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Sample records for accelerate manufacturing cost

  1. Tritium target manufacturing for use in accelerators

    NASA Astrophysics Data System (ADS)

    Bach, P.; Monnin, C.; Van Rompay, M.; Ballanger, A.

    2001-07-01

    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 target on copper substrate, and going to more sophisticated devices. A wide range of possible uses is covered, including thin targets for neutron calibration, thick targets with controlled loading of deuterium and tritium, rotating targets for higher lifetimes, or large size rotating targets for accelerators used in boron neutron therapy. Activity of targets lies in the 1 to 1000 Curie, diameter of targets being up to 30 cm. Special targets are also considered, including surface layer targets for lowering tritium desorption under irradiation, or those made from different kinds of occluders such as titanium, zirconium, erbium, scandium, with different substrates. It is then possible to optimize either neutron output, or lifetime and stability, or thermal behavior.

  2. 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.

  3. Manufacturing Large Membrane Mirrors at Low Cost

    NASA Technical Reports Server (NTRS)

    2007-01-01

    Relatively inexpensive processes have been developed for manufacturing lightweight, wide-aperture mirrors that consist mainly of reflectively coated, edge-supported polyimide membranes. The polyimide and other materials in these mirrors can withstand the environment of outer space, and the mirrors have other characteristics that make them attractive for use on Earth as well as in outer space: With respect to the smoothness of their surfaces and the accuracy with which they retain their shapes, these mirrors approach the optical quality of heavier, more expensive conventional mirrors. Unlike conventional mirrors, these mirrors can be stowed compactly and later deployed to their full sizes. In typical cases, deployment would be effected by inflation. Potential terrestrial and outer-space applications for these mirrors include large astronomical telescopes, solar concentrators for generating electric power and thermal power, and microwave reflectors for communication, radar, and short-distance transmission of electric power. The relatively low cost of manufacturing these mirrors stems, in part, from the use of inexpensive tooling. Unlike in the manufacture of conventional mirrors, there is no need for mandrels or molds that have highly precise surface figures and highly polished surfaces. The surface smoothness is an inherent property of a polyimide film. The shaped area of the film is never placed in contact with a mold or mandrel surface: Instead the shape of a mirror is determined by a combination of (1) the shape of a fixture that holds the film around its edge and (2) control of manufacturing- process parameters. In a demonstration of this manufacturing concept, spherical mirrors having aperture diameters of 0.5 and 1.0 m were fabricated from polyimide films having thicknesses ranging from <20 m to 150 m. These mirrors have been found to maintain their preformed shapes following deployment.

  4. 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.

  5. 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.

  6. SOLID OXIDE FUEL CELL MANUFACTURING COST MODEL: SIMULATING RELATIONSHIPS BETWEEN PERFORMANCE, MANUFACTURING, AND COST OF PRODUCTION

    SciTech Connect

    Eric J. Carlson; Yong Yang; Chandler Fulton

    2004-04-20

    The successful commercialization of fuel cells will depend on the achievement of competitive system costs and efficiencies. System cost directly impacts the capital equipment component of cost of electricity (COE) and is a major contributor to the O and M component. The replacement costs for equipment (also heavily influenced by stack life) is generally a major contributor to O and M costs. In this project, they worked with the SECA industrial teams to estimate the impact of general manufacturing issues of interest on stack cost using an activities-based cost model for anode-supported planar SOFC stacks with metallic interconnects. An earlier model developed for NETL for anode supported planar SOFCs was enhanced by a linkage to a performance/thermal/mechanical model, by addition of Quality Control steps to the process flow with specific characterization methods, and by assessment of economies of scale. The 3-dimensional adiabatic performance model was used to calculate the average power density for the assumed geometry and operating conditions (i.e., inlet and exhaust temperatures, utilization, and fuel composition) based on publicly available polarizations curves. The SECA team provided guidance on what manufacturing and design issues should be assessed in this Phase I demonstration of cost modeling capabilities. They considered the impact of the following parameters on yield and cost: layer thickness (i.e., anode, electrolyte, and cathode) on cost and stress levels, statistical nature of ceramic material failure on yield, and Quality Control steps and strategies. In this demonstration of the capabilities of the linked model, only the active stack (i.e., anode, electrolyte, and cathode) and interconnect materials were included in the analysis. Factory costs are presented on an area and kilowatt basis to allow developers to extrapolate to their level of performance, stack design, materials, seal and system configurations, and internal corporate overheads and margin

  7. Manufacturing R&D Initiative Lowers Costs and Boosts Quality

    SciTech Connect

    2015-06-30

    Fact sheet that provides an overview of DOE's Manufacturing R&D Initiative, which supports projects aimed at developing better-performing, lower-cost solid-state lighting while encouraging engineering and manufacturing in the United States.

  8. Manufacturing cost/design system: A CAD/CAM dialogue

    NASA Technical Reports Server (NTRS)

    Loshigian, H. H.; Rachowitz, B. I.; Judson, D.

    1980-01-01

    The development of the Manufacturing Cost/Design System (MC/DS) will provide the aerospace design engineer a tool with which to perform heretofore impractical design manufacturing cost tradeoffs. The Air Force Integrated Computer Aided Manufacturing (ICAM) Office has initiated the development and demonstration of an MC/DS which, when fully implemented, will integrate both design and manufacturing data bases to provide real time visibility into the manufacturing costs associated with various design options. The first release of a computerized system will be made before the end of 1981.

  9. Low Cost Manufacturing of Composite Cryotanks

    NASA Technical Reports Server (NTRS)

    Meredith, Brent; Palm, Tod; Deo, Ravi; Munafo, Paul M. (Technical Monitor)

    2002-01-01

    This viewgraph presentation reviews research and development of cryotank manufacturing conducted by Northrup Grumman. The objectives of the research and development included the development and validation of manufacturing processes and technology for fabrication of large scale cryogenic tanks, the establishment of a scale-up and facilitization plan for full scale cryotanks, the development of non-autoclave composite manufacturing processes, the fabrication of subscale tank joints for element tests, the performance of manufacturing risk reduction trials for the subscale tank, and the development of full-scale tank manufacturing concepts.

  10. A review of the solar array manufacturing industry costing standards

    NASA Technical Reports Server (NTRS)

    1977-01-01

    The solar array manufacturing industry costing standards model is designed to compare the cost of producing solar arrays using alternative manufacturing processes. Constructive criticism of the methodology used is intended to enhance its implementation as a practical design tool. Three main elements of the procedure include workbook format and presentation, theoretical model validity and standard financial parameters.

  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. Low Cost Lithography Tool for High Brightness LED Manufacturing

    SciTech Connect

    Andrew Hawryluk; Emily True

    2012-06-30

    The objective of this activity was to address the need for improved manufacturing tools for LEDs. Improvements include lower cost (both capital equipment cost reductions and cost-ofownership reductions), better automation and better yields. To meet the DOE objective of $1- 2/kilolumen, it will be necessary to develop these highly automated manufacturing tools. Lithography is used extensively in the fabrication of high-brightness LEDs, but the tools used to date are not scalable to high-volume manufacturing. This activity addressed the LED lithography process. During R&D and low volume manufacturing, most LED companies use contact-printers. However, several industries have shown that these printers are incompatible with high volume manufacturing and the LED industry needs to evolve to projection steppers. The need for projection lithography tools for LED manufacturing is identified in the Solid State Lighting Manufacturing Roadmap Draft, June 2009. The Roadmap states that Projection tools are needed by 2011. This work will modify a stepper, originally designed for semiconductor manufacturing, for use in LED manufacturing. This work addresses improvements to yield, material handling, automation and throughput for LED manufacturing while reducing the capital equipment cost.

  13. Manufacturing Cost Levelization Model – A User’s Guide

    SciTech Connect

    Morrow, William R.; Shehabi, Arman; Smith, Sarah Josephine

    2015-08-01

    The Manufacturing Cost Levelization Model is a cost-performance techno-economic model that estimates total large-scale manufacturing costs for necessary to produce a given product. It is designed to provide production cost estimates for technology researchers to help guide technology research and development towards an eventual cost-effective product. The model presented in this user’s guide is generic and can be tailored to the manufacturing of any product, including the generation of electricity (as a product). This flexibility, however, requires the user to develop the processes and process efficiencies that represents a full-scale manufacturing facility. The generic model is comprised of several modules that estimate variable costs (material, labor, and operating), fixed costs (capital & maintenance), financing structures (debt and equity financing), and tax implications (taxable income after equipment and building depreciation, debt interest payments, and expenses) of a notional manufacturing plant. A cash-flow method is used to estimate a selling price necessary for the manufacturing plant to recover its total cost of production. A levelized unit sales price ($ per unit of product) is determined by dividing the net-present value of the manufacturing plant’s expenses ($) by the net present value of its product output. A user defined production schedule drives the cash-flow method that determines the levelized unit price. In addition, an analyst can increase the levelized unit price to include a gross profit margin to estimate a product sales price. This model allows an analyst to understand the effect that any input variables could have on the cost of manufacturing a product. In addition, the tool is able to perform sensitivity analysis, which can be used to identify the key variables and assumptions that have the greatest influence on the levelized costs. This component is intended to help technology researchers focus their research attention on tasks

  14. Comparison of indirect cost multipliers for vehicle manufacturing

    SciTech Connect

    Vyas, A.; Santini, D.; Cuenca, R.

    2000-05-16

    In the process of manufacturing and selling vehicles, a manufacturer incurs certain costs. Among these costs are those incurred directly as a part of manufacturing operations and those incurred indirectly in the processes of manufacturing and selling. The indirect costs may be production-related, such as R and D and engineering; business-related, such as corporate staff salaries and pensions; or retail-sales-related, such as dealer support and marketing. These indirect costs are recovered by allocating them to each vehicle. Under a stable, high-volume production process, the allocation of these indirect costs can be approximated as multipliers (or factors) applied to the direct cost of manufacturing. A manufacturer usually allocates indirect costs to finished vehicles according to a corporation-specific pricing strategy. Because the volumes of sales and production vary widely by model within a corporation, the internal corporate percent allocation of various accounting categories (such as profit or corporate overheat) can vary widely among individual models. Approaches also vary across corporations. For these purposes, an average value is constructed, by means of a generic representative method, for vehicle models produced at high volume. To accomplish this, staff at Argonne National Laboratory's (ANL's) Center for Transportation Research analyzed the conventional vehicle cost structure and developed indirect cost multipliers for passenger vehicles. This memorandum summarizes the results of an effort to compare and put on a common basis the cost multipliers used in ANL's electric and hybrid electric vehicle cost estimation procedures with those resulting from two other methodologies. One of the two compared methodologies is derived from a 1996 presentation by Dr. Chris Borroni-Bird of Chrysler Corporation, the other is by Energy and Environmental Analysis, Inc. (EEA), as described in a 1995 report by the Office of Technology Assessment (OTA), Congress of the United

  15. SAMICS: Input data preparation. [Solar Array Manufacturing Industry Costing Standards

    NASA Technical Reports Server (NTRS)

    Chamberlain, R. G.; Aster, R. W.

    1979-01-01

    The Solar Array Manufacturing Industry Costing Standards (SAMICS) provide standard formats, data, assumptions, and procedures for estimating the price that a manufacturer would have to charge for the product of a specified manufacturing process sequence. A line-by-line explanation is given of those standard formats which describe the economically important characteristics of the manufacturing processes and the technological structure of the companies and the industry. This revision provides an updated presentation of Format A Process Description, consistent with the October 1978 version of that form. A checklist of items which should be entered on Format A as direct expenses is included.

  16. Manufacturing and Cost Considerations in Multidisciplinary Aircraft Design (Research on Mathematical Modeling of Manufacturability Factors)

    NASA Technical Reports Server (NTRS)

    Rais-Rohani, Masoud

    1996-01-01

    The identification of airframe Manufacturability Factors/Cost Drivers (MFCD) and the method by which the relationships between MFCD and designer-controlled parameters could be properly modeled are described.

  17. Productivity and Labor Costs Trends in Manufacturing, 12 Countries.

    ERIC Educational Resources Information Center

    Dean, Edwin; And Others

    1986-01-01

    Manufacturing productivity, as measured by output per hour, rose in 1984 in the United States and 11 other industrial countries studied. (Statistics are presented in the following areas: productivity trends, employment and hours, hourly compensation, unit labor costs, and relative productivity and labor cost trends.) (CT)

  18. Cost Estimation of Laser Additive Manufacturing of Stainless Steel

    NASA Astrophysics Data System (ADS)

    Piili, Heidi; Happonen, Ari; Väistö, Tapio; Venkataramanan, Vijaikrishnan; Partanen, Jouni; Salminen, Antti

    Laser additive manufacturing (LAM) is a layer wise fabrication method in which a laser beam melts metallic powder to form solid objects. Although 3D printing has been invented 30 years ago, the industrial use is quite limited whereas the introduction of cheap consumer 3D printers, in recent years, has familiarized the 3D printing. Interest is focused more and more in manufacturing of functional parts. Aim of this study is to define and discuss the current economic opportunities and restrictions of LAM process. Manufacturing costs were studied with different build scenarios each with estimated cost structure by calculated build time and calculating the costs of the machine, material and energy with optimized machine utilization. All manufacturing and time simulations in this study were carried out with a research machine equal to commercial EOS M series equipment. The study shows that the main expense in LAM is the investment cost of the LAM machine, compared to which the relative proportions of the energy and material costs are very low. The manufacturing time per part is the key factor to optimize costs of LAM.

  19. Cost-efficient manufacturing of composite structures

    NASA Technical Reports Server (NTRS)

    Freeman, W. Tom; Davis, John G.; Johnston, Norman J.

    1991-01-01

    The Advanced Composites Technology (ACT) program is seeking research breakthroughs that will allow structures made of graphite epoxy materials to replace metals in the wings and fuselages of future aircrafts. NASA's goals are to reduce acquisition cost by 20 to 25 percent, structural weight for a resized aircraft by 40 to 50 percent, and the number of parts by half compared to current production aluminum aircraft. The innovative structural concepts, materials, and fabrication techniques emerging from the ACT program are described, and the relationship between aerospace developments and industrial, commercial, and sporting goods applications are discussed.

  20. Additive Manufacturing of Low Cost Upper Stage Propulsion Components

    NASA Technical Reports Server (NTRS)

    Protz, Christopher; Bowman, Randy; Cooper, Ken; Fikes, John; Taminger, Karen; Wright, Belinda

    2014-01-01

    NASA is currently developing Additive Manufacturing (AM) technologies and design tools aimed at reducing the costs and manufacturing time of regeneratively cooled rocket engine components. These Low Cost Upper Stage Propulsion (LCUSP) tasks are funded through NASA's Game Changing Development Program in the Space Technology Mission Directorate. The LCUSP project will develop a copper alloy additive manufacturing design process and develop and optimize the Electron Beam Freeform Fabrication (EBF3) manufacturing process to direct deposit a nickel alloy structural jacket and manifolds onto an SLM manufactured GRCop chamber and Ni-alloy nozzle. In order to develop these processes, the project will characterize both the microstructural and mechanical properties of the SLMproduced GRCop-84, and will explore and document novel design techniques specific to AM combustion devices components. These manufacturing technologies will be used to build a 25K-class regenerative chamber and nozzle (to be used with tested DMLS injectors) that will be tested individually and as a system in hot fire tests to demonstrate the applicability of the technologies. These tasks are expected to bring costs and manufacturing time down as spacecraft propulsion systems typically comprise more than 70% of the total vehicle cost and account for a significant portion of the development schedule. Additionally, high pressure/high temperature combustion chambers and nozzles must be regeneratively cooled to survive their operating environment, causing their design to be time consuming and costly to build. LCUSP presents an opportunity to develop and demonstrate a process that can infuse these technologies into industry, build competition, and drive down costs of future engines.

  1. Validated Feasibility Study of Integrally Stiffened Metallic Fuselage Panels for Reducing Manufacturing Costs: Cost Assessment of Manufacturing/Design Concepts

    NASA Technical Reports Server (NTRS)

    Metschan, S.

    2000-01-01

    The objective of the Integral Airframe Structures (IAS) program was to demonstrate, for an integrally stiffened structural concept, performance and weight equal to "built-up" structure with lower manufacturing cost. This report presents results of the cost assessment for several design configuration/manufacturing method combinations. The attributes of various cost analysis models were evaluated and COSTRAN selected for this study. A process/design cost evaluation matrix was developed based on material, forming, machining, and assembly of structural sub-elements and assembled structure. A hybrid design, made from high-speed machined extruded frames that are mechanically fastened to high-speed machined plate skin/stringer panels, was identified as the most cost-effective manufacturing solution. Recurring labor and material costs of the hybrid design are up to 61 percent less than the current built-up technology baseline. This would correspond to a total cost reduction of $1.7 million per ship set for a 777-sized airplane. However, there are important outstanding issues with regard to the cost of capacity of high technology machinery, and the ability to cost-effectively provide surface finish acceptable to the commercial aircraft industry. The projected high raw material cost of large extrusions also played an important role in the trade-off between plate and extruded concepts.

  2. Reducing the Manufacturing Cost of Tubular SOFC Technology

    SciTech Connect

    George, R.A.; Bessette, N.F.

    1997-12-31

    In recent years, Westinghouse Electric Corporation has made great strides in advancing tubular solid oxide fuel cell (SOFC) technology towards commercialization by the year 2001. In 1993, Westinghouse initiated a program to develop a `MWe Class` (1-3 MWe) pressurized SOFC (PSOFC) gas turbine (GT) combined cycle power system for distributed power applications because of its: (1) ultra high efficiency (approx. 63% net AC/LHV CH{sub 4}), (2) its compatibility with a factory packaged, minimum site work philosophy, and (3) its cost effectiveness. Since then two cost studies on this market entry product performed by consultants to the U.S. Department of Energy have confirmed Westinghouse cost studies that fully installed costs of under $1300/kWe can be achieved in the early commercialization years for such small PSOFC/GT power systems. The paper will present the results of these cost studies in the areas of cell manufacturing cost, PSOFC generator manufacturing cost, balance-of-plant (BOP) cost, and system installation cost. In addition, cost of electricity calculations will be presented.

  3. Manufacturing cost analysis for photovoltaic concentrator tracking structures

    NASA Astrophysics Data System (ADS)

    Heller, B.; Pass, N.; Blackwell, R.

    1983-11-01

    Detailed manufacturing, transportation and installation costs are developed for the current design of three different photovoltaic concentrator tracking structures at a production rate of 10 to the 5th power/sq m per year. These costs are combined with array field performance estimates to obtain cost per watt and levelized energy costs for 500 kW fields. Installed structure costs for the three arrays (including G and A and profit but not module FOB costs) range from $166 to $208/sqm, or $1.04 to $1.28/W sub ap in 1982 dollars. The pedestal tracking structure has a lower cost than the post/frame or pylon/torque tube arrays.

