast gas switching, good process sensing compatibility and significant similarity to the real manufacturing environment, is constructed. The reactor has a unique movable reactor cap design that allows two possible operation modes: (1) steady-state flow with alternating gas species; or (2) fill-and-pump-out cycling of each gas, accelerating the pump-out by lifting the cap to employ the large chamber volume as ballast. Downstream quadrupole mass spectrometry (QMS) sampling is applied for in-situ process sensing of tungsten ALD process. The QMS reveals essential surface reaction dynamics through real-time signals associated with byproduct generation as well as precursor introduction and depletion for each ALD half cycle, which are then used for process learning and optimization. More subtle interactions such as imperfect surface saturation and reactant dose interaction are also directly observed by QMS, indicating that ALD process is more complicated than the suggested layer-by-layer growth. By integrating in real-time the byproduct QMS signals over each exposure and plotting it against process cycle number, the deposition kinetics on the wafer is directly measured. For continuous ALD runs, the total integrated byproduct QMS signal in each ALD run is also linear to ALD film thickness, and therefore can be used for ALD film thickness metrology. The in-situ process sensing is also applied to HfO2 ALD process that is carried out in a furnace type ALD reactor. Precursor dose end-point control is applied to precisely control the precursor dose in each half cycle. Multiple process sensors, including quartz crystal microbalance (QCM) and QMS are used to provide real time process information. The

  10. About the use of stoichiometric hydroxyapatite in compression - incidence of manufacturing process on compressibility.

    PubMed

    Pontier, C; Viana, M; Champion, E; Bernache-Assollant, D; Chulia, D

    2001-05-01

    Literature concerning calcium phosphates in pharmacy exhibits the chemical diversity of the compounds available. Some excipient manufacturers offer hydroxyapatite as a direct compression excipient, but the chemical analysis of this compound usually shows a variability of the composition: the so-called materials can be hydroxyapatite or other calcium phosphates, uncalcined (i.e. with a low crystallinity) or calcined and well-crystallized hydroxyapatite. This study points out the incidence of the crystallinity of one compound (i.e. hydroxyapatite) on the mechanical properties. Stoichiometric hydroxyapatite is synthesized and compounds differing in their crystallinity, manufacturing process and particle size are manufactured. X-Ray diffraction analysis is used to investigate the chemical nature of the compounds. The mechanical study (study of the compression, diametral compressive strength, Heckel plots) highlights the negative effect of calcination on the mechanical properties. Porosity and specific surface area measurements show the effect of calcination on compaction. Uncalcined materials show bulk and mechanical properties in accordance with their use as direct compression excipients. PMID:11343890

  11. System-Cost-Optimized Smart EVSE for Residential Application: Final Technical Report including Manufacturing Plan

    SciTech Connect

    Zhu, Charles

    2015-05-15

    In the 2nd quarter of 2012, a program was formally initiated at Delta Products to develop smart-grid-enabled Electric Vehicle Supply Equipment (EVSE) product for residential use. The project was funded in part by the U.S. Department of Energy (DOE), under award DE-OE0000590. Delta products was the prime contractor to DOE during the three year duration of the project. In addition to Delta Products, several additional supplier-partners were engaged in this research and development (R&D) program, including Detroit Edison DTE, Mercedes Benz Research and Development North America, and kVA. This report summarizes the program and describes the key research outcomes of the program. A technical history of the project activities is provided, which describes the key steps taken in the research and the findings made at successive stages in the multi-stage work. The evolution of an EVSE prototype system is described in detail, culminating in prototypes shipped to Department of Energy Laboratories for final qualification. After the program history is reviewed, the key attributes of the resulting EVSE are described in terms of functionality, performance, and cost. The results clearly demonstrate the ability of this EVSE to meet or exceed DOE's targets for this program, including: construction of a working product-intent prototype of a smart-grid-enabled EVSE, with suitable connectivity to grid management and home-energy management systems, revenue-grade metering, and related technical functions; and cost reduction of 50% or more compared to typical market priced EVSEs at the time of DOE's funding opportunity announcement (FOA), which was released in mid 2011. In addition to meeting all the program goals, the program was completed within the original budget and timeline established at the time of the award. The summary program budget and timeline, comparing plan versus actual values, is provided for reference, along with several supporting explanatory notes. Technical information