  4. Accelerating Industrial Adoption of Metal Additive Manufacturing Technology

    NASA Astrophysics Data System (ADS)

    Vartanian, Kenneth; McDonald, Tom

    2016-03-01

    While metal additive manufacturing (AM) technology has clear benefits, there are still factors preventing its adoption by industry. These factors include the high cost of metal AM systems, the difficulty for machinists to learn and operate metal AM machines, the long approval process for part qualification/certification, and the need for better process controls; however, the high AM system cost is the main barrier deterring adoption. In this paper, we will discuss an America Makes-funded program to reduce AM system cost by combining metal AM technology with conventional computerized numerical controlled (CNC) machine tools. Information will be provided on how an Optomec-led team retrofitted a legacy CNC vertical mill with laser engineered net shaping (LENS®—LENS is a registered trademark of Sandia National Labs) AM technology, dramatically lowering deployment cost. The upgraded system, dubbed LENS Hybrid Vertical Mill, enables metal additive and subtractive operations to be performed on the same machine tool and even on the same part. Information on the LENS Hybrid system architecture, learnings from initial system deployment and continuing development work will also be provided to help guide further development activities within the materials community.

  5. Cost effective manufacturing of the SEA 10X concentrator array

    SciTech Connect

    Kaminar, N.; McEntee, J.; Curchod, D. )

    1991-11-01

    This report describes a low-cost, mass-producible 10X concentrator system that has been claimed to produce electricity at $0.04/kWh. It details changes in manufacturing techniques that could produce a concentrator system at a selling price of $0.71/W. (A simple design and a minimum number of parts and manufacturing steps reduced production costs.) Present production techniques, changes to improve these techniques, impediments to changes, and solutions to the impediments are described. This 10X concentrator system uses available components and manufacturing processes and one-sun solar cells in conjunction with inexpensive plastic lenses to generate about eight times the amount of electricity normally produced by these cells.

  6. Cost-effectiveness of conservation upgrades in manufactured homes

    SciTech Connect

    Lee, A.D.; Conner, C.C.; Englin, J.E.; Hadley, D.L.; Lucas, R.G.; Miller, N.E.; Monroe, W.H.

    1988-09-01

    This study addresses the costs of upgrading the efficiency of electrically heated manufactured homes in the Bonneville Power Administration's (Bonneville's) service territory. It was prepared by the Battelle Pacific Northwest Laboratory (PNL) for Bonneville under a Related Services Agreement with the US Department of Energy, Contract AC06-76RLO1830. Manufactured homes (commonly called mobile homes) represent a significant lost conservation resource in the region. Manufactured homes are required to meet national energy standards that do not reflect the recent increases in energy prices, and the preemptive nature of the national standards prevents local jurisdictions from establishing stricter requirements. Bonneville has undertaken several programs to analyze the efficiency of manufactured homes and encourage the industry to produce more efficient homes and consumers to increase their demand for efficient units. This study constitutes one portion of Bonneville's overall strategy. 45 refs.

  7. Cost Estimation in Engineer-to-Order Manufacturing

    NASA Astrophysics Data System (ADS)

    Hooshmand, Yousef; Köhler, Peter; Korff-Krumm, Andrea

    2016-02-01

    In Engineer-to-Order (ETO) manufacturing the price of products must be defined during early stages of product design and during the bidding process, thus an overestimation of product development (PD) costs may lead to the loss of orders and an underestimation causes a profit loss. What many ETO systems have in common is that the products have to be developed based on different customer requirements so that each order usually results in a new variant. Furthermore, many customer requirement change-requests may arise in different phases of the PD, which is to be considered properly. Thus it is utmost important for ETO systems to have an accurate cost estimation in first stages of the product design and to be able to determine the cost of customer requirement changes in different phases of PD. This paper aims to present a cost estimation methodology as well as a cost estimation model, which estimate the cost of products by relative comparison of the attributes of new product variants with the attributes of standard product variants. In addition, as a necessity in ETO manufacturing, the cost calculation of customer requirement changes in different phases of PD is integrated in the presented method.

  8. 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.

  9. Low-Cost Manufacturing of High- Temperature Polymer Composites

    NASA Technical Reports Server (NTRS)

    Sutter, James K.

    1998-01-01

    Major goals of NASA and the Integrated High Performance Turbine Engine Technology (IHPTET) initiative include improvements in the affordability of propulsion systems, significant increases in the thrust/weight ratio, and increases in the temperature capability of components of gas turbine engines. Members of NASA Lewis Research Center's HITEMP project worked cooperatively with Allison Advanced Development Corporation to develop a manufacturing method to produce low-cost components for gas turbine engines. Affordability for these polymer composites is defined by the savings in acquisition and life-cycle costs associated with engine weight reduction. To lower engine component costs, the Lewis/Allison team focused on chopped graphite fiber/polyimide resin composites. The high-temperature polyimide resin chosen, PMR-II-50, was developed at NASA Lewis.

  10. Innovative manufacturing and materials for low cost lithium ion batteries

    SciTech Connect

    Carlson, Steven

    2015-12-29

    This project demonstrated entirely new manufacturing process options for lithium ion batteries with major potential for improved cost and performance. These new manufacturing approaches are based on the use of the new electrode-coated separators instead of the conventional electrode-coated metal current collector foils. The key enabler to making these electrode-coated separators is a new and unique all-ceramic separator with no conventional porous plastic separator present. A simple, low cost, and high speed manufacturing process of a single coating of a ceramic pigment and polymer binder onto a re-usable release film, followed by a subsequent delamination of the all-ceramic separator and any layers coated over it, such as electrodes and metal current collectors, was utilized. A suitable all-ceramic separator was developed that demonstrated the following required features needed for making electrode-coated separators: (1) no pores greater than 100 nanometer (nm) in diameter to prevent any penetration of the electrode pigments into the separator; (2) no shrinkage of the separator when heated to the high oven heats needed for drying of the electrode layer; and (3) no significant compression of the separator layer by the high pressure calendering step needed to densify the electrodes by about 30%. In addition, this nanoporous all-ceramic separator can be very thin at 8 microns thick for increased energy density, while providing all of the performance features provided by the current ceramic-coated plastic separators used in vehicle batteries: improved safety, longer cycle life, and stability to operate at voltages up to 5.0 V in order to obtain even more energy density. The thin all-ceramic separator provides a cost savings of at least 50% for the separator component and by itself meets the overall goal of this project to reduce the cell inactive component cost by at least 20%. The all-ceramic separator also enables further cost savings by its excellent heat stability

  11. Manufacturing and wetting low-cost microfluidic cell separation devices

    PubMed Central

    Pawell, Ryan S.; Inglis, David W.; Barber, Tracie J.; Taylor, Robert A.

    2013-01-01

    Deterministic lateral displacement (DLD) is a microfluidic size-based particle separation or filter technology with applications in cell separation and enrichment. Currently, there are no cost-effective manufacturing methods for this promising microfluidic technology. In this fabrication paper, however, we develop a simple, yet robust protocol for thermoplastic DLD devices using regulatory-approved materials and biocompatible methods. The final standalone device allowed for volumetric flow rates of 660 μl min−1 while reducing the manufacturing time to <1 h. Optical profilometry and image analysis were employed to assess manufacturing accuracy and precision; the average replicated post height was 0.48% less than the average post height on the master mold and the average replicated array pitch was 1.1% less than the original design with replicated posts heights of 62.1 ± 5.1 μm (mean ± 6 standard deviations) and replicated array pitches of 35.6 ± 0.31 μm. PMID:24404077

  12. Manufactured Homes Simulated Thermal Analysis and Cost Effectiveness Report.

    SciTech Connect

    Baylon, David

    1990-05-17

    In 1988 and 1989, 150 manufactured homes were built to comply with Super Good Cents (SGC) specifications adapted from the existing specifications for site-built homes under the Residential Construction Demonstration Project (RCDP). Engineering calculations and computer simulations were used to estimate the effects of the SGC specifications on the thermal performance of the homes. These results were compared with consumer costs to establish the cost-effectiveness of individual measures. Heat loss U-factors for windows, walls, floors and ceilings were established using the standard ASHRAE parallel heat flow method. Adjustments resulted in higher U-factors for ceilings and floors than assumed at the time the homes were approved as meeting the SGC specifications. Except for those homes which included heat pumps, most of the homes did not meet the SGC compliance standards. Nonetheless these homes achieved substantial reductions in overall heat loss rate (UA) compared to UAs estimated for the same homes using the standard insulation packages provided by the manufacturers in the absence of the RCDP program. Homes with conventional electric furnaces showed a 35% reduction in total UA while homes with heat pumps had a 25% reduction. A regression analysis showed no significant relationship between climate zone, manufacturer and UA. A modified version of SUNDAY building simulation program which simulates duct and heat pump performance was used to model the thermal performance of each RCDP home as built and the same home as it would have been built without SGC specifications (base case). Standard assumptions were used for thermostat setpoint, thermal mass, internal gains and infiltration rates. 11 refs., 5 figs., 5 tabs.

  13. DEVELOPMENT AND MANUFACTURE OF COST EFFECTIVE COMPOSITE DRILL PIPE

    SciTech Connect

    James C. Leslie; Jeffrey R. Jean; Hans Neubert; Lee Truong

    2001-10-30

    This technical report presents the engineering research and data accomplishments that have transpired to date in support of the development of Cost Effective Composite Drill Pipe (CDP). The report discusses and illustrates all progress in the first two years of this NETL/DOE supported program. The following have been accomplished and are reported in detail herein: (1) Specifications for both 5 5/16 inch and 3 3/8 inch composite drill pipe have been finalized. (2) All basic laboratory testing has been completed and has provide sufficient data for the selection of materials for the composite tubing, adhesives, and abrasion coatings. (3) Successful demonstration of composite/metal joint interfacial connection. (4) Upgrade of facilities to provide a functional pilot plant manufacturing facility. (5) Arrangements to have the 3 3/8 inch CDP used in a drilling operation early in C.Y. 2002. (6) Arrangements to have the 5 5/16 inch CDP marketed and produced by a major drill pipe manufacturer.

  14. Development and Manufacture of Cost Effective Composite Drill Pipe

    SciTech Connect

    James C. Leslie; Jeffrey R. Jean; Hans Neubert; Lee Truong; James T. Heard

    2002-09-29

    This technical report presents the engineering research and data accomplishments that have transpired to date in support of the development of Cost Effective Composite Drill Pipe (CDP). The report reiterates the presentation made to DOE/NETL in Morgantown, WV on August 1st, 2002 with the addition of accomplishments made from that time forward until the issue date. The following have been accomplished and are reported in detail herein: {sm_bullet} Specifications for both 5-1/2'' and 1-5/8'' composite drill pipe have been finalized. {sm_bullet} Full scale testing of Short Radius (SR) CDP has been conducted. {sm_bullet} Successful demonstration of metal to composite interface (MCI) connection. {sm_bullet} Preparations for full scale manufacturing of ER/DW CDP have begun. {sm_bullet} Manufacturing facility rearranged to accommodate CDP process flow through plant. {sm_bullet} Arrangements to have the 3 3/8'' CDP used in 4 separate drilling applications in Oman, Oklahoma, and Texas.

  15. 48 CFR 31.205-25 - Manufacturing and production engineering costs.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 48 Federal Acquisition Regulations System 1 2012-10-01 2012-10-01 false Manufacturing and... Commercial Organizations 31.205-25 Manufacturing and production engineering costs. (a) The costs of manufacturing and production engineering effort as described in (1) through (4) below are all allowable:...

  16. 48 CFR 31.205-25 - Manufacturing and production engineering costs.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 48 Federal Acquisition Regulations System 1 2014-10-01 2014-10-01 false Manufacturing and... Commercial Organizations 31.205-25 Manufacturing and production engineering costs. (a) The costs of manufacturing and production engineering effort as described in (1) through (4) below are all allowable:...

  17. 48 CFR 31.205-25 - Manufacturing and production engineering costs.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 48 Federal Acquisition Regulations System 1 2013-10-01 2013-10-01 false Manufacturing and... Commercial Organizations 31.205-25 Manufacturing and production engineering costs. (a) The costs of manufacturing and production engineering effort as described in (1) through (4) below are all allowable:...

  18. 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.

  19. 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.

  20. 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.

  1. Low Cost Manufacturing Approach of High Temperature PMC Components

    NASA Technical Reports Server (NTRS)

    Kannmacher, Kevin

    1997-01-01

    The overall objective is to develop a satisfactory sheet molding compound (SMC) of a high temperature polyimide, such as PMR-11-50, VCAP-75, or NB2-76, and to develop compression molding processing parameters for a random, chopped fiber, high temperature, sheet molding compound that will be more affordable than the traditional hand lay-up fabrication methods. Compression molding will reduce manufacturing costs of composites by: (1) minimizing the conventional machining required after fabrication due to the use of full 360 deg matched tooling, (2) reducing fabrication time by minimizing the intensive hand lay-up operations associated with individual ply fabrication techniques, such as ply orientation and ply count and (3) possibly reducing component mold time by advanced B-staging prior to molding. This program is an integral part of Allison's T406/AE engine family's growth plan, which will utilize technologies developed under NASA's Sub-sonic Transport (AST) programs, UHPTET initiatives, and internally through Allison's IR&D projects. Allison is aggressively pursuing this next generation of engines, with both commercial and military applications, by reducing the overall weight of the engine through the incorporation of advanced, lightweight, high temperature materials, such as polymer matrix composites. This infusion of new materials into the engine is also a major factor in reducing engine cost because it permits the use of physically smaller structural components to achieve the same thrust levels as the generation that it replaced. A lighter, more efficient propulsion system translates to a substantial cost and weight savings to an airframe's structure.

  2. 48 CFR 31.205-25 - Manufacturing and production engineering costs.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 48 Federal Acquisition Regulations System 1 2011-10-01 2011-10-01 false Manufacturing and... ACQUISITION REGULATION GENERAL CONTRACTING REQUIREMENTS CONTRACT COST PRINCIPLES AND PROCEDURES Contracts With Commercial Organizations 31.205-25 Manufacturing and production engineering costs. (a) The costs...

  3. 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

  4. Cost and Performance Report Accelerated Site Technology Deployment Program

    SciTech Connect

    P. S. Morris

    2002-05-01

    The U.S. Department of Energy (DOE), National Nuclear Security Administration Nevada Operations Office (NNSA/NV) Environmental Restoration Division (ERD) Industrial Sites Project Deactivation and Decommissioning (D and D) source group has limited budget and is constantly searching for new technologies to reduce programmatic costs. Partnering with the DOE Office of Science and Technology Deactivation and Decommissioning Focus Area (DDFA) reduces NNSA/NV programmatic risk and encourages accelerated deployment of potentially beneficial technologies to the Nevada Test Site (NTS).

  5. Development of advanced manufacturing technologies for low cost hydrogen storage vessels

    SciTech Connect

    Leavitt, Mark; Lam, Patrick

    2014-12-29

    The U.S. Department of Energy (DOE) defined a need for low-cost gaseous hydrogen storage vessels at 700 bar to support cost goals aimed at 500,000 units per year. Existing filament winding processes produce a pressure vessel that is structurally inefficient, requiring more carbon fiber for manufacturing reasons, than would otherwise be necessary. Carbon fiber is the greatest cost driver in building a hydrogen pressure vessel. The objective of this project is to develop new methods for manufacturing Type IV pressure vessels for hydrogen storage with the purpose of lowering the overall product cost through an innovative hybrid process of optimizing composite usage by combining traditional filament winding (FW) and advanced fiber placement (AFP) techniques. A numbers of vessels were manufactured in this project. The latest vessel design passed all the critical tests on the hybrid design per European Commission (EC) 79-2009 standard except the extreme temperature cycle test. The tests passed include burst test, cycle test, accelerated stress rupture test and drop test. It was discovered the location where AFP and FW overlap for load transfer could be weakened during hydraulic cycling at 85°C. To design a vessel that passed these tests, the in-house modeling software was updated to add capability to start and stop fiber layers to simulate the AFP process. The original in-house software was developed for filament winding only. Alternative fiber was also investigated in this project, but the added mass impacted the vessel cost negatively due to the lower performance from the alternative fiber. Overall the project was a success to show the hybrid design is a viable solution to reduce fiber usage, thus driving down the cost of fuel storage vessels. Based on DOE’s baseline vessel size of 147.3L and 91kg, the 129L vessel (scaled to DOE baseline) in this project shows a 32% composite savings and 20% cost savings when comparing Vessel 15 hybrid design and the Quantum

  6. Manufacturing of Monolithic Electrodes from Low-Cost Renewable Resources

    SciTech Connect

    McNutt, Nichiolas William; Rios, Orlando; Johs, Alexander; Tenhaeff, Wyatt E; Chatterjee, Sabornie; Keffer, David

    2014-01-01

    Lignin, a low-cost, biomass derived precursor, was selected as an alternative for carbon based free standing anodes in Li-ion batteries. Industrially scalable melt-spinning and melt-blowing synthesis methods were developed at Oak Ridge National Laboratory that are compatible with industrially viable production. Engineering studies predict that LCFs can be manufactured at $3/lb using these technologies, which compares favorably to $12/lb for battery grade graphite. The physical properties of lignin carbon fibers, specifically the tunable electrochemical and thermal transport, are suitable for energy storage applications as both an active material and current collector. The elimination of inactive components in the slurry-coated electrodes was enabled by LCF processing parameters modifications to produce monolithic mats in which the fibers are electrically interconnected. These mats were several hundreds of micrometers thick, and the fibers functioned as both current collector and active material by virtue of their mixed ionic/electronic conductivities. The LCFs were coated onto copper current collectors with PVDF binder and conductive carbon additive through conventional slurry processing. Galvanostatic cycling of the LCFs against Li revealed reversible capacities greater than 300 mAh/g. The coulombic efficiencies were over 99.8%. The mats were galvanostatically cycled in half cells against Li. Specific capacities as high as 250 mAh/g were achieved approximately 17% lower than the capacities of the same fibers in slurries. However, there were no inactive materials reducing the practical specific capacity of the entire electrode construction. Lithiation and delithiation of the LCFs proceeded with coulombic efficiencies greater than 99.9%, and the capacity retention was greater than 99% over 100 cycles at a rate of 15 mA/g. Research sponsored by the Laboratory Directed Research and Development Program of Oak Ridge National Laboratory, managed by UT-Battelle, LLC, for

  7. V1.6 Development of Advanced Manufacturing Technologies for Low Cost Hydrogen Storage Vessels

    SciTech Connect

    Leavitt, Mark; Lam, Patrick; Nelson, Karl M.; johnson, Brice A.; Johnson, Kenneth I.; Alvine, Kyle J.; Ruiz, Antonio; Adams, Jesse

    2012-10-01

    The goal of this project is to develop an innovative manufacturing process for Type IV high-pressure hydrogen storage vessels, with the intent to significantly lower manufacturing costs. Part of the development is to integrate the features of high precision AFP and commercial FW. Evaluation of an alternative fiber to replace a portion of the baseline fiber will help to reduce costs further.

  8. Manufacturing High-Quality Carbon Nanotubes at Lower Cost

    NASA Technical Reports Server (NTRS)

    Benavides, Jeanette M.; Lidecker, Henning

    2004-01-01

    A modified electric-arc welding process has been developed for manufacturing high-quality batches of carbon nanotubes at relatively low cost. Unlike in some other processes for making carbon nanotubes, metal catalysts are not used and, consequently, it is not necessary to perform extensive cleaning and purification. Also, unlike some other processes, this process is carried out at atmospheric pressure under a hood instead of in a closed, pressurized chamber; as a result, the present process can be implemented more easily. Although the present welding-based process includes an electric arc, it differs from a prior electric-arc nanotube-production process. The welding equipment used in this process includes an AC/DC welding power source with an integral helium-gas delivery system and circulating water for cooling an assembly that holds one of the welding electrodes (in this case, the anode). The cathode is a hollow carbon (optionally, graphite) rod having an outside diameter of 2 in. (approximately equal to 5.1 cm) and an inside diameter of 5/8 in. (approximately equal to 1.6 cm). The cathode is partly immersed in a water bath, such that it protrudes about 2 in. (about 5.1 cm) above the surface of the water. The bottom end of the cathode is held underwater by a clamp, to which is connected the grounding cable of the welding power source. The anode is a carbon rod 1/8 in. (approximately equal to 0.3 cm) in diameter. The assembly that holds the anode includes a thumbknob- driven mechanism for controlling the height of the anode. A small hood is placed over the anode to direct a flow of helium downward from the anode to the cathode during the welding process. A bell-shaped exhaust hood collects the helium and other gases from the process. During the process, as the anode is consumed, the height of the anode is adjusted to maintain an anode-to-cathode gap of 1 mm. The arc-welding process is continued until the upper end of the anode has been lowered to a specified height

  9. Flat plate vs. concentrator solar photovoltaic cells - A manufacturing cost analysis

    NASA Technical Reports Server (NTRS)

    Granon, L. A.; Coleman, M. G.

    1980-01-01

    The choice of which photovoltaic system (flat plate or concentrator) to use for utilizing solar cells to generate electricity depends mainly on the cost. A detailed, comparative manufacturing cost analysis of the two types of systems is presented. Several common assumptions, i.e., cell thickness, interest rate, power rate, factory production life, polysilicon cost, and direct labor rate are utilized in this analysis. Process sequences, cost variables, and sensitivity analyses have been studied, and results of the latter show that the most important parameters which determine manufacturing costs are concentration ratio, manufacturing volume, and cell efficiency. The total cost per watt of the flat plate solar cell is $1.45, and that of the concentrator solar cell is $1.85, the higher cost being due to the increased process complexity and material costs.

  10. Development and Manufacture of Cost-Effective Composite Drill Pipe

    SciTech Connect

    James C. Leslie

    2008-12-31

    Advanced Composite Products and Technology, Inc. (ACPT) has developed composite drill pipe (CDP) that matches the structural and strength properties of steel drill pipe, but weighs less than 50 percent of its steel counterpart. Funding for the multiyear research and development of CDP was provided by the U.S. Department of Energy Office of Fossil Energy through the Natural Gas and Oil Projects Management Division at the National Energy Technology Laboratory (NETL). Composite materials made of carbon fibers and epoxy resin offer mechanical properties comparable to steel at less than half the weight. Composite drill pipe consists of a composite material tube with standard drill pipe steel box and pin connections. Unlike metal drill pipe, composite drill pipe can be easily designed, ordered, and produced to meet specific requirements for specific applications. Because it uses standard joint connectors, CDP can be used in lieu of any part of or for the entire steel drill pipe section. For low curvature extended reach, deep directional drilling, or ultra deep onshore or offshore drilling, the increased strength to weight ratio of CDP will increase the limits in all three drilling applications. Deceased weight will reduce hauling costs and increase the amount of drill pipe allowed on offshore platforms. In extreme extended reach areas and high-angle directional drilling, drilling limits are associated with both high angle (fatigue) and frictional effects resulting from the combination of high angle curvature and/or total weight. The radius of curvature for a hole as small as 40 feet (12.2 meters) or a build rate of 140 degrees per 100 feet is within the fatigue limits of specially designed CDP. Other properties that can be incorporated into the design and manufacture of composite drill pipe and make it attractive for specific applications are corrosion resistance, non-magnetic intervals, and abrasion resistance coatings. Since CDP has little or no electromagnetic force

  11. Manufacturing costs for planar solid oxide fuel cells

    SciTech Connect

    Krist, K.; Wright, J.D.; Romero, C.

    1995-12-31

    In this paper the authors calculate how much one can afford to pay for a fuel cell, and set quantitative performance and cost targets that if met, will result in SOFC technology where the performance is high enough and the cost is low enough to generate commercial interest. To do this, the authors first calculate how much one can afford to pay for a fuel cell stack in two important applications: small scale cogeneration (200 kW{sub e}) and large scale power generation (50 MW{sub e}). They then compare the cost of the materials needed to fabricate the fuel cell with the allowable cost. Finally, they use a mathematical model of fuel cell performance to quantify some of the improvements that will be needed if planar fuel cells are to operate efficiently at 800 C or below.

  12. Analysis of the influence of advanced materials for aerospace products R&D and manufacturing cost

    NASA Astrophysics Data System (ADS)

    Shen, A. W.; Guo, J. L.; Wang, Z. J.

    2015-12-01

    In this paper, we pointed out the deficiency of traditional cost estimation model about aerospace products Research & Development (R&D) and manufacturing based on analyzing the widely use of advanced materials in aviation products. Then we put up with the estimating formulas of cost factor, which representing the influences of advanced materials on the labor cost rate and manufacturing materials cost rate. The values ranges of the common advanced materials such as composite materials, titanium alloy are present in the labor and materials two aspects. Finally, we estimate the R&D and manufacturing cost of F/A-18, F/A- 22, B-1B and B-2 aircraft based on the common DAPCA IV model and the modified model proposed by this paper. The calculation results show that the calculation precision improved greatly by the proposed method which considering advanced materials. So we can know the proposed method is scientific and reasonable.

  13. Cost savings for manufacturing lithium batteries in a flexible plant

    NASA Astrophysics Data System (ADS)

    Nelson, Paul A.; Ahmed, Shabbir; Gallagher, Kevin G.; Dees, Dennis W.

    2015-06-01

    The flexible plant postulated in this study would produce four types of batteries for electric-drive vehicles - a hybrid (HEV), 10-mile range and 40-mile range plug-in hybrids (PHEV), and a 150-mile range battery-electric (EV). The annual production rate of the plant is 235,000 battery packs (HEV: 100,000; PHEV10: 60,000; PHEV40: 45,000; EV: 30,000). The cost savings per battery pack calculated with the Argonne BatPaC model for this flex plant vs. dedicated plants range from 9% for the EV battery packs to 21% for the HEV packs including the battery management systems (BMS). The investment cost savings are even larger, ranging from 21% for EVs to 43% for HEVs. The costs of the 1.0-kWh HEV batteries are projected to approach 714 per unit and that of the EV batteries to approach 188 per kWh with the most favorable cell chemistries. The best single indicator of the cost of producing lithium-manganate spinel/graphite batteries in a flex plant is the total cell area of the battery. For the four batteries studied, the price range is 20-24 per m2 of cell area, averaging 21 per m2 for the entire flex plant.

  14. Manufacturing and cost analyses of heliostats based on the second-generation heliostat-development study

    NASA Astrophysics Data System (ADS)

    Norris, H. F., Jr.; White, S. S.

    1982-12-01

    The manufacturing processes and users' costs were analyzed for the second generation heliostats. Mass production scenarios are examined by comparison and manufacturing analysis, including facility site selection and design, operations, equipment and tooling, and labor. Different transportation scenarios are compared, as are the site assembly and installation procedures. Users' costs are allocated to the central manufacturing facility, to transportation from the central manufacturing facility to the field, and to the field sites. Costs are compared for the major components: reflective assembly, drive mechanism, controls and field wiring, foundation/pedestal, and support structure. Breakdowns are given for direct materials, direct labor, and other expenses including an estimate of the gross profit. A contractor estimated capital price to the utility for each heliostat design and estimated operations and maintenance expenses are shown.

  15. Space system production cost benefits from contemporary philosophies in management and manufacturing

    NASA Technical Reports Server (NTRS)

    Rosmait, Russell L.

    1991-01-01

    The cost of manufacturing space system hardware has always been expensive. The Engineering Cost Group of the Program Planning office at Marshall is attempting to account for cost savings that result from new technologies in manufacturing and management. The objective is to identify and define contemporary philosophies in manufacturing and management. The seven broad categories that make up the areas where technological advances can assist in reducing space system costs are illustrated. Included within these broad categories is a list of the processes or techniques that specifically provide the cost savings within todays design, test, production and operations environments. The processes and techniques listed achieve savings in the following manner: increased productivity; reduced down time; reduced scrap; reduced rework; reduced man hours; and reduced material costs. In addition, it should be noted that cost savings from production and processing improvements effect 20 to 40 pct. of production costs whereas savings from management improvements effects 60 to 80 of production cost. This is important because most efforts in reducing costs are spent trying to reduce cost in the production.

  16. Development and Manufacture of Cost Effective Composite Drill Pipe

    SciTech Connect

    James C. Leslie; James C. Leslie, II; Lee Truong; James T. Heard

    2006-09-29

    This technical report presents the engineering research, process development and data accomplishments that have transpired to date in support of the development of Cost Effective Composite Drill Pipe (CDP). The report presents progress made from October 1, 2005 through September 30, 2006 and contains the following discussions: Qualification Testing; Prototype Development and Testing of ''Smart Design'' Configuration; Field Test Demonstration; Development of Ultra-Short Radius Composite Drill Pipe (USR-CDP); and Development of Smart USR-CDP.

  17. DEVELOPMENT AND MANUFACTURE OF COST EFFECTIVE COMPOSITE DRILL PIPE

    SciTech Connect

    Dr. James C. Leslie; Mr. Jeffrey R. Jean; Hans Neubert; Lee Truong

    2000-10-30

    This annual, technical report will discuss the engineering research and data accomplishments that have transpired in support of the development of Cost Effective Composite Drill Pipe (CDP). The report discusses and illustrates the first iteration design of the tube and the tool joint interface. The report discusses standards and specifications to which the CDP design will be tailored and tested, and discusses conclusions of the first iteration design for future design enhancements.

  18. Development and Manufacture of Cost Effective Composite Drill Pipe

    SciTech Connect

    James C. Leslie; James C. Leslie II; Lee Truong; James T. Heard; Steve Loya

    2006-02-20

    This technical report presents the engineering research, process development and data accomplishments that have transpired to date in support of the development of Cost Effective Composite Drill Pipe (CDP). The report presents progress made from October 1, 2004 through September 30, 2005 and contains the following discussions: (1) Qualification Testing; (2) Prototype Development and Testing of ''Smart Design'' Configuration; (3) Field Test Demonstration; and (4) Commercial order for SR-CDP from Torch International. The objective of this contract is to develop and demonstrate ''cost effective'' Composite Drill Pipe. It is projected that this drill pipe will weigh less than half of its steel counter part. The resultant weight reduction will provide enabling technology that will increase the lateral distance that can be reached from an offshore drilling platform and the depth of water in which drilling and production operations can be carried out. Further, composite drill pipe has the capability to carry real time signal and power transmission within the pipe walls. CDP can also accommodate much shorter drilling radius than is possible with metal drill pipe. As secondary benefits, the lighter weight drill pipe can increase the storage capability of floating off shore drilling platforms and provide substantial operational cost savings.

  19. Validated Feasibility Study of Integrally Stiffened Metallic Fuselage Panels for Reducing Manufacturing Costs

    NASA Technical Reports Server (NTRS)

    Pettit, R. G.; Wang, J. J.; Toh, C.

    2000-01-01

    The continual need to reduce airframe cost and the emergence of high speed machining and other manufacturing technologies has brought about a renewed interest in large-scale integral structures for aircraft applications. Applications have been inhibited, however, because of the need to demonstrate damage tolerance, and by cost and manufacturing risks associated with the size and complexity of the parts. The Integral Airframe Structures (IAS) Program identified a feasible integrally stiffened fuselage concept and evaluated performance and manufacturing cost compared to conventional designs. An integral skin/stiffener concept was produced both by plate hog-out and near-net extrusion. Alloys evaluated included 7050-T7451 plate, 7050-T74511 extrusion, 6013-T6511 extrusion, and 7475-T7351 plate. Mechanical properties, structural details, and joint performance were evaluated as well as repair, static compression, and two-bay crack residual strength panels. Crack turning behavior was characterized through panel tests and improved methods for predicting crack turning were developed. Manufacturing cost was evaluated using COSTRAN. A hybrid design, made from high-speed machined extruded frames that are mechanically fastened to high-speed machined plate skin/stringer panels, was identified as the most cost-effective manufacturing solution. Recurring labor and material costs of the hybrid design are up to 61 percent less than the current technology baseline.

  20. Utilization of UV Curing Technology to Significantly Reduce the Manufacturing Cost of LIB Electrodes

    SciTech Connect

    Voelker, Gary; Arnold, John

    2015-11-30

    Previously identified novel binders and associated UV curing technology have been shown to reduce the time required to apply and finish electrode coatings from tens of minutes to less than one second. This revolutionary approach can result in dramatic increases in process speeds, significantly reduced capital (a factor of 10 to 20) and operating costs, reduced energy requirements, and reduced environmental concerns and costs due to the virtual elimination of harmful volatile organic solvents and associated solvent dryers and recovery systems. The accumulated advantages of higher speed, lower capital and operating costs, reduced footprint, lack of VOC recovery, and reduced energy cost is a reduction of 90% in the manufacturing cost of cathodes. When commercialized, the resulting cost reduction in Lithium batteries will allow storage device manufacturers to expand their sales in the market and thereby accrue the energy savings of broader utilization of HEVs, PHEVs and EVs in the U.S., and a broad technology export market is also envisioned.

  1. DEVELOPMENT AND MANUFACTURE OF COST EFFECTIVE COMPOSITE DRILL PIPE

    SciTech Connect

    James C. Leslie; James C. Leslie II; Lee Truong; James T. Heard; Peter Manekas

    2005-03-18

    This technical report presents the engineering research, process development and data accomplishments that have transpired to date in support of the development of Cost Effective Composite Drill Pipe (CDP). The report presents progress made from October 1, 2003 through September 30, 2004 and contains the following discussions: (1) Direct Electrical Connection for Rotary Shoulder Tool Joints; (2) Conductors for inclusion in the pipe wall (ER/DW-CDP); (3) Qualify fibers from Zoltek; (4) Qualify resin from Bakelite; (5) First commercial order for SR-CDP from Integrated Directional Resources (SR-CDP); and (6) Preparation of papers for publication and conference presentations.

  2. DEVELOPMENT AND MANUFACTURE OF COST EFFECTIVE COMPOSITE DRILL PIPE

    SciTech Connect

    James C. Leslie; James C. Leslie II; Lee Truong; James T. Heard

    2003-03-30

    This technical report presents the engineering research and data accomplishments that have transpired to date in support of the development of Cost Effective Composite Drill Pipe (CDP). The report presents accomplishments made from October 1, 2002 through September 30, 2003. The following have been accomplished and are reported in detail herein: Metal-to-Composite Interface (MCI) redesign and testing; Successful demonstration of MCI connection for both SR and ER/DW CDP; Specifications for a 127mm (5 inch) ID by 152.4 mm (6 inch) OD composite drill pipe have been finalized for Extended Reach/Deep Water applications (ER/DW); Field testing of Short Radius CDP (SR); Sealing composite laminate to contain high pressure; Amendments; Amendment for ''Smart'' feature added to ER/DW development along with time and funding to complete battery of qualification tests with option for field demonstration; and Preparation of papers for publication and conference presentations.

  3. MANUFACTURING AND COST EVALUATION OF SECOND GENERATION HELIOSTATS VOLUME I - ANALYSIS AND RESULTS

    SciTech Connect

    Drumheller, K.; Bondurant, P. D.; Brown, D. R.; Williams, T. A.

    1981-09-01

    The Second Generation Heliostat Program involved five contractors who provided designs, manufacturing plans, and cost estimates for heliostats. The program was sponsored by the Department of Energy and managed by Sandia National Laboratories, Livermore. As part of the program, Pacific Northwest Laboratory (PNL) evaluated and compared the contractors' costs and production plans, and compared the actual costs of the Solar One (Barstow, California) pilot-plant heliostats to estimated mass production costs. One purpose of this review was to adjust contractor estimates to provide a common basis for cost comparisons. The five contractors were: Boeing Engineering and Construction, Martin Marietta Corporation, McDonnell Douglas Astronautics Company, Northrup Incorporated, and Westinghouse Electric Corporation. PNL evaluated the components and assembly of the five heliostats in terms of material, direct labor, production equipment, production building requirements, and overheads. Two adjustments were made to the costs estimated by the manufacturers. The first, producing "Adjusted Costs," was primarily to add items that appeared to have been omitted from the contractors' estimates or delete items that were not required. The second, called "Uniform Assumptions Costs," used common ground rules for major materials, building, labor, and overhead costs. The review of the contractors' production plans and cost estimates did not reveal any errors or omissions that would change the costs by more than 30%, when compared using uniform assumptions. This range is adequate for policy planning, and costs of $100/m{sup 2} appear achievable.

  4. Solar PV Manufacturing Cost Model Group: Installed Solar PV System Prices (Presentation)

    SciTech Connect

    Goodrich, A. C.; Woodhouse, M.; James, T.

    2011-02-01

    EERE's Solar Energy Technologies Program is charged with leading the Secretary's SunShot Initiative to reduce the cost of electricity from solar by 75% to be cost competitive with conventional energy sources without subsidy by the end of the decade. As part of this Initiative, the program has funded the National Renewable Energy Laboratory (NREL) to develop module manufacturing and solar PV system installation cost models to ensure that the program's cost reduction targets are carefully aligned with current and near term industry costs. The NREL cost analysis team has leveraged the laboratories' extensive experience in the areas of project finance and deployment, as well as industry partnerships, to develop cost models that mirror the project cost analysis tools used by project managers at leading U.S. installers. The cost models are constructed through a "bottoms-up" assessment of each major cost element, beginning with the system's bill of materials, labor requirements (type and hours) by component, site-specific charges, and soft costs. In addition to the relevant engineering, procurement, and construction costs, the models also consider all relevant costs to an installer, including labor burdens and overhead rates, supply chain costs, and overhead and materials inventory costs, and assume market-specific profits.

  5. Development of hybrid lifecycle cost estimating tool (HLCET) for manufacturing influenced design tradeoff

    NASA Astrophysics Data System (ADS)

    Sirirojvisuth, Apinut

    In complex aerospace system design, making an effective design decision requires multidisciplinary knowledge from both product and process perspectives. Integrating manufacturing considerations into the design process is most valuable during the early design stages since designers have more freedom to integrate new ideas when changes are relatively inexpensive in terms of time and effort. Several metrics related to manufacturability are cost, time, and manufacturing readiness level (MRL). Yet, there is a lack of structured methodology that quantifies how changes in the design decisions impact these metrics. As a result, a new set of integrated cost analysis tools are proposed in this study to quantify the impacts. Equally important is the capability to integrate this new cost tool into the existing design methodologies without sacrificing agility and flexibility required during the early design phases. To demonstrate the applicability of this concept, a ModelCenter environment is used to develop software architecture that represents Integrated Product and Process Development (IPPD) methodology used in several aerospace systems designs. The environment seamlessly integrates product and process analysis tools and makes effective transition from one design phase to the other while retaining knowledge gained a priori. Then, an advanced cost estimating tool called Hybrid Lifecycle Cost Estimating Tool (HLCET), a hybrid combination of weight-, process-, and activity-based estimating techniques, is integrated with the design framework. A new weight-based lifecycle cost model is created based on Tailored Cost Model (TCM) equations [3]. This lifecycle cost tool estimates the program cost based on vehicle component weights and programmatic assumptions. Additional high fidelity cost tools like process-based and activity-based cost analysis methods can be used to modify the baseline TCM result as more knowledge is accumulated over design iterations. Therefore, with this

  6. Costs of controlling emissions from the manufacture of silicon photovoltaic cells using dendritic web technology

    SciTech Connect

    Wilenitz, I.