  12. The Colloidal Stabilization of Quantum Dots: Towards Manufacturable, Efficient Solution-Processed Solar Cells

    NASA Astrophysics Data System (ADS)

    Rollny, Lisa

    Understanding colloidal stabilization can influence the design of optoelectronic devices and enable improvements to their performance and stability. For photovoltaics, important characteristics of the active layer material are high conductivity along with a minimum of recombination centers. In order to capitalize on the benefits of solution-processed materials, it is important to minimize the number of processing steps: ideally, to achieve a low-cost solution, materials would be deposited using a single process step compatible with roll-to-roll manufacturing. Prior to this work, the highest-performing colloidal quantum dots (CQD) solar cells have relied on several deposition steps that are repeated in a layer-by-layer (LBL) fashion. The purpose of these process steps has been to remove the long insulating ligands used in synthesis and replace them with short ligands that allow electrical conduction. The large number of steps combined, typically implemented via spin coating, leads to inefficient materials utilization and fails to show a path to a manufacturable solution. In this work, the first CQD solar cells were designed, built, and characterized combining state-of-art performance with scalable manufacture. Firstly, I report the first automated CQD synthesis to result in CQDs that form high-performance CQD solar cells. I analyze the CQD synthesis and by separating it into two phases---nucleation and growth phase---my insights are used to create higher-quality CQDs exhibiting enhanced monodispersity. I then proceed to develop a CQD ink: a CQD solution ready for direct deposition to form a semiconducting film exhibiting low trap state density. In early trials the CQD ink showed only limited power conversion efficiencies of 2%. I designed a new ink strategy, which I term cleavable hemiketal ligands. This novel two-component ligand strategy enables the combination of colloidal stabilization (via this longer two-component ligand) and cleavability (enabling excellent

  13. Optimization of PWR behavior of stress-relieved Zircaloy-4 cladding tubes by improving the manufacturing and inspection process

    SciTech Connect

    Mardon, J.P.; Charquet, D.; Senevat, J.

    1994-12-31

    With the aim of optimizing the basic properties of stress-relieved Zircaloy-4 cladding tubes, particularly those that make it possible to push back the initial technological limits that may be encountered, and of reducing the scatter of those properties and enhancing tube quality, the role of the main parameters involved in manufacturing the ingot, Trex, and cladding tube has been evaluated on an industrial scale. A series of large-sized tube lots were produced under controlled manufacturing conditions, then characterized by out-of-pile test results (short- and long-term corrosion, stress corrosion cracking (SCC), creep, mechanical, and structural properties) on finished tubes. For the investigated parameters (chemical compositions, number of melt, quench rate, accumulated annealing parameter, the {Sigma}A factor, surface condition (outside and inside diameters), and finished tube quality), this role is indeed important but complex due to the highly interactive nature of the variables investigated. Adjustment of the chemical composition within ASTM limits enables generalized corrosion resistance to be enhanced and irradiation growth to be minimized. A significant decrease of the observed scatter in corrosion and mechanical properties is obtained by optimization of the {Sigma}A range, the quenching rate, and the final heat treatment. The optimum seems to be reached for a final treatment at the highest possible temperature compatible with the stress-relieved state, corresponding to an average precipitate size and {Sigma}A. Moreover, by adding anneals upstream in the process, a further increase in this {Sigma}A no longer seems to have a significant effect on generalized corrosion.