    1983-11-01

    Detailed analyses were conducted to determine environmental control costs associated with the production of silicon dendritic web photovoltaic (PV) cells. In these analyses (i) likely manufacturing processing steps were identified, (ii) material inputs and uncontrolled material outputs were estimated, (iii) need for and capability of environmental control equipment were examined, and (iv) capital and operation and maintenance costs for environmental controls for integrated and disaggregated plant designs were estimated. These estimates were developed for a hypothetical facility with a yearly output of PV cells capable of producing 10 MWp. Analysis suggested that the annualized incremental environmental control costs, based on capital recovery over a 10 year plant life, would be 1.4 cents and 2.8 cents per watt for integrated and disaggregated plant designs, respectively. Capital costs ranged from 50% to 55% (integrated) and 36% to 40% (disaggregated) of the estimated costs; the ranges reflected differences in assumed real discount rates. Because of the small emission flows projected, treatment equipment to be used, for the most part, represents the smallest size readily available from equipment manufacturers. Consequently, larger emission flows could be accommodated without additional capital costs. Total control costs are small in comparison with current production costs for silicon photovoltaic devices ($5/watt), but may be of greater importance at projected production cost of $0.5 to 1.0/watt. These conclusions may not apply to other material or process options.

  7. 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.

  8. 21 CFR 1004.1 - Manufacturer's obligation to repair, replace, or refund cost of electronic products.

    Code of Federal Regulations, 2013 CFR

    2013-04-01

    ... 21 Food and Drugs 8 2013-04-01 2013-04-01 false Manufacturer's obligation to repair, replace, or refund cost of electronic products. 1004.1 Section 1004.1 Food and Drugs FOOD AND DRUG ADMINISTRATION, DEPARTMENT OF HEALTH AND HUMAN SERVICES (CONTINUED) RADIOLOGICAL HEALTH REPURCHASE, REPAIRS, OR REPLACEMENT OF ELECTRONIC PRODUCTS §...

  9. 21 CFR 1004.1 - Manufacturer's obligation to repair, replace, or refund cost of electronic products.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... 21 Food and Drugs 8 2014-04-01 2014-04-01 false Manufacturer's obligation to repair, replace, or refund cost of electronic products. 1004.1 Section 1004.1 Food and Drugs FOOD AND DRUG ADMINISTRATION, DEPARTMENT OF HEALTH AND HUMAN SERVICES (CONTINUED) RADIOLOGICAL HEALTH REPURCHASE, REPAIRS, OR...

  10. 21 CFR 1004.1 - Manufacturer's obligation to repair, replace, or refund cost of electronic products.

    Code of Federal Regulations, 2011 CFR

    2011-04-01

    ... 21 Food and Drugs 8 2011-04-01 2011-04-01 false Manufacturer's obligation to repair, replace, or refund cost of electronic products. 1004.1 Section 1004.1 Food and Drugs FOOD AND DRUG ADMINISTRATION, DEPARTMENT OF HEALTH AND HUMAN SERVICES (CONTINUED) RADIOLOGICAL HEALTH REPURCHASE, REPAIRS, OR...

  11. 21 CFR 1004.1 - Manufacturer's obligation to repair, replace, or refund cost of electronic products.

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... 21 Food and Drugs 8 2012-04-01 2012-04-01 false Manufacturer's obligation to repair, replace, or refund cost of electronic products. 1004.1 Section 1004.1 Food and Drugs FOOD AND DRUG ADMINISTRATION, DEPARTMENT OF HEALTH AND HUMAN SERVICES (CONTINUED) RADIOLOGICAL HEALTH REPURCHASE, REPAIRS, OR...

  12. 21 CFR 1004.1 - Manufacturer's obligation to repair, replace, or refund cost of electronic products.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... 21 Food and Drugs 8 2010-04-01 2010-04-01 false Manufacturer's obligation to repair, replace, or refund cost of electronic products. 1004.1 Section 1004.1 Food and Drugs FOOD AND DRUG ADMINISTRATION, DEPARTMENT OF HEALTH AND HUMAN SERVICES (CONTINUED) RADIOLOGICAL HEALTH REPURCHASE, REPAIRS, OR...

  13. Automated packaging platform for low-cost high-performance optical components manufacturing

    NASA Astrophysics Data System (ADS)

    Ku, Robert T.

    2004-05-01

    Delivering high performance integrated optical components at low cost is critical to the continuing recovery and growth of the optical communications industry. In today's market, network equipment vendors need to provide their customers with new solutions that reduce operating expenses and enable new revenue generating IP services. They must depend on the availability of highly integrated optical modules exhibiting high performance, small package size, low power consumption, and most importantly, low cost. The cost of typical optical system hardware is dominated by linecards that are in turn cost-dominated by transmitters and receivers or transceivers and transponders. Cost effective packaging of optical components in these small size modules is becoming the biggest challenge to be addressed. For many traditional component suppliers in our industry, the combination of small size, high performance, and low cost appears to be in conflict and not feasible with conventional product design concepts and labor intensive manual assembly and test. With the advent of photonic integration, there are a variety of materials, optics, substrates, active/passive devices, and mechanical/RF piece parts to manage in manufacturing to achieve high performance at low cost. The use of automation has been demonstrated to surpass manual operation in cost (even with very low labor cost) as well as product uniformity and quality. In this paper, we will discuss the value of using an automated packaging platform.for the assembly and test of high performance active components, such as 2.5Gb/s and 10 Gb/s sources and receivers. Low cost, high performance manufacturing can best be achieved by leveraging a flexible packaging platform to address a multitude of laser and detector devices, integration of electronics and handle various package bodies and fiber configurations. This paper describes the operation and results of working robotic assemblers in the manufacture of a Laser Optical Subassembly

  14. Low-cost tape system measures velocity of acceleration

    NASA Technical Reports Server (NTRS)

    Hartenstein, R.

    1964-01-01

    By affixing perforated magnetic recording tape to the falling end of a body, acceleration and velocity were measured. The measurement was made by allowing the tape to pass between a light source and a photoelectric sensor. Data was obtained from a readout device.

  15. 38 CFR 36.4251 - Loans to finance the purchase of manufactured homes and the cost of necessary site preparation.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... 38 Pensions, Bonuses, and Veterans' Relief 2 2011-07-01 2011-07-01 false Loans to finance the... Manufactured Home Lot Loans § 36.4251 Loans to finance the purchase of manufactured homes and the cost of necessary site preparation. (a) A loan to finance the purchase of a manufactured home may include funds...

  16. 38 CFR 36.4251 - Loans to finance the purchase of manufactured homes and the cost of necessary site preparation.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 38 Pensions, Bonuses, and Veterans' Relief 2 2010-07-01 2010-07-01 false Loans to finance the... Manufactured Home Lot Loans § 36.4251 Loans to finance the purchase of manufactured homes and the cost of necessary site preparation. (a) A loan to finance the purchase of a manufactured home may include funds...

  17. 38 CFR 36.4251 - Loans to finance the purchase of manufactured homes and the cost of necessary site preparation.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... 38 Pensions, Bonuses, and Veterans' Relief 2 2013-07-01 2013-07-01 false Loans to finance the... Manufactured Home Lot Loans § 36.4251 Loans to finance the purchase of manufactured homes and the cost of necessary site preparation. (a) A loan to finance the purchase of a manufactured home may include funds...

  18. 38 CFR 36.4251 - Loans to finance the purchase of manufactured homes and the cost of necessary site preparation.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... 38 Pensions, Bonuses, and Veterans' Relief 2 2012-07-01 2012-07-01 false Loans to finance the... Manufactured Home Lot Loans § 36.4251 Loans to finance the purchase of manufactured homes and the cost of necessary site preparation. (a) A loan to finance the purchase of a manufactured home may include funds...

  19. 38 CFR 36.4251 - Loans to finance the purchase of manufactured homes and the cost of necessary site preparation.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... 38 Pensions, Bonuses, and Veterans' Relief 2 2014-07-01 2014-07-01 false Loans to finance the... Manufactured Home Lot Loans § 36.4251 Loans to finance the purchase of manufactured homes and the cost of necessary site preparation. (a) A loan to finance the purchase of a manufactured home may include funds...

  20. 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.

  1. 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).

  2. Manufacture of an Ultrafine-Grained TiN-Cu Composition Using an Erosion-Type Coaxial Hybrid Magnetoplasma Accelerator

    NASA Astrophysics Data System (ADS)

    Sivkov, A. A.; Gerasimov, D. Yu.; Evdokimov, A. A.

    2015-12-01

    It is shown that a TiN+Cu powder mixture could be manufactured using a combined barel of a coaxial magnetoplasma accelerator. The method is proved to ensure a wide-range regulation over the copper-to-titanium nitride ratio in the final product yield.

  3. Manufacturing of high performance, low cost dual mirror lamp reflector modules

    NASA Astrophysics Data System (ADS)

    Shen, Li

    The Lamp Reflector Module (LRM) is a key component in every micro display projection system, which has played a dominant role in the large-screen display market today. The goal of this research is to (1) improve the Dual Mirror prototype's light output performance, (2) investigate the underlying principles of its slow output deterioration so as to help develop effective and efficient LRM thermal management for maximized lifetime performance, and (3) improve/enable low cost mass LRM manufacturing for the projection display market. The first part of this research addresses the prototype's low output problem. More sophisticated 3D Optical Ray Tracing (ORT) models were generated to provide the output prediction depending on the arc gap, system collection etendue, etc. It was concluded that upgrading the manufacturing processes, particularly the reflector shape, surface and cold mirror coating, could effectively improve the output performance. Additionally, these theoretical models are shown to be used to design a LRM with 16% output gain for the consumer Rear Projection display market. The second part of this research focuses on the issue of lifetime performance. The electrode, arc attachment and envelope evolution were monitored by camera systems. The upgraded ORT models confirmed the arc length insensitivity property of the Dual Mirror LRM being one of the major reasons for its longer native lifetime. The third part of this research focuses on issues related to the entire LRM manufacturing. A series of quality control tools were developed to help implement manufacturing process optimization. LRMs made with the upgraded manufacturing processes showed about 25% output gain over the previous prototypes. Based on the imaging property of the Dual Mirror LRM, a lower cost lamp reflector alignment method, called cold alignment, was developed. In this method, the etendue efficiency is maintained and a slower degrading and more stable lifetime output performance are achieved

  4. Energy conserved and costs saved by small and medium-size manufacturers, 1988--1989

    SciTech Connect

    Kirsch, F.W.

    1991-05-01

    Energy Analysis and Diagnostic Centers (EADCs) provided energy-conserving and cost saving assistance in 339 small and medium-size manufacturing plants nationwide during 1988-89. This report presents the results of what was recommended to those manufacturers, the record of what was implemented by them, and an analysis of the financial rewards gained by them. It also includes an accounting of the financial returns to the federal government, derived from taxes upon the cost savings, or incremental income, of the manufacturers who implement the EADCs` recommendations. EADCs collect implementation data within a year of the energy audit, and for these results that time period extended through 1990. The EADCs are located at accredited engineering departments of universities and staffed by faculty and students. At present there are 18 EADCs serving manufacturers in 37 states; of these, two were established as a result of the 1989 competition, and five more were chosen competitively in 1990. Most of the results in this report were generated by 11 EADCs (named in the Appendix); two others withdrew voluntarily after completing only 10 energy audits during 1988-89. Primary responsibility for selecting, training, evaluating, and managing the EADCs belongs to the Industrial Technology and Energy Management (ITEM) division of University City Science Center (UCSC). The Department of Energy`s Office of Industrial Technologies sponsors the EADC program through an agreement with UCSC.

  5. Development of hybrid lifecycle cost estimating tool (HLCET) for manufacturing influenced design tradeoff

    NASA Astrophysics Data System (ADS)

    Sirirojvisuth, Apinut

    In complex aerospace system design, making an effective design decision requires multidisciplinary knowledge from both product and process perspectives. Integrating manufacturing considerations into the design process is most valuable during the early design stages since designers have more freedom to integrate new ideas when changes are relatively inexpensive in terms of time and effort. Several metrics related to manufacturability are cost, time, and manufacturing readiness level (MRL). Yet, there is a lack of structured methodology that quantifies how changes in the design decisions impact these metrics. As a result, a new set of integrated cost analysis tools are proposed in this study to quantify the impacts. Equally important is the capability to integrate this new cost tool into the existing design methodologies without sacrificing agility and flexibility required during the early design phases. To demonstrate the applicability of this concept, a ModelCenter environment is used to develop software architecture that represents Integrated Product and Process Development (IPPD) methodology used in several aerospace systems designs. The environment seamlessly integrates product and process analysis tools and makes effective transition from one design phase to the other while retaining knowledge gained a priori. Then, an advanced cost estimating tool called Hybrid Lifecycle Cost Estimating Tool (HLCET), a hybrid combination of weight-, process-, and activity-based estimating techniques, is integrated with the design framework. A new weight-based lifecycle cost model is created based on Tailored Cost Model (TCM) equations [3]. This lifecycle cost tool estimates the program cost based on vehicle component weights and programmatic assumptions. Additional high fidelity cost tools like process-based and activity-based cost analysis methods can be used to modify the baseline TCM result as more knowledge is accumulated over design iterations. Therefore, with this

  6. 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.

  7. A discounted-cost continuous-time flexible manufacturing and operator scheduling model solved by deconvexification over time

    SciTech Connect

    Eaves, B.C.; Rothblum, U.G.

    1990-08-01

    A discounted-cost, continuous-time, infinite-horizon version of a flexible manufacturing and operator scheduling model is solved. The solution procedure is to convexify the discrete operator-assignment constraints to obtain a linear program, and then to regain the discreteness and obtain an approximate manufacturing schedule by deconvexification of the solution of the linear program over time. The strong features of the model are the accommodation of linear inequality relations among the manufacturing activities and the discrete manufacturing scheduling, whereas the weak features are intra-period relaxation of inventory availability constraints, and the absence of inventory costs, setup times, and setup charges.

  8. Low Cost Injection Mold Creation via Hybrid Additive and Conventional Manufacturing

    SciTech Connect

    Dehoff, Ryan R.; Watkins, Thomas R.; List, III, Frederick Alyious; Carver, Keith; England, Roger

    2015-12-01

    The purpose of the proposed project between Cummins and ORNL is to significantly reduce the cost of the tooling (machining and materials) required to create injection molds to make plastic components. Presently, the high cost of this tooling forces the design decision to make cast aluminum parts because Cummins typical production volumes are too low to allow injection molded plastic parts to be cost effective with the amortized cost of the injection molding tooling. In addition to reducing the weight of components, polymer injection molding allows the opportunity for the alternative cooling methods, via nitrogen gas. Nitrogen gas cooling offers an environmentally and economically attractive cooling option, if the mold can be manufactured economically. In this project, a current injection molding design was optimized for cooling using nitrogen gas. The various components of the injection mold tooling were fabricated using the Renishaw powder bed laser additive manufacturing technology. Subsequent machining was performed on the as deposited components to form a working assembly. The injection mold is scheduled to be tested in a projection setting at a commercial vendor selected by Cummins.

  9. Cost Study for Manufacturing of Solid Oxide Fuel Cell Power Systems

    SciTech Connect

    Weimar, Mark R.; Chick, Lawrence A.; Gotthold, David W.; Whyatt, Greg A.

    2013-09-30

    Solid oxide fuel cell (SOFC) power systems can be designed to produce electricity from fossil fuels at extremely high net efficiencies, approaching 70%. However, in order to penetrate commercial markets to an extent that significantly impacts world fuel consumption, their cost will need to be competitive with alternative generating systems, such as gas turbines. This report discusses a cost model developed at PNNL to estimate the manufacturing cost of SOFC power systems sized for ground-based distributed generation. The power system design was developed at PNNL in a study on the feasibility of using SOFC power systems on more electric aircraft to replace the main engine-mounted electrical generators [Whyatt and Chick, 2012]. We chose to study that design because the projected efficiency was high (70%) and the generating capacity was suitable for ground-based distributed generation (270 kW).

  10. Technology Needs for Reduced Design and Manufacturing Cost of Commercial Transport Engines

    NASA Technical Reports Server (NTRS)

    Rohn, Douglas A.

    1997-01-01

    The objective of the study was to assess the needs in the design and manufacturing processes and identify areas where technology could impact in cost and cycle-time reduction. At the highest level, the team first identified the goals that were in line with long-range needs of the aeropropulsion industry, and to which technology and process improvements would be required to contribute. These goals are to reduce the time and costs in the development cycle of aircraft engines by a factor of two, reduce production cycle time by a factor of four, and to reduce production costs by 25%. Also, it was the intent of the team to identify the highest impact technologies that could be developed and demonstrated in five years.

  11. Advanced Materials and Manufacturing for Low-Cost, High-Performance Liquid Rocket Combustion Chambers

    NASA Technical Reports Server (NTRS)

    Williams, Brian E.; Arrieta, Victor M.

    2013-01-01

    A document describes the low-cost manufacturing of C103 niobium alloy combustion chambers, and the use of a high-temperature, oxidation-resistant coating that is superior to the standard silicide coating. The manufacturing process involved low-temperature spray deposition of C103 on removable plastic mandrels produced by rapid prototyping. Thin, vapor-deposited platinum-indium coatings were shown to substantially improve oxidation resistance relative to the standard silicide coating. Development of different low-cost plastic thrust chamber mandrel materials and prototyping processes (selective laser sintering and stereolithography) yielded mandrels with good dimensional accuracy (within a couple of mils) for this stage of development. The feasibility of using the kinetic metallization cold-spray process for fabrication of free-standing C1O3 thrusters on removable plastic mandrels was also demonstrated. The ambient and elevated temperature mechanical properties of the material were shown to be reasonably good relative to conventionally processed C103, but the greatest potential benefit is that coldsprayed chambers require minimal post-process machining, resulting in substantially lower machining and material costs. The platinum-iridium coating was shown to provide greatly increased oxidation resistance over the silicide when evaluated through oxyacetylene torch testing to as high as 300 F (= 150 C). The iridium component minimizes reaction with the niobium alloy chamber at high temperatures, and provides the high-temperature oxidation resistance needed at the throat.

  12. Innovative hybrid optics: combining the thermal stability of glass with low manufacturing cost of polymers

    NASA Astrophysics Data System (ADS)

    Doushkina, Valentina

    2010-08-01

    Innovative hybrid glass-polymer optical solutions on a component, module, or system level offer thermal stability of glass with low manufacturing cost of polymers reducing component weight, enhancing the safety and appeal of the products. Narrow choice of polymer materials is compensated by utilizing sophisticated optical surfaces such as refractive, reflective, and diffractive substrates with spherical, aspherical, cylindrical, and freeform prescriptions. Current advancements in polymer technology and injection molding capabilities placed polymer optics in the heart of many high tech devices and applications including Automotive Industry, Defense & Aerospace; Medical/Bio Science; Projection Displays, Sensors, Information Technology, Commercial and Industrial. This paper is about integration of polymer and glass optics for enhanced optical performance with reduced number of components, thermal stability, and low manufacturing cost. The listed advantages are not achievable when polymers or glass optics are used as stand-alone. The author demonstrates that integration of polymer and glass on component or optical system level on one hand offers high resolution and diffraction limited image quality, similar to the glass optics with stable refractive index and stable thermal performance when design is athermalized within the temperature range. On the other hand, the integrated hybrid solution significantly reduces cost, weight, and complexity, just like the polymer optics. The author will describe the design and analyzes process of combining glass and polymer optics for variety of challenging applications such as fast optics with low F/#, wide field of view lenses or systems, free form optics, etc.

  13. Design and high-volume manufacture of low-cost molded IR aspheres for personal thermal imaging devices

    NASA Astrophysics Data System (ADS)

    Zelazny, A. L.; Walsh, K. F.; Deegan, J. P.; Bundschuh, B.; Patton, E. K.

    2015-05-01

    The demand for infrared optical elements, particularly those made of chalcogenide materials, is rapidly increasing as thermal imaging becomes affordable to the consumer. The use of these materials in conjunction with established lens manufacturing techniques presents unique challenges relative to the cost sensitive nature of this new market. We explore the process from design to manufacture, and discuss the technical challenges involved. Additionally, facets of the development process including manufacturing logistics, packaging, supply chain management, and qualification are discussed.

  14. Low cost composite manufacturing utilizing intelligent pultrusion and resin transfer molding (IPRTM)

    NASA Astrophysics Data System (ADS)

    Bradley, James E.; Wysocki, Tadeusz S., Jr.

    1993-02-01

    This article describes an innovative method for the economical manufacturing of large, intricately-shaped tubular composite parts. Proprietary intelligent process control techniques are combined with standard pultrusion and RTM methodologies to provide high part throughput, performance, and quality while substantially reducing scrap, rework costs, and labor requirements. On-line process monitoring and control is achieved through a smart tooling interface consisting of modular zone tiles installed on part-specific die assemblies. Real-time archiving of process run parameters provides enhanced SPC and SQC capabilities.

  15. New materials and manufacturing options for low-cost candle filter production

    SciTech Connect

    Hanus, G.J.; Uznanski, K.T.; Decoursin, D.G.; Shtessel, E.

    1997-07-01

    Using self-propagating, high-temperature synthesis fabrication techniques, unique combinations of materials were studied for use in candle filter development. Materials suitable for corrosive atmospheres with improved filtration and mechanical properties were identified within the context of manufacturing simplicity, versatility and cost-effectiveness. Material combinations suitable for combustion synthesis were identified which match the temperature, strength and corrosion resistance requirements of operation in pressurized, fluidized-bed combustion (PFBC) environments. Tests on porosity, permeability and strength indicated the ability of the method to process porous filter material which matches or surpasses the performance levels of current, production candle filter material samples.

  16. PEM fuel cell cost minimization using ``Design For Manufacture and Assembly`` techniques

    SciTech Connect

    Lomax, F.D. Jr.; James, B.D.; Mooradian, R.P.

    1997-12-31

    Polymer Electrolyte Membrane (PEM) fuel cells fueled with direct hydrogen have demonstrated substantial technical potential to replace Internal Combustion Engines (ICE`s) in light duty vehicles. Such a transition to a hydrogen economy offers the potential of substantial benefits from reduced criteria and greenhouse emissions as well as reduced foreign fuel dependence. Research conducted for the Ford Motor Co. under a US Department of Energy contract suggests that hydrogen fuel, when used in a fuel cell vehicle (FCV), can achieve a cost per vehicle mile less than or equal to the gasoline cost per mile when used in an ICE vehicle. However, fuel cost parity is not sufficient to ensure overall economic success: the PEM fuel cell power system itself must be of comparable cost to the ICE. To ascertain if low cost production of PEM fuel cells is feasible, a powerful set of mechanical engineering tools collectively referred to as Design for Manufacture and Assembly (DFMA) has been applied to several representative PEM fuel cell designs. The preliminary results of this work are encouraging, as presented.

  17. The costs of work-related musculoskeletal disorders in automotive manufacturing.

    PubMed

    Punnett, L

    1999-01-01

    Inadequate application of ergonomic principles to the design of workplaces and individual jobs has adverse consequences for worker health and safety, especially in terms of strains, sprains, and other musculoskeletal disorders. In addition to the human pain and suffering, other losses are externalized to workers, with adverse financial and psychosocial impacts. There are also costs to employers through workers' compensation claims, scrap, and decreased production quality, medical insurance premiums, labor turnover, and adverse impacts on labor relations, although many of these are not linked by traditional accounting methods to ergonomic problems per se. Data collected in five plants of two major U.S. automotive manufacturing companies in the last decade have been used to estimate some of the costs associated with work-related musculoskeletal disorders (MSDs), only some of which resulted in workers compensation claims. In one plant in 1984-85, the payroll cost of all back and shoulder disorders was at least $320 per year per worker, not including workers' compensation premiums or claims paid. A large proportion of these costs were accrued by "unreported" cases, that is, cases that either had never been reported to the plant clinic or had been reported in the past and were considered administratively to have recovered. In the other four plants, annual costs associated with in-plant medical visits for MSDs in 1989-93 were almost as high as those resulting from compensation claims. At least one-half of these disorders were estimated to be attributable to physical ergonomic exposures in the workplace and thus preventable. These data are consistent with estimates by others that the real costs to employers are at least two to three times the amount paid in workers' compensation cases, and that at least 50 percent of all work-related musculoskeletal disorders among the working population could be prevented by appropriate ergonomic job design. Furthermore, recent

  18. Low-cost small scale parabolic trough collector design for manufacturing and deployment in Africa

    NASA Astrophysics Data System (ADS)

    Orosz, Matthew; Mathaha, Paul; Tsiu, Anadola; Taele, B. M.; Mabea, Lengeta; Ntee, Marcel; Khakanyo, Makoanyane; Teker, Tamer; Stephens, Jordan; Mueller, Amy

    2016-05-01

    Concentrating Solar Power is expanding its deployment on the African subcontinent, highlighting the importance of efforts to indigenize manufacturing of this technology to increase local content and therefore local economic benefits of these projects. In this study a design for manufacturing (DFM) exercise was conducted to create a locally produced parabolic trough collector (the G4 PTC). All parts were sourced or fabricated at a production facility in Lesotho, and several examples of the design were prototyped and tested with collaborators in the Government of Lesotho's Appropriate Technology Services division and the National University of Lesotho. Optical and thermal performance was simulated and experimentally validated, and pedagogical pre-commercial versions of the PTC have been distributed to higher education partners in Lesotho and Europe. The cost to produce the PTC is 180 USD/m2 for a locally manufactured heat collection element (HCE) capable of sustaining 250C operation at ~65% efficiency. A version with an imported evacuated HCE can operate at 300°C with 70% efficiency. Economically relevant applications for this locally produced PTC include industrial process heat and distributed generation scenarios where cogeneration is required.

  19. Additive Manufacturing for Cost Efficient Production of Compact Ceramic Heat Exchangers and Recuperators

    SciTech Connect

    Shulman, Holly; Ross, Nicole

    2015-10-30

    An additive manufacture technique known as laminated object manufacturing (LOM) was used to fabricate compact ceramic heat exchanger prototypes. LOM uses precision CO2 laser cutting of ceramic green tapes, which are then precision stacked to build a 3D object with fine internal features. Modeling was used to develop prototype designs and predict the thermal response, stress, and efficiency in the ceramic heat exchangers. Build testing and materials analyses were used to provide feedback for the design selection. During this development process, laminated object manufacturing protocols were established. This included laser optimization, strategies for fine feature integrity, lamination fluid control, green handling, and firing profile. Three full size prototypes were fabricated using two different designs. One prototype was selected for performance testing. During testing, cross talk leakage prevented the application of a high pressure differential, however, the prototype was successful at withstanding the high temperature operating conditions (1300 °F). In addition, analysis showed that the bulk of the part did not have cracks or leakage issues. This led to the development of a module method for next generation LOM heat exchangers. A scale-up cost analysis showed that given a purpose built LOM system, these ceramic heat exchangers would be affordable for the applications.

  20. Optical Metrology for CIGS Solar Cell Manufacturing and its Cost Implications

    NASA Astrophysics Data System (ADS)

    Sunkoju, Sravan Kumar

    Solar energy is a promising source of renewable energy which can meet the demand for clean energy in near future with advances in research in the field of photovoltaics and cost reduction by commercialization. Availability of a non-contact, in-line, real time robust process control strategies can greatly aid in reducing the gap between cell and module efficiencies, thereby leading to cost-effective large-scale manufacturing of high efficiency CIGS solar cells. In order to achieve proper process monitoring and control for the deposition of the functional layers of CuIn1-xGaxSe 2 (CIGS) based thin film solar cell, optical techniques such as spectroscopic reflectometry and polarimetry are advantageous because they can be set up in an unobtrusive manner in the manufacturing line, and collect data in-line and in-situ. The use of these techniques requires accurate optical models that correctly represent the properties of the layers being deposited. In this study, Spectroscopic ellipsometry (SE) has been applied for the characterization of each individual stage of CIGS layers deposited using the 3-stage co-evaporation process along with the other functional layers. Dielectric functions have been determined for the energy range from 0.7 eV to 5.1 eV. Critical-point line-shape analysis was used in this study to determine the critical point energies of the CIGS based layers. To control the compositional and thickness uniformity of all the functional layers during the fabrication of CIGS solar cells over large areas, multilayer photovoltaics (PV) stack optical models were developed with the help of extracted dielectric functions. In this study, mapping capability of RC2 spectroscopic ellipsometer was used to map all the functional layer thicknesses of a CIGS solar cell in order to probe the spatial non-uniformities that can affect the performance of a cell. The optical functions for each of the stages of CIGS 3-stage deposition process along with buffer layer and transparent

  1. Low Cost and Energy Efficient Methods for the Manufacture of Semi-Solid (SSM) Feedstock

    SciTech Connect

    Diran Apelian; Qingyue Pan; Makhlouf Makhlouf

    2005-11-07

    The SSM Consortium (now ACRC) at WPI has been carrying out fundamental, pre-competitive research in SSM for several years. Current and past research (at WPI) has generated many results of fundamental and applied nature, which are available to the SSM community. These include materials characterization, yield stress effects, alloy development, rheological properties, process modeling/simulation, semi-solid slurry formation, etc. Alternative method to produce SSM slurries at lower processing costs and with reduced energy consumption is a critical need. The production of low cost SSM feedstock will certainly lead to a dramatic increase in the tonnage of castings produced by SSM, and will provide end users such as the transportation industry, with lighter, cheaper and high performance materials. In this program, the research team has addressed three critical issues in semi-solid processing. They are: (1) Development of low cost, reliable slurry-on-demand approaches for semi-solid processing; (2) Application of the novel permanent grain refining technology-SiBloy for the manufacture of high-quality SSM feedstock, and (3) Development of computational and modeling tools for semi-solid processing to enhance SSM process control. Salient results from these studies are summarized and detailed in our final technical report.

  2. Comparative study on cost evaluation and network visualization of particle accelerator components for heavy ion inertial fusion

    NASA Astrophysics Data System (ADS)

    Inoue, A.; Takahashi, K.; Sasaki, T.; Kikuchi, T.; Harada, Nob; Barnard, J. J.

    2016-05-01

    By visualizing accelerator system components in heavy ion inertial fusion, the connection between the components becomes clear. We clarify an influential component on the entire cost by the relation of node connections due to the visualization result. Since a low cost component affects a high cost component, not only the cost estimation but also the relation between the components is considerable and important issue. A cost estimation result changing with an induction core cost indicates no influences in the rate of details.

  3. Low cost method for manufacturing a data acquisition system with USB connectivity

    NASA Astrophysics Data System (ADS)

    Niculescu, V.; Dobre, R. A.; Popovici, E.

    2016-06-01

    In the process of designing and manufacturing an electronic system the digital oscilloscope plays an essential role but it also represents one of the most expensive equipment present on the typical workbench. In order to make electronic design more accessible to students and hobbyists, an affordable data acquisition system was imagined. The paper extensively presents the development and testing of a low cost, medium speed, data acquisition system which can be used in a wide range of electronic measurement and debugging applications, assuring also great portability due to the small physical dimensions. Each hardware functional block and is thoroughly described, highlighting the challenges that occurred as well as the solutions to overcome them. The entire system was successfully manufactured using high quality components to assure increased reliability, and high frequency PCB materials and techniques were preferred. The measured values determined based on test signals were compared to the ones obtained using a digital oscilloscope available on the market and differences less than 1% were observed.

  4. Cost justification for an interactive Computer-Aided Design Drafting/Manufacturing system

    SciTech Connect

    Norton, F.J.

    1980-09-23

    Many factors influence the capital investment decision. System costs and benefits are weighed by methods of financial analysis to determine the advisability of an investment. Capital, expense, and benefits as related to Interactive Computer-Aided Design Drafting/Manufacturing (CADD/M) Systems are discussed and model calculations are included. An example is treated by the simple payback method and the more sophisticated methods of Net Present Value (NPV) and Internal Rate of Return (IRR). The NPV and IRR approaches include in the calculation the time value of money and provide a sounder foundation on which to base the purchase decision. It is hoped that an understanding of these techniques by technical personnel will make an optimum system purchase more likely.

  5. Sustainable chemical manufacturing: a matter of resources, wastes, hazards, and costs.

    PubMed

    Lange, Jean-Paul

    2009-01-01

    Sustainable development is gaining importance in the chemical industry. It encompasses social, environmental, and economical aspects. Herein, sustainable development is translated into four basic dimensions, called "sustainability stresses": resources, wastes, hazards, and costs. These sustainability stresses are discussed in some detail and their usefulness is illustrated by applying them to three manufacturing processes applied commercially by Shell, namely Shell's OMEGA, SMPO, and "low monol" technologies for producing ethene diol, styrene/propene oxide, and polyether polyols, respectively. These examples show that large reductions in sustainable stresses have been achieved in a few decades. They also show that the economical, environmental, and social issues are not in conflict when tackled at their roots: they can be all addressed simultaneously. PMID:19437479

  6. Cost-Effective Additive Manufacturing in Space: HELIOS Technology Challenge Guide

    NASA Technical Reports Server (NTRS)

    DeVieneni, Alayna; Velez, Carlos Andres; Benjamin, David; Hollenbeck, Jay

    2012-01-01

    Welcome to the HELIOS Technology Challenge Guide. This document is intended to serve as a general road map for participants of the HELIOS Technology Challenge [HTC] Program and the associated inaugural challenge: HTC-01: Cost-Effective Additive Manufacturing in Space. Please note that this guide is not a rule book and is not meant to hinder the development of innovative ideas. Its primary goal is to highlight the objectives of the HTC-01 Challenge and to describe possible solution routes and pitfalls that such technology may encounter in space. Please also note that participants wishing to demonstrate any hardware developed under this program during any future HELIOS Technology Challenge showcase event(s) may be subject to event regulations to be published separately at a later date.

  7. Enabling cost-effective high-current burst-mode operation in superconducting accelerators

    DOE PAGESBeta

    Sheffield, Richard L.

    2015-06-01

    Superconducting (SC) accelerators are very efficient for CW or long-pulse operation, and normal conducting (NC) accelerators are cost effective for short-pulse operation. The addition of a short NC linac section to a SC linac can correct for the energy droop that occurs when pulsed high-current operation is required that exceeds the capability of the klystrons to replenish the cavity RF fields due to the long field fill-times of SC structures, or a requirement to support a broad range of beam currents results in variable beam loading. This paper describes the implementation of this technique to enable microseconds of high beam-current,more » 90 mA or more, in a 12 GeV SC long-pulse accelerator designed for the MaRIE 42-keV XFEL proposed for Los Alamos National Laboratory.« less

  8. Enabling cost-effective high-current burst-mode operation in superconducting accelerators

    SciTech Connect

    Sheffield, Richard L.

    2015-06-01

    Superconducting (SC) accelerators are very efficient for CW or long-pulse operation, and normal conducting (NC) accelerators are cost effective for short-pulse operation. The addition of a short NC linac section to a SC linac can correct for the energy droop that occurs when pulsed high-current operation is required that exceeds the capability of the klystrons to replenish the cavity RF fields due to the long field fill-times of SC structures, or a requirement to support a broad range of beam currents results in variable beam loading. This paper describes the implementation of this technique to enable microseconds of high beam-current, 90 mA or more, in a 12 GeV SC long-pulse accelerator designed for the MaRIE 42-keV XFEL proposed for Los Alamos National Laboratory.

  9. Cost-performance tradeoff between design and manufacturing: DfM or MfD?

    NASA Astrophysics Data System (ADS)

    Balasinski, A.; Cetin, J.; Karklin, L.

    2007-03-01

    Design, CAD, and manufacturing are focused on optimizing translation methodology from electrical design to physical layout, and finally to mask data. The general goal is to improve integrated circuit (IC) functionality, reliability, manufacturability, testability, etc., using Design-for-X-ability (DfX) rules. Among those, the key role is played by DfM which is most directly related to the yield and therefore, the profit. A lot of pressure is being put on design to improve their understanding of all technology implementation issues, such that the mask pattern generated out of design layout would be "correct by construction" and comply with all of them. One can expect that such DfM-compliant layout should require significant effort to create, and its salient features would include: Manhattan geometries, and restricted grid for critical geometries, such as poly gates, large enclosures of the active area in the corners of implant layers, complete symmetry and proximity of the matched devices on all masking levels, minimal amount of jogs even for the complex features, neat alignment of source and drain contacts, line ends of gates and interconnects, doubled contacts and vias, etc. The question is if the cost of following all these practices at design time is not higher than that of other design improvement options. One alternative approach is to automatically adjust the "draft" layout using CAD post-processing such that all geometries would be optimized to conform to the DfM rules. Another approach to the DfM methodology is to improve the manufacturing capabilities such that the process tools would be able to achieve high yield for a layout which conforms only to some basic set of rules. This approach becomes even more relevant when the product line tries to address only selected DfM issues to improve die performance where it is most needed. We discussed the layout flow charts to determine the best approach, depending on the direct cost of the solution, the wafer volume

  10. Cost data collection for manufactured homes in RCDP (Residential Construction Demonstration Project)

    SciTech Connect

    Weakley, S.A.; Eckert, R.L.; Lee, A.D.