  14. Influence of manufacturing processes on cell surface properties of probiotic strain Lactobacillus rhamnosus Lcr35®.

    PubMed

    Nivoliez, Adrien; Veisseire, Philippe; Alaterre, Elina; Dausset, Caroline; Baptiste, Fabrice; Camarès, Olivier; Paquet-Gachinat, Marylise; Bonnet, Muriel; Forestier, Christiane; Bornes, Stéphanie

    2015-01-01

    The influence of the industrial process on the properties of probiotics, administered as complex manufactured products, has been poorly investigated. In the present study, we comparatively assessed the cell wall characteristics of the probiotic strain Lactobacillus rhamnosus Lcr35® together with three of its commercial formulations with intestinal applications. Putative secreted and transmembrane-protein-encoding genes were initially searched in silico in the genome of L. rhamnosus Lcr35®. A total of 369 candidate genes were identified which expressions were followed using a custom Lactobacillus DNA chip. Among them, 60 or 67 genes had their expression either upregulated or downregulated in the Lcr Restituo® packet or capsule formulations, compared to the native Lcr35® strain. Moreover, our data showed that the probiotic formulations (Lcr Lenio®, Lcr restituo® capsule and packet) showed a better capacity to adhere to intestinal epithelial Caco-2 cells than the native Lcr35® strain. Microbial (MATS) tests showed that the probiotic was an electron donor and that they were more hydrophilic than the native strain. The enhanced adhesion capacity of the active pharmaceutical ingredients (APIs) to epithelial Caco-2 cells and their antipathogen effect could be due to this greater surface hydrophilic character. These findings suggest that the manufacturing process influences the protein composition and the chemical properties of the cell wall. It is therefore likely that the antipathogen effect of the formulation is modulated by the industrial process. Screening of the manufactured products' properties would therefore represent an essential step in evaluating the effects of probiotic strains. PMID:25280746

  15. Innovative Approaches to Low-Cost Module Manufacturing of String Ribbon Si PV Modules; Final Subcontract Report, March 2002 - January 2005

    SciTech Connect

    Hanoka, J. I.

    2005-10-01

    As a result of this work, Evergreen Solar, Inc., is now poised to take String Ribbon technology to new heights. In the ribbon growth area, Project Gemini-the growth of dual ribbons from a single crucible-has reached or exceeded all the manufacturing goals set for it. This project grew from an R&D concept to a production pilot phase and finally to a full production phase, all within the span of this subcontract. A major aspect of the overall effort was the introduction of controls and instrumentation as in-line diagnostic tools. In the ribbon production area, the result has been a 12% increase in yields, a 10% increase in machine uptime, and the flattest ribbon ever grown at Evergreen. In the cell area, advances in process development and robotic handling of Gemini wafers have contributed, along with the advances in crystal growth, to a yield improvement of 6%. Particularly noteworthy in the cell area was the refinement of the no-etch process whereby the as-grown ribbon surface could be controlled sufficiently to allow this process to succeed as well as it has. This process obviates any need for wet chemistry or etching between ribbon growth and diffusion.

  16. TOWARD LOW-COST FABRICATION OF MICROCHANNEL PROCESS TECHNOLOGIES - COST MODELING FOR MANUFACTURING DEVELOPMENT

    SciTech Connect

    Leith, Steven D.; King, Dale A.; Paul, Brian

    2010-11-07

    Chemical and energy conversion systems based on microchannel process technology (MPT) demonstrate high performance in applications in which rates are controlled by diffusive heat and mass transfer flux. The performance of MPT-based heat exchangers, absorbers/desorbers and chemical reactors all benefit from process intensification and have been used in a variety of mobile energy conversion systems including fuel reformers/converters, heat pumps and waste heat scavenging technologies. The service environments typical of MPTs often require the devices to be fabricated from metals such as aluminum, titanium, stainless steel or high temperature super alloys. Flow channels and associated critical dimensions in these devices can be as small as 50 um, but generally range from 100 to 1000 um in width and height with characteristic flow channel lengths normally in the mm to cm range. High surface area architectures (e.g. wicks or textured surfaces) are often included in the flow channels as well for enhanced mass transfer and/or catalytic functionality. Fabrication of MPT devices has historically been performed using a stacked-shim approach in which individual metal sheets are first patterned with micro- and meso-scale flow channels and subsequently bonded in a stack to create an array of miniaturized, parallel flow paths. Typical proof-of-concept fabrication efforts have utilized photo chemical machining (PCM) for shim patterning and diffusion bonding or diffusion brazing for joining of shim stacks. While flexible and capable of supporting technology demonstration, however, these techniques can be expensive at prototyping volumes. The high fabrication cost associated with these prototyping processes has contributed to a perception that MPT technology is expensive and will be relegated to a small application space. Recent work at the Microproducts Breakthrough Institute (MBI) has focused on exploring the cost structure of high volume manufacturing of MPT devices in effort to