    1990-01-01

    In the Pacific Northwest, a major effort has been made to improve the energy efficiency of new buildings. In the residential building sector, energy-efficient standards for new construction, called Model Conservation Standards (MCS), have been proposed; and demonstration projects are under way to implement MCS features and to explore new conservation possibilities. Bonneville Power Administration (Bonneville) administers a Pacific Northwest program to promote the construction and marketing of energy-efficient site-built homes. This program, Super Good Cents (SGC), pays incentives for new buildings that meet the MCS energy-efficiency levels. Starting in late 1987, Bonneville began a research and demonstration project to include HUD-code manufactured homes (homes built under the US Department of Housing and Urban Development's standards) in the SGC program. This report provides information on PNL's activities in collecting technical and cost data, and presents selected descriptive results from the cost database. Analysis will be performed under a separate Bonneville contract after energy, ventilation, and infiltration rate data are collected. 2 refs., 12 tabs.

  11. 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.

  12. Warranty optimisation based on the prediction of costs to the manufacturer using neural network model and Monte Carlo simulation

    NASA Astrophysics Data System (ADS)

    Stamenkovic, Dragan D.; Popovic, Vladimir M.

    2015-02-01

    Warranty is a powerful marketing tool, but it always involves additional costs to the manufacturer. In order to reduce these costs and make use of warranty's marketing potential, the manufacturer needs to master the techniques for warranty cost prediction according to the reliability characteristics of the product. In this paper a combination free replacement and pro rata warranty policy is analysed as warranty model for one type of light bulbs. Since operating conditions have a great impact on product reliability, they need to be considered in such analysis. A neural network model is used to predict light bulb reliability characteristics based on the data from the tests of light bulbs in various operating conditions. Compared with a linear regression model used in the literature for similar tasks, the neural network model proved to be a more accurate method for such prediction. Reliability parameters obtained in this way are later used in Monte Carlo simulation for the prediction of times to failure needed for warranty cost calculation. The results of the analysis make possible for the manufacturer to choose the optimal warranty policy based on expected product operating conditions. In such a way, the manufacturer can lower the costs and increase the profit.

  13. Optical Metrology for CIGS Solar Cell Manufacturing and its Cost Implications

    NASA Astrophysics Data System (ADS)

    Sunkoju, Sravan Kumar

    Solar energy is a promising source of renewable energy which can meet the demand for clean energy in near future with advances in research in the field of photovoltaics and cost reduction by commercialization. Availability of a non-contact, in-line, real time robust process control strategies can greatly aid in reducing the gap between cell and module efficiencies, thereby leading to cost-effective large-scale manufacturing of high efficiency CIGS solar cells. In order to achieve proper process monitoring and control for the deposition of the functional layers of CuIn1-xGaxSe 2 (CIGS) based thin film solar cell, optical techniques such as spectroscopic reflectometry and polarimetry are advantageous because they can be set up in an unobtrusive manner in the manufacturing line, and collect data in-line and in-situ. The use of these techniques requires accurate optical models that correctly represent the properties of the layers being deposited. In this study, Spectroscopic ellipsometry (SE) has been applied for the characterization of each individual stage of CIGS layers deposited using the 3-stage co-evaporation process along with the other functional layers. Dielectric functions have been determined for the energy range from 0.7 eV to 5.1 eV. Critical-point line-shape analysis was used in this study to determine the critical point energies of the CIGS based layers. To control the compositional and thickness uniformity of all the functional layers during the fabrication of CIGS solar cells over large areas, multilayer photovoltaics (PV) stack optical models were developed with the help of extracted dielectric functions. In this study, mapping capability of RC2 spectroscopic ellipsometer was used to map all the functional layer thicknesses of a CIGS solar cell in order to probe the spatial non-uniformities that can affect the performance of a cell. The optical functions for each of the stages of CIGS 3-stage deposition process along with buffer layer and transparent

  14. PVMaT Cost Reductions in the EFG High-Volume PV Manufacturing Line: Annual Report, August 1998-December 2000

    SciTech Connect

    Bathey, B.; Brown, B.; Cao, J.; Ebers, S.; Gonsiorawski, R.; Heath, B.; Kalejs, J., Mackintosh, B.; Ouellette, M.; Piwczyk, B., Rosenblum, M.; Southimath, B.

    2001-02-22

    The PVMaT 5A2 program at ASE Americas is a three-year program that addresses topics in the development of manufacturing systems, low-cost processing approaches, and flexible manufacturing methods. The three-year objectives are as follows: (1) implementation of computer-aided manufacturing systems, including Statistical Process Control, to aid in electrical and mechanical yield improvements of 10%, (2) development and implementation of ISO 9000 and ISO 14000, (3) deployment of wafer production from large-diameter (up to 1 m) EFG cylinders and wafer thicknesses down to 95 microns, (4) development of low-damage, high-yield laser-cutting methods for thin wafers, (5) cell designs for >15% cell efficiencies on 100-micron-thick EFG wafers, (6) development of Rapid Thermal Anneal processing for thin high-efficiency EFG cells, and (7) deployment of flexible manufacturing methods for diversification in wafer size and module design. In the second year of this program, the significant accomplishments in each of three tasks that cover these areas are as follows: Task 4-Manufacturing systems, Task 5-Low-cost processes, and Task 6-Flexible manufacturing.

  15. The Relationship between National Heart, Lung, and Blood Institute Weight Guidelines and Concurrent Medical Costs in a Manufacturing Population.

    ERIC Educational Resources Information Center

    Wang, Feifei; Schultz, Alyssa B.; Musich, Shirley; McDonald, Tim; Hirschland, David; Edington, Dee W.

    2003-01-01

    Explored the relationship between the 1998 National Heart, Lung, and Blood Institute (NHLBI) weight guidelines and concurrent medical costs among 177,971 employees, retirees, and adult dependents from a nationwide manufacturing corporation. Results indicated that the six weight groups defined by the NHLBI guidelines were consistent with concurrent…

  16. Development of Low-Cost Manufacturing Processes for Planar, Multilayer Solid Oxide Fuel Cell Elements

    SciTech Connect

    Scott Swartz; Matthew Seabaugh; William Dawson; Tim Armstrong; Harlan Anderson; John Lannutti

    2001-09-30

    This report summarizes the results of Phase II of this program, 'Low-Cost Manufacturing Of Multilayer Ceramic Fuel Cells'. The objective of the program is to develop advanced ceramic manufacturing technologies for making planar solid oxide fuel cell (SOFC) components that are more economical and reliable for a variety of applications. Phase II development work focused on three distinct manufacturing approaches (or tracks) for planar solid oxide fuel cell elements. Two development tracks, led by NexTech Materials and Oak Ridge National Laboratory, involved co-sintering of planar SOFC elements of cathode-supported and anode-supported variations. A third development track, led by the University of Missouri-Rolla, focused on a revolutionary approach for reducing operating temperature of SOFCs by using spin-coating to deposit ultra-thin, nano-crystalline YSZ electrolyte films. The work in Phase II was supported by characterization work at Ohio State University. The primary technical accomplishments within each of the three development tracks are summarized. Track 1--NexTech's targeted manufacturing process for planar SOFC elements involves tape casting of porous electrode substrates, colloidal-spray deposition of YSZ electrolyte films, co-sintering of bi-layer elements, and screen printing of opposite electrode coatings. The bulk of NexTech's work focused on making cathode-supported elements, although the processes developed at NexTech also were applied to the fabrication of anode-supported cells. Primary accomplishments within this track are summarized below: (1) Scale up of lanthanum strontium manganite (LSM) cathode powder production process; (2) Development and scale-up of tape casting methods for cathode and anode substrates; (3) Development of automated ultrasonic-spray process for depositing YSZ films; (4) Successful co-sintering of flat bi-layer elements (both cathode and anode supported); (5) Development of anode and cathode screen-printing processes; and (6

  17. LOW-COST COMPOSITES IN VEHICLE MANUFACTURE - Natural-fiber-reinforced polymer composites in automotive applications.

    SciTech Connect

    Holbery, Jim; Houston, Dan

    2006-11-01

    In the last decade, natural fiber composites have experienced rapid growth in the European automotive market, and this trend appears to be global in scale, provided the cost and performance is justified against competing technologies. However, mass reduction, recyclability, and performance requirements can be met today by competing systems such as injection-molded unreinforced thermoplastics; natural fiber composites will continue to expand their role in automotive applications only if such technical challenges as moisture stability, fiber-polymer interface compatibility, and consistent, repeatable fiber sources are available to supply automotive manufacturers. Efforts underway by Tier I and II automotive suppliers to explore hybrid glass-natural fiber systems, as well as applications that exploit such capabilities as natural fiber sound dampening characteristics, could very well have far-reaching effects. In addition, the current development underway of bio-based resins such as Polyhydroxyalkanoate (PHA) biodegradable polyesters and bio-based polyols could provide fully bio-based composite options to future automotive designers. In short, the development of the natural fiber composite market would make a positive impact on farmers and small business owners on a global scale, reduce US reliance on foreign oil, improve environmental quality through the development of a sustainable resource supply chain, and achieve a better CO2 balance over the vehicle?s lifetime with near-zero net greenhouse gas emissions.

  18. Electron Beam Freeform Fabrication (EBF3) for Cost Effective Near-Net Shape Manufacturing

    NASA Technical Reports Server (NTRS)

    Taminger, Karen M.; Hafley, Robert A.

    2006-01-01

    Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley Research Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF3), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. EBF3 deposits of 2219 aluminium and Ti-6Al-4V have exhibited a range of grain morphologies depending upon the deposition parameters. These materials have exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF3 process is capable of bulk metal deposition at deposition rates in excess of 2500 cubic centimeters per hour (150 in3/hr) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

  19. Electron Beam Freeform Fabrication for Cost Effective Near-Net Shape Manufacturing

    NASA Technical Reports Server (NTRS)

    Taminger, Karen M.; Hafley, Robert A.

    2006-01-01

    Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley Research Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF3), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. EBF3 deposits of 2219 aluminium and Ti-6Al-4V have exhibited a range of grain morphologies depending upon the deposition parameters. These materials have exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF3 process is capable of bulk metal deposition at deposition rates in excess of 2500 cm3/hr (150 in3/hr) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

  20. Manufacturing Cost Analysis for YSZ-Based FlexCells at Pilot and Full Scale Production Scales

    SciTech Connect

    Scott Swartz; Lora Thrun; Robin Kimbrell; Kellie Chenault

    2011-05-01

    Significant reductions in cell costs must be achieved in order to realize the full commercial potential of megawatt-scale SOFC power systems. The FlexCell designed by NexTech Materials is a scalable SOFC technology that offers particular advantages over competitive technologies. In this updated topical report, NexTech analyzes its FlexCell design and fabrication process to establish manufacturing costs at both pilot scale (10 MW/year) and full-scale (250 MW/year) production levels and benchmarks this against estimated anode supported cell costs at the 250 MW scale. This analysis will show that even with conservative assumptions for yield, materials usage, and cell power density, a cost of $35 per kilowatt can be achieved at high volume. Through advancements in cell size and membrane thickness, NexTech has identified paths for achieving cell manufacturing costs as low as $27 per kilowatt for its FlexCell technology. Also in this report, NexTech analyzes the impact of raw material costs on cell cost, showing the significant increases that result if target raw material costs cannot be achieved at this volume.

  1. Cost Based Failure Modes and Effects Analysis (FMEA) for Systems of Accelerator Magnets.

    SciTech Connect

    Spencer, Cherrill M

    2003-06-02

    The proposed Next Linear Collider (NLC) has a proposed 85% overall availability goal, the availability specifications for all its 7200 magnets and their 6167 power supplies are 97.5% each. Thus all of the electromagnets and their power supplies must be highly reliable or quickly repairable. Improved reliability or repairability comes at a higher cost. We have developed a set of analysis procedures for magnet designers to use as they decide how much effort to exert, i.e. how much money to spend, to improve the reliability of a particular style of magnet. We show these procedures being applied to a standard SLAC electromagnet design in order to make it reliable enough to meet the NLC availability specs. First, empirical data from SLAC's accelerator failure database plus design experience are used to calculate MTBF for failure modes identified through a FMEA. Availability for one particular magnet can be calculated. Next, labor and material costs to repair magnet failures are used in a Monte Carlo simulation to calculate the total cost of all failures over a 30-year lifetime. Opportunity costs are included. Engineers choose from amongst various designs by comparing lifecycle costs.

  2. Preliminary estimate of the manufacturing cost for lithium/metal sulfide cells for stationary and mobile applications

    SciTech Connect

    Chilenskas, A. A.; Schaefer, J. C.; Towle, W. L.; Barney, D. L.

    1980-01-01

    A preliminary estimate has been made of the manufacturing cost for lithium/iron sulfide cells for stationary energy-storage and electric-vehicle applications. This preliminary cost analysis indicated that the manufacturing cost (in 1979 dollars) is $24 to 41/kW-h for stationary energy-storage cells and $31 to 55/kW-h for electric-vehicle cells. The materials cost was found to contribute between 52 and 65% of this manufacturing cost. The most expensive materials and components were lithium (metal and compounds), $4.61 to $14.26/kW-h; BN felt, $4.00 to 8.50/kW-h; feed-through components, $2.40/kW-h; positive current collectors, $1.48 to 2.20/kW-h; and aluminum, $1.43 to 1.66/kW-h. The projected lithium requirements were determined for use in lithium/iron sulfide batteries and conventional uses to the year 2006. The results showed that the lithium requirements were about 275,000 short tons by 2006, which is equivalent to about 51% of presently known US resources. Of this amount, about 33% would be used in battery production and 67% consumed in conventional uses. It is expected that the lithium used in battery production would be recycled.

  3. The effect of adopting new storage methods for extending product validity periods on manufacturers expected inventory costs.

    PubMed

    Chen, Po-Yu

    2014-01-01

    The validness of the expiration dates (validity period) that manufacturers provide on food product labels is a crucial food safety problem. Governments must study how to use their authority by implementing fair awards and punishments to prompt manufacturers into adopting rigorous considerations, such as the effect of adopting new storage methods for extending product validity periods on expected costs. Assuming that a manufacturer sells fresh food or drugs, this manufacturer must respond to current stochastic demands at each unit of time to determine the purchase amount of products for sale. If this decision maker is capable and an opportunity arises, new packaging methods (e.g., aluminum foil packaging, vacuum packaging, high-temperature sterilization after glass packaging, or packaging with various degrees of dryness) or storage methods (i.e., adding desiccants or various antioxidants) can be chosen to extend the validity periods of products. To minimize expected costs, this decision maker must be aware of the processing costs of new storage methods, inventory standards, inventory cycle lengths, and changes in relationships between factors such as stochastic demand functions in a cycle. Based on these changes in relationships, this study established a mathematical model as a basis for discussing the aforementioned topics. PMID:25302332

  4. Doing More with Less: Cost-effective, Compact Particle Accelerators (489th Brookhaven Lecture)

    SciTech Connect

    Trbojevic, Dejan

    2013-10-22

    Replace a 135-ton magnet used for cancer-fighting particle therapies with a magnet that weighs only two tons? Such a swap is becoming possible thanks to new particle accelerator advances being developed by researchers at Brookhaven Lab. With an approach that combines techniques used by synchrotron accelerators with the ability to accept more energy, these new technologies could be used for more than fighting cancer. They could also decrease the lifecycle of byproducts from nuclear power plants and reduce costs for eRHIC—a proposed electron-ion collider for Brookhaven Lab that researchers from around the world would use to explore the glue that holds together the universe’s most basic building blocks and explore the proton-spin puzzle. During this lecture, Dr. Trbojevic provides an overview of accelerator technologies and techniques—particularly a non-scaling, fixed-focused alternating gradient—to focus particle beams using fewer, smaller magnets. He discusses how these technologies will benefit eRHIC and other applications, including particle therapies being developed to combat cancer.

  5. Low cost and manufacturable complete microTAS for detecting bacteria.

    PubMed

    Sauer-Budge, Alexis F; Mirer, Paul; Chatterjee, Anirban; Klapperich, Catherine M; Chargin, David; Sharon, Andre

    2009-10-01

    In this paper, we present a fully integrated lab-on-a-chip and associated instrument for the detection of bacteria from liquid samples. The system conducts bacterial lysis, nucleic acid isolation and concentration, polymerase chain reaction (PCR), and end-point fluorescent detection. To enable truly low-cost manufacture of the single-use disposable chip, we designed the plastic chip in a planar format without any active components to be amenable to injection molding and utilized a novel porous polymer monolith (PPM) embedded with silica that has been shown to lyse bacteria and isolate the nucleic acids from clinical samples (M. D. Kulinski, M. Mahalanabis, S. Gillers, J. Y. Zhang, S. Singh and C. M. Klapperich, Biomed. Microdevices, 2009, 11, 671-678).(1) The chip is made of Zeonex(R), a thermoplastic with a high melting temperature to allow PCR, good UV transmissibility for UV-curing of the PPM, and low auto-fluorescence for fluorescence detection of the amplicon. We have built a prototype instrument to automate control of the fluids, temperature cycling, and optical detection with the capability of accommodating various chip designs. To enable fluid control without including valves or pumps on the chip, we utilized a remote valve switching technique. To allow fluid flow rate changes on the valveless chip, we incorporated speed changing fluid reservoirs. The PCR thermal cycling was achieved with a ceramic heater and air cooling, while end-point fluorescence detection was accomplished with an optical spectrometer; all integrated in the instrument. The chip seamlessly and automatically is mated to the instrument through an interface block that presses against the chip. The interface block aligns and ensures good contact of the chip to the temperature controlled region and the optics. The integrated functionality of the chip was demonstrated using Bacillus subtilis as a model bacterial target. A Taqman assay was employed on-chip to detect the isolated bacterial DNA

  6. Low-cost Design and Manufacturing of Surgical Guides for Mandibular Reconstruction Using a Fibula

    PubMed Central

    Nakamura, Hiroko; Sowa, Yoshihiro; Nishino, Kenichi

    2016-01-01

    Background: Surgical cutting guides are used in mandibular reconstruction involving osteotomy of the mandible and fibula. Cutting guides produced using computer-aided design (CAD) and computer-aided manufacturing (CAM) technologies have been reported recently. These guides aim to increase the benefits to patients by improving the accuracy, shortening the operating time, and correcting occlusion. However, the availability of these advanced technologies is limited in some regions of the world. To test whether we could produce low-cost surgical cutting guides, we made surgical guides and investigated their accuracy. Methods: Using free CAD software, we designed surgical cutting guides for the mandible and fibula and used these to perform virtual mandibular segmental osteotomies and fibula transplants in 12 model surgeries. The cutting guides were printed on a 3-dimensional (3D) printer. The model surgeries were performed using 3D mandibular models and cutting guides to check their accuracy. Deviations between the virtually simulated plan and the actual model surgery were investigated. Results: CAD and CAM technologies were used to design and 3D print the cutting guides and models. The guided surgeries were performed. The deviations were about 1.3 mm for mandibular osteotomy, less than 1 mm for fibular osteotomy, and within 2.4 mm for reconstructions of the mandible. Conclusions: Without using expensive software or products, we were able to design surgical cutting guides for the mandible and fibula and used these to perform virtual simulation of mandibular segmental osteotomy and fibular reconstruction. Model surgeries using 3D-printed surgical guides showed that the accuracy of reconstruction was within a 3-mm deviation. In circumstances where commercial CAD/CAM guides are not available, it may be possible to use CAD/CAM surgical guides in the clinic if doctors are willing to volunteer their time for the design and printing. PMID:27536484

  7. Industrialization of Biology. A Roadmap to Accelerate the Advanced Manufacturing of Chemicals

    SciTech Connect

    Friedman, Douglas C.

    2015-09-01

    The report stresses the need for efforts to inform the public of the nature of industrial biotechnology and of its societal benefits, and to make sure that concerns are communicated effectively between the public and other stakeholders. In addition to scientific advances, a number of governance and societal factors will influence the industrialization of biology. Industry norms and standards need to be established in areas such as read/write accuracy for DNA, data and machine technology specifications, and organism performance in terms of production rates and yields. An updated regulatory regime is also needed to accelerate the safe commercialization of new host organisms, metabolic pathways, and chemical products, and regulations should be coordinated across nations to enable rapid, safe, and global access to new technologies and products.

  8. 48 CFR 31.205-25 - Manufacturing and production engineering costs.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ..., production scheduling and control, methods and job analysis, equipment capabilities and capacities, inspection techniques, and tooling analysis (including tooling design and application improvements); and (4) Material and manufacturing producibility analysis for production suitability and to optimize...

  9. Value and manufacturing costs of planar solid oxide fuel cell stacks. Topical report, January 1994-July 1996

    SciTech Connect

    Romero, C.A.; Wright, J.D.

    1996-07-01

    In the first part of this report, the authors analyze the economics of three different fuel cell applications, 200 kW cogeneration, 50 MW stand alone power generation, and a central power plant application of a fuel cell integrated into a 225 MW gas turbine/combined cycle power plant. In the second part of this report, the authors estimated the cost of fabricating a planar SOFC stack using a variety of manufacturing techniques. For a facility producing 200 MW/year of fuel cell systems, the authors obtained vendor equipment quotations, material cost estimates, utility requirements, and projected labor and overhead costs. The authors used a minimum after tax rate of return requirement of 20% to estimate SOFC stack costs.

  10. Life cycle cost study for coated conductor manufacture by metal organic chemical vapor deposition

    SciTech Connect

    Chapman, J.N.

    1999-07-13

    The purpose of this report is to calculate the cost of producing high temperature superconducting wire by the Metal Organic Chemical Vapor Deposition (MOCVD) process. The technology status is reviewed from the literature and a plant conceptual design is assumed for the cost calculation. The critical issues discussed are the high cost of the metal organic precursors, the material utilization efficiency and the capability of the final product as measured by the critical current density achieved. Capital, operating and material costs are estimated and summed as the basis for calculating the cost per unit length of wire. Sensitivity analyses of key assumptions are examined to determine their effects on the final wire cost. Additionally, the cost of wire on the basis of cost per kiloampere per meter is calculated for operation at lower temperatures than the liquid nitrogen boiling temperature. It is concluded that this process should not be ruled out on the basis of high cost of precursors alone.

  11. 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.

  12. Early-life stress and reproductive cost: A two-hit developmental model of accelerated aging?

    PubMed

    Shalev, Idan; Belsky, Jay

    2016-05-01

    Two seemingly independent bodies of research suggest a two-hit model of accelerated aging, one highlighting early-life stress and the other reproduction. The first, informed by developmental models of early-life stress, highlights reduced longevity effects of early adversity on telomere erosion, whereas the second, informed by evolutionary theories of aging, highlights such effects with regard to reproductive cost (in females). The fact that both early-life adversity and reproductive effort are associated with shorter telomeres and increased oxidative stress raises the prospect, consistent with life-history theory, that these two theoretical frameworks currently informing much research are tapping into the same evolutionary-developmental process of increased senescence and reduced longevity. Here we propose a mechanistic view of a two-hit model of accelerated aging in human females through (a) early-life adversity and (b) early reproduction, via a process of telomere erosion, while highlighting mediating biological embedding mechanisms that might link these two developmental aging processes. PMID:27063083

  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. Costs incurred by applying computer-aided design/computer-aided manufacturing techniques for the reconstruction of maxillofacial defects.

    PubMed

    Rustemeyer, Jan; Melenberg, Alex; Sari-Rieger, Aynur

    2014-12-01

    This study aims to evaluate the additional costs incurred by using a computer-aided design/computer-aided manufacturing (CAD/CAM) technique for reconstructing maxillofacial defects by analyzing typical cases. The medical charts of 11 consecutive patients who were subjected to the CAD/CAM technique were considered, and invoices from the companies providing the CAD/CAM devices were reviewed for every case. The number of devices used was significantly correlated with cost (r = 0.880; p < 0.001). Significant differences in mean costs were found between cases in which prebent reconstruction plates were used (€3346.00 ± €29.00) and cases in which they were not (€2534.22 ± €264.48; p < 0.001). Significant differences were also obtained between the costs of two, three and four devices, even when ignoring the cost of reconstruction plates. Additional fees provided by statutory health insurance covered a mean of 171.5% ± 25.6% of the cost of the CAD/CAM devices. Since the additional fees provide financial compensation, we believe that the CAD/CAM technique is suited for wide application and not restricted to complex cases. Where additional fees/funds are not available, the CAD/CAM technique might be unprofitable, so the decision whether or not to use it remains a case-to-case decision with respect to cost versus benefit. PMID:25459375

  15. Handbook of estimating data, factors, and procedures. [for manufacturing cost studies

    NASA Technical Reports Server (NTRS)

    Freeman, L. M.

    1977-01-01

    Elements to be considered in estimating production costs are discussed in this manual. Guidelines, objectives, and methods for analyzing requirements and work structure are given. Time standards for specific specfic operations are listed for machining, sheet metal working, electroplating and metal treating; painting; silk screening, etching and encapsulating; coil winding; wire preparation and wiring; soldering; and the fabrication of etched circuits and terminal boards. The relation of the various elements of cost to the total cost as proposed for various programs by various contractors is compared with government estimates.

  16. PV Inverter Products Manufacturing and Design Improvements for Cost Reduction and Performance Enhancements: Final Subcontract Report, November 2003 (Revised)

    SciTech Connect

    West, R.

    2004-04-01

    The specific objectives of this subcontracted development work by Xantrex Technology Inc. were to: (1) Capture the newest digital signal processor (DSP) technology to create high-impact,''next generation'' power conversion equipment for the PV industry; (2) Create a common resource base for three PV product lines. This standardized approach to both hardware and software control platforms will provide significant market advantage over foreign competition; (3) Achieve cost reductions through increased volume of common components, reduced assembly labor, and the higher efficiency of producing more products with fewer design, manufacturing, and production test variations; (4) Increase PV inverter product reliability. Reduce inverter size, weight and conversion losses. The contract goals were to achieve an overall cost reduction of 10% to 20% for the three inverters and with no compromise in performance. The cost of the 10-kW inverter was reduced by 56%, and the cost of the 25-kW inverter was reduced by 53%. The 2.5-kW inverter has no basis for comparison, but should benefit equally from this design approach. Not only were the contract cost reduction goals exceeded by a wide margin, but the performance and reliability of the products were also enhanced. The conversion efficiency improvement, as reflected in the 50% conversion loss reduction, adds significant value in renewable energy applications. The size and weight reductions also add value by providing less cumbersome product solutions for system designers.

  17. Manufacturing Cost Analysis of Novel Steel/Concrete Composite Vessel for Stationary Storage of High-Pressure Hydrogen

    SciTech Connect

    Feng, Zhili; Zhang, Wei; Wang, Jy-An John; Ren, Fei

    2012-09-01

    A novel, low-cost, high-pressure, steel/concrete composite vessel (SCCV) technology for stationary storage of compressed gaseous hydrogen (CGH2) is currently under development at Oak Ridge National Laboratory (ORNL) sponsored by DOE s Fuel Cell Technologies (FCT) Program. The SCCV technology uses commodity materials including structural steels and concretes for achieving cost, durability and safety requirements. In particular, the hydrogen embrittlement of high-strength low-alloy steels, a major safety and durability issue for current industry-standard pressure vessel technology, is mitigated through the use of a unique layered steel shell structure. This report presents the cost analysis results of the novel SCCV technology. A high-fidelity cost analysis tool is developed, based on a detailed, bottom-up approach which takes into account the material and labor costs involved in each of the vessel manufacturing steps. A thorough cost study is performed to understand the SCCV cost as a function of the key vessel design parameters, including hydrogen pressure, vessel dimensions, and load-carrying ratio. The major conclusions include: The SCCV technology can meet the technical/cost targets set forth by DOE s FCT Program for FY2015 and FY2020 for all three pressure levels (i.e., 160, 430 and 860 bar) relevant to the hydrogen production and delivery infrastructure. Further vessel cost reduction can benefit from the development of advanced vessel fabrication technologies such as the highly automated friction stir welding (FSW). The ORNL-patented multi-layer, multi-pass FSW can not only reduce the amount of labor needed for assembling and welding the layered steel vessel, but also make it possible to use even higher strength steels for further cost reductions and improvement of vessel structural integrity. It is noted the cost analysis results demonstrate the significant cost advantage attainable by the SCCV technology for different pressure levels when compared to the

  18. Next generation grinding spindle for cost-effective manufacture of advanced ceramic components

    SciTech Connect

    Kovach, J.A.; Laurich, M.A.

    2000-01-01

    Finish grinding of advanced structural ceramics has generally been considered an extremely slow and costly process. Recently, however, results from the High-Speed, Low-Damage (HSLD) program have clearly demonstrated that numerous finish-process performance benefits can be realized by grinding silicon nitride at high wheel speeds. A new, single-step, roughing-process capable of producing high-quality silicon nitride parts at high material removal rates while dramatically reducing finishing costs has been developed.

  19. Reducing metal alloy powder costs for use in powder bed fusion additive manufacturing: Improving the economics for production

    NASA Astrophysics Data System (ADS)

    Medina, Fransisco

    Titanium and its associated alloys have been used in industry for over 50 years and have become more popular in the recent decades. Titanium has been most successful in areas where the high strength to weight ratio provides an advantage over aluminum and steels. Other advantages of titanium include biocompatibility and corrosion resistance. Electron Beam Melting (EBM) is an additive manufacturing (AM) technology that has been successfully applied in the manufacturing of titanium components for the aerospace and medical industry with equivalent or better mechanical properties as parts fabricated via more traditional casting and machining methods. As the demand for titanium powder continues to increase, the price also increases. Titanium spheroidized powder from different vendors has a price range from 260/kg-450/kg, other spheroidized alloys such as Niobium can cost as high as $1,200/kg. Alternative titanium powders produced from methods such as the Titanium Hydride-Dehydride (HDH) process and the Armstrong Commercially Pure Titanium (CPTi) process can be fabricated at a fraction of the cost of powders fabricated via gas atomization. The alternative powders can be spheroidized and blended. Current sectors in additive manufacturing such as the medical industry are concerned that there will not be enough spherical powder for production and are seeking other powder options. It is believed the EBM technology can use a blend of spherical and angular powder to build fully dense parts with equal mechanical properties to those produced using traditional powders. Some of the challenges with angular and irregular powders are overcoming the poor flow characteristics and the attainment of the same or better packing densities as spherical powders. The goal of this research is to demonstrate the feasibility of utilizing alternative and lower cost powders in the EBM process. As a result, reducing the cost of the raw material to reduce the overall cost of the product produced with

  20. Compensation of the impact of low-cost manufacturing techniques in the design of E-plane multiport waveguide junctions

    NASA Astrophysics Data System (ADS)

    San-Blas, A. A.; Roca, J. M.; Cogollos, S.; Morro, J. V.; Boria, V. E.; Gimeno, B.

    2016-06-01

    In this work, a full-wave tool for the accurate analysis and design of compensated E-plane multiport junctions is proposed. The implemented tool is capable of evaluating the undesired effects related to the use of low-cost manufacturing techniques, which are mostly due to the introduction of rounded corners in the cross section of the rectangular waveguides of the device. The obtained results show that, although stringent mechanical effects are imposed, it is possible to compensate for the impact of the cited low-cost manufacturing techniques by redesigning the matching elements considered in the original device. Several new designs concerning a great variety of E-plane components (such as right-angled bends, T-junctions and magic-Ts) are presented, and useful design guidelines are provided. The implemented tool, which is mainly based on the boundary integral-resonant mode expansion technique, has been successfully validated by comparing the obtained results to simulated data provided by a commercial software based on the finite element method.

  1. Cost-effective manufacturing of compact TDLAS sensors for hazardous area applications

    NASA Astrophysics Data System (ADS)

    Frish, Michael B.; Laderer, Mathew C.; Smith, Clinton J.; Ehid, Ryan; Dallas, Joseph

    2016-03-01

    Tunable Diode Laser Absorption Spectroscopy (TDLAS) is finding ever increasing utility for industrial process measurement and control. The technique's sensitivity and selectivity benefit continuous concentration measurements of specific gas components in complex gas mixtures which are often laden with liquids or solid particulates. Tradeoff options among optical path length, absorption linestrength, linewidth, cross-interferences, and sampling methodology enable sensor designers to optimize detection for specific applications. Emerging applications are demanding increasing numbers of distributed miniaturized sensors at diminishing costs. In these applications, the TDLAS specificity is a key attribute, and its high sensitivity enables novel sampling package designs with short optical path lengths. This paper describes a miniature hermetically-sealed backscatter TDLAS transceiver package designed for high-volume production at acceptable cost. Occupying a volume less than 1in3 and weighing less than 0.06 lb, the transceiver is a key component of TDLAS sensors intended for in-situ measurements of potentially explosive gas mixtures.

  2. A low-cost, manufacturable method for fabricating capillary and optical fiber interconnects for microfluidic devices.

    PubMed

    Hartmann, Daniel M; Nevill, J Tanner; Pettigrew, Kenneth I; Votaw, Gregory; Kung, Pang-Jen; Crenshaw, Hugh C

    2008-04-01

    Microfluidic chips require connections to larger macroscopic components, such as light sources, light detectors, and reagent reservoirs. In this article, we present novel methods for integrating capillaries, optical fibers, and wires with the channels of microfluidic chips. The method consists of forming planar interconnect channels in microfluidic chips and inserting capillaries, optical fibers, or wires into these channels. UV light is manually directed onto the ends of the interconnects using a microscope. UV-curable glue is then allowed to wick to the end of the capillaries, fibers, or wires, where it is cured to form rigid, liquid-tight connections. In a variant of this technique, used with light-guiding capillaries and optical fibers, the UV light is directed into the capillaries or fibers, and the UV-glue is cured by the cone of light emerging from the end of each capillary or fiber. This technique is fully self-aligned, greatly improves both the quality and the manufacturability of the interconnects, and has the potential to enable the fabrication of interconnects in a fully automated fashion. Using these methods, including a semi-automated implementation of the second technique, over 10,000 interconnects have been formed in almost 2000 microfluidic chips made of a variety of rigid materials. The resulting interconnects withstand pressures up to at least 800psi, have unswept volumes estimated to be less than 10 femtoliters, and have dead volumes defined only by the length of the capillary. PMID:18369517

  3. Integral Airframe Structures (IAS): Validated Feasibility Study of Integrally Stiffened Metallic Fuselage Panels for Reducing Manufacturing Costs

    NASA Technical Reports Server (NTRS)

    Munroe, J.; Wilkins, K.; Gruber, M.; Domack, Marcia S. (Technical Monitor)

    2000-01-01

    The Integral Airframe Structures (IAS) program investigated the feasibility of using "integrally stiffened" construction for commercial transport fuselage structure. The objective of the program was to demonstrate structural performance and weight equal to current "built-up" structure with lower manufacturing cost. Testing evaluated mechanical properties, structural details, joint performance, repair, static compression, and two-bay crack residual strength panels. Alloys evaluated included 7050-T7451 plate, 7050-T74511 extrusion, 6013-T6511x extrusion, and 7475-T7351 plate. Structural performance was evaluated with a large 7475-T7351 pressure test that included the arrest of a two-bay longitudinal crack, and a measure of residual strength for a two-bay crack centered on a broken frame. Analysis predictions for the two-bay longitudinal crack panel correlated well with the test results. Analysis activity conducted by the IAS team strongly indicates that current analysis tools predict integral structural behavior as accurately as built-up structure. The cost study results indicated that, compared to built-up fabrication methods, high-speed machining structure from aluminum plate would yield a recurring cost savings of 61%. Part count dropped from 78 individual parts on a baseline panel to just 7 parts for machined IAS structure.

  4. Make or buy analysis model based on tolerance allocation to minimize manufacturing cost and fuzzy quality loss

    NASA Astrophysics Data System (ADS)

    Rosyidi, C. N.; Puspitoingrum, W.; Jauhari, W. A.; Suhardi, B.; Hamada, K.

    2016-02-01

    The specification of tolerances has a significant impact on the quality of product and final production cost. The company should carefully pay attention to the component or product tolerance so they can produce a good quality product at the lowest cost. Tolerance allocation has been widely used to solve problem in selecting particular process or supplier. But before merely getting into the selection process, the company must first make a plan to analyse whether the component must be made in house (make), to be purchased from a supplier (buy), or used the combination of both. This paper discusses an optimization model of process and supplier selection in order to minimize the manufacturing costs and the fuzzy quality loss. This model can also be used to determine the allocation of components to the selected processes or suppliers. Tolerance, process capability and production capacity are three important constraints that affect the decision. Fuzzy quality loss function is used in this paper to describe the semantic of the quality, in which the product quality level is divided into several grades. The implementation of the proposed model has been demonstrated by solving a numerical example problem that used a simple assembly product which consists of three components. The metaheuristic approach were implemented to OptQuest software from Oracle Crystal Ball in order to obtain the optimal solution of the numerical example.

  5. High Efficiency, Low Cost Solar Cells Manufactured Using 'Silicon Ink' on Thin Crystalline Silicon Wafers

    SciTech Connect

    Antoniadis, H.

    2011-03-01

    Reported are the development and demonstration of a 17% efficient 25mm x 25mm crystalline Silicon solar cell and a 16% efficient 125mm x 125mm crystalline Silicon solar cell, both produced by Ink-jet printing Silicon Ink on a thin crystalline Silicon wafer. To achieve these objectives, processing approaches were developed to print the Silicon Ink in a predetermined pattern to form a high efficiency selective emitter, remove the solvents in the Silicon Ink and fuse the deposited particle Silicon films. Additionally, standard solar cell manufacturing equipment with slightly modified processes were used to complete the fabrication of the Silicon Ink high efficiency solar cells. Also reported are the development and demonstration of a 18.5% efficient 125mm x 125mm monocrystalline Silicon cell, and a 17% efficient 125mm x 125mm multicrystalline Silicon cell, by utilizing high throughput Ink-jet and screen printing technologies. To achieve these objectives, Innovalight developed new high throughput processing tools to print and fuse both p and n type particle Silicon Inks in a predetermined pat-tern applied either on the front or the back of the cell. Additionally, a customized Ink-jet and screen printing systems, coupled with customized substrate handling solution, customized printing algorithms, and a customized ink drying process, in combination with a purchased turn-key line, were used to complete the high efficiency solar cells. This development work delivered a process capable of high volume producing 18.5% efficient crystalline Silicon solar cells and enabled the Innovalight to commercialize its technology by the summer of 2010.