  17. Improved performance of quantum cascade lasers through a scalable, manufacturable epitaxial-side-down mounting process

    PubMed Central

    Tsekoun, Alexei; Go, Rowel; Pushkarsky, Michael; Razeghi, Manijeh; Patel, C. Kumar N.

    2006-01-01

    We report substantially improved performance of high-power quantum cascade lasers (QCLs) by using epitaxial-side-down mounting that provides superior heat dissipation properties. We used aluminum nitride as the heatsink material and gold–tin eutectic solder. We have obtained continuous wave power output of 450 mW at 20°C from mid-IR QCLs. The improved thermal management achieved with epitaxial-side-down mounting combined with a highly manufacturable and scalable assembly process should permit incorporation of mid-IR QCLs in reliable instrumentation. PMID:16547130

  18. Factors Affecting the Corporate Decision-Making Process of Air Transport Manufacturers

    NASA Technical Reports Server (NTRS)

    Ollila, R. G.; Hill, J. D.; Noton, B. R.; Duffy, M. A.; Epstein, M. M.

    1976-01-01

    Fuel economy is a pivotal question influencing the future sale and utilization of commercial aircraft. The NASA Aircraft Energy Efficiency (ACEE) Program Office has a program intended to accelerate the readiness of advanced technologies for energy efficient aircraft. Because the decision to develop a new airframe or engine is a major financial hazard for manufacturers, it is important to know what factors influence the decision making process. A method is described for identifying and ranking individuals and organizations involved at each stage of commercial air transport development, and the barriers that must be overcome in adopting new technologies.

  19. Preliminary Evaluation of Mechanical Properties of Co-Cr Alloys Fabricated by Three New Manufacturing Processes.

    PubMed

    Jang, Seong-Ho; Lee, Dae-Ho; Ha, Jung-Yun; Hanawa, Takao; Kim, Kyo-Han; Kwon, Tae-Yub

    2015-01-01

    A preliminary tensile test was performed to evaluate the mechanical properties of cobalt-chromium (Co-Cr) alloys fabricated by three new manufacturing processes: metal milling, milling for soft metal, and rapid prototyping (n=6). For comparison, the three alloy materials were also used to fabricate specimens by a casting procedure. In all groups tested, the proof strength and elongation were over 500 MPa and 2%, respectively. The milled soft alloy in particular showed a substantially greater elongation, whereas the alloy fabricated by rapid prototyping exhibited a higher proof strength. PMID:26218024

  20. Process for manufacture of inertial confinement fusion targets and resulting product

    DOEpatents

    Masnari, Nino A.; Rensel, Walter B.; Robinson, Merrill G.; Solomon, David E.; Wise, Kensall D.; Wuttke, Gilbert H.

    1982-01-01

    An ICF target comprising a spherical pellet of fusion fuel surrounded by a concentric shell; and a process for manufacturing the same which includes the steps of forming hemispheric shells of a silicon or other substrate material, adhering the shell segments to each other with a fuel pellet contained concentrically therein, then separating the individual targets from the parent substrate. Formation of hemispheric cavities by deposition or coating of a mold substrate is also described. Coatings or membranes may also be applied to the interior of the hemispheric segments prior to joining.