  6. Comparison Study of Electromagnet and Permanent Magnet Systems for an Accelerator Using Cost-Based Failure Modes and Effects Analysis.

    SciTech Connect

    Spencer, C

    2004-02-19

    The next generation of particle accelerators will be one-of-a-kind facilities, and to meet their luminosity goals they must have guaranteed availability over their several decade lifetimes. The Next Linear Collider (NLC) is one viable option for a 1 TeV electron-positron linear collider, it has an 85% overall availability goal. We previously showed how a traditional Failure Modes and Effects Analysis (FMEA) of a SLAC electromagnet leads to reliability-enhancing design changes. Traditional FMEA identifies failure modes with high risk but does not consider the consequences in terms of cost, which could lead to unnecessarily expensive components. We have used a new methodology, ''Life Cost-Based FMEA'', which measures risk of failure in terms of cost, in order to evaluate and compare two different technologies that might be used for the 8653 NLC magnets: electromagnets or permanent magnets. The availabilities for the two different types of magnet systems have been estimated using empirical data from SLAC's accelerator failure database plus expert opinion on permanent magnet failure modes and industry standard failure data. Labor and material costs to repair magnet failures are predicted using a Monte Carlo simulation of all possible magnet failures over a 30-year lifetime. Our goal is to maximize up-time of the NLC through magnet design improvements and the optimal combination of electromagnets and permanent magnets, while reducing magnet system lifecycle costs.

  7. A program to accelerate the deployment of CO{sub 2} capture and storage: rational, objectives and cost

    SciTech Connect

    Vello A. Kuuskraa

    2007-10-15

    This White Paper, the first of a series, analyzes one strategy for accelerating the deployment of carbon capture and storage (CCS) by the coal-fueled electricity generation industry. This strategy involves providing reimbursement for the incremental costs of installing and operating CCS systems, with reimbursement provided for retrofitting existing coal-fuelled electricity generation plants with CCS, incorporating CCS into new plants, and launching large-scale demonstrations of geologic storage of carbon. 14 refs., 4 figs., 23 tabs., 3 apps.

  8. A low-cost technique to manufacture a container to process meiofauna for scanning electron microscopy.

    PubMed

    Abolafia, J

    2015-09-01

    An easy and low-cost method to elaborate a container to dehydrate nematodes and other meiofauna in order to process them for scanning electron microscopy (SEM) is presented. Illustrations of its elaboration, step by step, are included. In addition, a brief methodology to process meiofauna, especially nematodes and kinorhynchs, and illustrations are provided. With this methodology it is possible to easily introduce the specimens, to lock them in a closed chamber allowing the infiltration of fluids and gases (ethanol, acetone, carbon dioxide) but avoiding losing the specimens. After using this meiofauna basket for SEM the results are efficient. Examples of nematode and kinorhynch SEM pictures obtained using this methodology are also included. PMID:26178782

  9. Self Aligned Cell: Scaling Up Manufacture of a Cost Effective Cell Architecture for Multicrystalline Silicon Photovoltaics

    SciTech Connect

    Gabor, A.; van Mierlo, F.

    2010-12-01

    Two areas of technology for fabrication of higher efficiency Si-wafer solar cells were addressed: (1) the formation of structured texturing that is an improvement over the industry-standard isotexture process for multicrystalline wafers. (2) the formation of fine line (<50 micron) metallization seed layers in a self-aligned manner where the fingers can be automatically and perfectly lined up to a selective emitter and where expensive silver screen printing paste can be mostly replaced by plating up the seed layers with silver or copper. The benefits are: a) Lower reflectivity , b) Decoupling the performance of the texture from the saw damage, thus allowing for better advances in sawing and a more robust wet process. 1366 Technologies developed 2 pilot machines for 1) deposition and patterning of low-cost resist layers to enable simultaneous Honeycomb front texturing and groove formation for multicrystalline Si wafers, and 2) fine-line dispensing of materials that are self aligned to the grooves.

  10. 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

  11. Low-cost and highly manufacturable 30-Gb/s parallel optical transmitter module

    NASA Astrophysics Data System (ADS)

    Chen, Yi-Ming; Cheng, Yao-Ling; Chen, Ying-Chin; Wu, Cherng-Shiun; Chu, Mu-Tao

    2004-10-01

    This paper describes a 12-channels parallel optical transmitter module with a MPO-Connector designed for a very short reach OC-192 and SNAP 12 specifications. It is important to design the micro array lens for better couple efficiency of array optical transmitter module. The authors design the high accuracy micro array lens for injection modeling to reduce the price and suit for further mass production. In this 12-channel parallel optical transmitter module, it is very difficult to posit the chip on correct position according to guide pin or guide pin hole. Therefore, the authors develop the method of two steps flip chip bonding to release the difficulty of chip alignment on ceramic substrate without two guide pin holes. The performance of the module is demonstrated to fulfill the requirements of SNAP 12[1]. The extinction ratio of the 12-channels array transmitter module is tested above 6dB, respectively. The optical shift by heat is an important factor affecting the performance of the array module. Thermal analysis of 12-channel parallel optical transmitter module is used to improve the effect of optical shift by heat in this paper. And the temperature among the case of transmitter module is greatly reduced from 52.7 degree to 31.9 degree. In this paper, a 12-channel array transmitter module package and thermal simulation are discussed and tested. This is a low cost package design and is suitable for mass production.

  12. Cable manufacture

    NASA Technical Reports Server (NTRS)

    Gamble, P.

    1972-01-01

    A survey is presented of flat electrical cable manufacturing, with particular reference to patented processes. The economics of manufacture based on an analysis of material and operating costs is considered for the various methods. Attention is given to the competitive advantages of the several processes and their resulting products. The historical area of flat cable manufacture is presented to give a frame of reference for the survey.

  13. Design, development and manufacture of high-efficiency low-cost solar modules based on CIGS PVICs

    NASA Astrophysics Data System (ADS)

    Eldada, Louay

    2010-02-01

    We describe the design, development and manufacture of solar power panels based on photovoltaic integrated circuits (PVICs) with high-quality high-uniformity Copper Indium Gallium Selenide (CIGS) thin films produced with the unique combination of low-cost ink-based and physical vapor deposition (PVD) based nanoengineered precursor thin films and a reactive transfer printing method. Reactive transfer is a two-stage process relying on chemical reaction between two separate precursor films to form CIGS, one deposited on the substrate and the other on a printing plate in the first stage. In the second stage, these precursors are brought into intimate contact and rapidly reacted under pressure in the presence of an electrostatic field while heat is applied. The use of two independent thin films provides the benefits of independent composition and flexible deposition technique optimization, and eliminates pre-reaction prior to the synthesis of CIGS. High quality CIGS with large grains on the order of several microns, and of preferred crystallographic orientation, are formed in just several minutes based on compositional and structural analysis by XRF, SIMS, SEM and XRD. Cell efficiencies of 14% and module efficiencies of 12% have been achieved using this method. When atmospheric pressure deposition of inks is utilized for the precursor films, the approach additionally provides lower energy consumption, higher throughput, and further reduced capital equipment cost with higher uptime.

  14. Laser generated microstructures in tape cast electrodes for rapid electrolyte wetting: new technical approach for cost efficient battery manufacturing

    NASA Astrophysics Data System (ADS)

    Pfleging, W.; Kohler, R.; Pröll, J.

    2014-03-01

    Three-dimensional (3D) battery architectures are under current scientific investigation since they can achieve large areal energy capacities while maintaining high power densities. A main objective of surface patterning is the enhancement of lithium-ion diffusion which is often a limiting factor in lithium-ion cells. By using a rather new approach, laser material processing of thick-film electrodes has been investigated for the precise adjustment of 3D surface topography. Besides lithium-ion diffusion in electrode materials as an electrochemically limited process, a critical step in lithium-ion pouch cell manufacturing is the homogeneous electrolyte wetting of stacked electrodes and separators. This process requires cost expensive and time-consuming vacuum and storage processes at elevated temperatures. A new and cost efficient laser process has been successfully applied in order to significantly improve the electrode wetting and the battery operation. Preliminary investigations for testing the process on pouch cell geometry revealed higher capacities and increased cell life-time compared to standard cells without storage processes at elevated temperatures. The laser structuring process can be applied to commercial electrode materials and integrated into existing production lines.

  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. The cost of transport of human running is not affected, as in walking, by wide acceleration/deceleration cycles.

    PubMed

    Minetti, Alberto E; Gaudino, Paolo; Seminati, Elena; Cazzola, Dario

    2013-02-15

    Although most of the literature on locomotion energetics and biomechanics is about constant-speed experiments, humans and animals tend to move at variable speeds in their daily life. This study addresses the following questions: 1) how much extra metabolic energy is associated with traveling a unit distance by adopting acceleration/deceleration cycles in walking and running, with respect to constant speed, and 2) how can biomechanics explain those metabolic findings. Ten males and ten females walked and ran at fluctuating speeds (5 ± 0, ± 1, ± 1.5, ± 2, ± 2.5 km/h for treadmill walking, 11 ± 0, ± 1, ± 2, ± 3, ± 4 km/h for treadmill and field running) in cycles lasting 6 s. Field experiments, consisting of subjects following a laser spot projected from a computer-controlled astronomic telescope, were necessary to check the noninertial bias of the oscillating-speed treadmill. Metabolic cost of transport was found to be almost constant at all speed oscillations for running and up to ±2 km/h for walking, with no remarkable differences between laboratory and field results. The substantial constancy of the metabolic cost is not explained by the predicted cost of pure acceleration/deceleration. As for walking, results from speed-oscillation running suggest that the inherent within-stride, elastic energy-free accelerations/decelerations when moving at constant speed work as a mechanical buffer for among-stride speed fluctuations, with no extra metabolic cost. Also, a recent theory about the analogy between sprint (level) running and constant-speed running on gradients, together with the mechanical determinants of gradient locomotion, helps to interpret the present findings. PMID:23221963

  17. Manufacturing cost analysis of a parabolic dish concentrator (General Electric design) for solar thermal electric power systems in selected production volumes

    NASA Technical Reports Server (NTRS)

    1981-01-01

    The manufacturing cost of a General Electric 12 meter diameter concentrator was estimated. This parabolic dish concentrator for solar thermal system was costed in annual production volumes of 100 - 1,000 - 5,000 - 10,000 - 50,000 100,000 - 400,000 and 1,000,000 units. Presented for each volume are the costs of direct labor, material, burden, tooling, capital equipment and buildings. Also presented is the direct labor personnel and factory space requirements. All costs are based on early 1981 economics.

  18. High Performance Packaging Solutions for Low Cost, Reliable PV Modules: Final Subcontract Report, 26 May 2005 - 30 November 2008

    SciTech Connect

    Keotla, B. M.; Marinik, B. J.

    2009-06-01

    During this research effort, Dow Corning Corporation has addressed the PV manufacturing goals of: (i) improving PV manufacturing processes and equipment; (ii) accelerating manufacturing cost reductions of PV modules; (iii) increasing commercial product performance and reliability; and (iv) scaling up U.S. manufacturing capacity.

  19. Can Low-Cost Support Programmes with Coaching Accelerate Doctoral Completion in Health Science Faculty Academics?

    ERIC Educational Resources Information Center

    Geber, Hilary; Bentley, Alison

    2012-01-01

    Career development for full-time Health Sciences academics through to doctoral studies is a monumental task. Many academics have difficulty completing their studies in the minimum time as well as publishing after obtaining their degree. As this problem is particularly acute in the Health Sciences, the PhD Acceleration Programme in Health Sciences…

  20. Advanced Manufacturing Technologies

    NASA Technical Reports Server (NTRS)

    Fikes, John

    2016-01-01

    Advanced Manufacturing Technologies (AMT) is developing and maturing innovative and advanced manufacturing technologies that will enable more capable and lower-cost spacecraft, launch vehicles and infrastructure to enable exploration missions. The technologies will utilize cutting edge materials and emerging capabilities including metallic processes, additive manufacturing, composites, and digital manufacturing. The AMT project supports the National Manufacturing Initiative involving collaboration with other government agencies.

  1. Design, development, and manufacturing of highly advanced and cost effective aluminium sputtering plant for large area telescopic mirrors.

    NASA Astrophysics Data System (ADS)

    Pillai, Rajeev R.; Sanjith K., K.; Mohanachandran, K.; Sakhamuri, Nagarjun; Shukla, Vishal; Gupta, Alok

    2012-09-01

    The design, development and manufacturing of a fully automated and cost effective aluminum sputtering unit for the deposition of aluminum on large area telescopic mirrors (maximum diameter of 3600mm) is presented here. The unit employs DC planar magnetron sputtering for the deposition process. A large area glow discharge unit is also designed for the pre-cleaning of the mirrors prior to aluminum coating. A special kinematic support structure with rotation is designed to support heavy mirrors of large area to minimize the deflection of the mirrors during deposition process. A custom designed 'mask' is employed in the magnetron system to improve the thickness uniformity within <±3%. The adhesion, thickness uniformity and reflectivity properties are studied in detail to validate the sputtering plant. Special fixtures have been designed for the system to accommodate smaller mirrors and studies have been conducted for the coatings and reported in the paper. The unit was successfully tested at HHV facility in Bangalore and will be installed at the ARIES Facility, Nainital.

  2. Study of Potential Cost Reductions Resulting from Super-Large-Scale Manufacturing of PV Modules: Final Subcontract Report, 7 August 2003--30 September 2004

    SciTech Connect

    Keshner, M. S.; Arya, R.

    2004-10-01

    Hewlett Packard has created a design for a ''Solar City'' factory that will process 30 million sq. meters of glass panels per year and produce 2.1-3.6 GW of solar panels per year-100x the volume of a typical, thin-film, solar panel manufacturer in 2004. We have shown that with a reasonable selection of materials, and conservative assumptions, this ''Solar City'' can produce solar panels and hit the price target of $1.00 per peak watt (6.5x-8.5x lower than prices in 2004) as the total price for a complete and installed rooftop (or ground mounted) solar energy system. This breakthrough in the price of solar energy comes without the need for any significant new invention. It comes entirely from the manufacturing scale of a large plant and the cost savings inherent in operating at such a large manufacturing scale. We expect that further optimizations from these simple designs will lead to further improvements in cost. The manufacturing process and cost depend on the choice for the active layer that converts sunlight into electricity. The efficiency by which sunlight is converted into electricity can range from 7% to 15%. This parameter has a large effect on the overall price per watt. There are other impacts, as well, and we have attempted to capture them without creating undue distractions. Our primary purpose is to demonstrate the impact of large-scale manufacturing. This impact is largely independent of the choice of active layer. It is not our purpose to compare the pro's and con's for various types of active layers. Significant improvements in cost per watt can also come from scientific advances in active layers that lead to higher efficiency. But, again, our focus is on manufacturing gains and not on the potential advances in the basic technology.

  3. A retrospective investigation of energy efficiency standards: policies may have accelerated long term declines in appliance costs

    NASA Astrophysics Data System (ADS)

    Van Buskirk, R. D.; Kantner, C. L. S.; Gerke, B. F.; Chu, S.

    2014-11-01

    We perform a retrospective investigation of multi-decade trends in price and life-cycle cost (LCC) for home appliances in periods with and without energy efficiency (EE) standards and labeling polices. In contrast to the classical picture of the impact of efficiency standards, the introduction and updating of appliance standards is not associated with a long-term increase in purchase price; rather, quality-adjusted prices undergo a continued or accelerated long-term decline. In addition, long term trends in appliance LCCs—which include operating costs—consistently show an accelerated long term decline with EE policies. We also show that the incremental price of efficiency improvements has declined faster than the baseline product price for selected products. These observations are inconsistent with a view of EE standards that supposes a perfectly competitive market with static supply costs. These results suggest that EE policies may be associated with other forces at play, such as innovation and learning-by-doing in appliance production and design, that can affect long term trends in quality-adjusted prices and LCCs.

  4. Process-Based Cost Modeling of Photonics Manufacture: The Cost Competitiveness of Monolithic Integration of a 1550-nm DFB Laser and an Electroabsorptive Modulator on an InP Platform

    NASA Astrophysics Data System (ADS)

    Fuchs, Erica R. H.; Bruce, E. J.; Ram, R. J.; Kirchain, Randolph E.

    2006-08-01

    The monolithic integration of components holds promise to increase network functionality and reduce packaging expense. Integration also drives down yield due to manufacturing complexity and the compounding of failures across devices. Consensus is lacking on the economically preferred extent of integration. Previous studies on the cost feasibility of integration have used high-level estimation methods. This study instead focuses on accurate-to-industry detail, basing a process-based cost model of device manufacture on data collected from 20 firms across the optoelectronics supply chain. The model presented allows for the definition of process organization, including testing, as well as processing conditions, operational characteristics, and level of automation at each step. This study focuses on the cost implications of integration of a 1550-nm DFB laser with an electroabsorptive modulator on an InP platform. Results show the monolithically integrated design to be more cost competitive over discrete component options regardless of production scale. Dominant cost drivers are packaging, testing, and assembly. Leveraging the technical detail underlying model projections, component alignment, bonding, and metal-organic chemical vapor deposition (MOCVD) are identified as processes where technical improvements are most critical to lowering costs. Such results should encourage exploration of the cost advantages of further integration and focus cost-driven technology development.

  5. Accelerating PV Cost Effectiveness Through Systems Design, Engineering, and Quality Assurance: Phase I Annual Technical Report, 4 November 2004 - 3 November 2005

    SciTech Connect

    Botkin, J.

    2006-07-01

    During Phase I of this PV Manufacturing R&D subcontract, PowerLight Corporation has made significant progress toward the reduction of installed costs for commercial-scale, rooftop PV systems. PowerLight has worked to reduce operating costs by improving long-term reliability and performance through the development of more sophisticated tools used in system design and monitoring. Additionally, PowerLight has implemented design improvements with the goal of reducing cost while maintaining and/or improving product quality. As part of this effort, PowerLight also modified manufacturing and shipping processes to accommodate these design changes, streamline material flow, reduce cost, and decrease waste streams. During Phase II of this project, PowerLight plans to continue this work with the goal of reducing system cost and improving system performance.

  6. Manufacturing improvements in the Photovoltaic Manufacturing Technology (PVMaT) Project

    SciTech Connect

    Witt, C.E.; Mitchell, R.L.; Thomas, H.P.; Symko, M.I.; King, R.; Ruby, D.S.

    1998-08-01

    The Photovoltaic Manufacturing Technology Project (PVMaT) is a government/industry research and development (R and D) partnership between the US federal government (through the US Department of Energy [DOE]) and members of the US PV industry. The goals of PVMaT are to help the US PV industry improve module manufacturing processes and equipment; accelerate manufacturing cost reductions for PV modules, balance-of-systems components, and integrated systems; increase commercial product performance and reliability; and enhance the investment opportunities for substantial scale-ups of US-based PV manufacturing plant capacities. The approach for PVMaT has been to cost-share risk taking by industry as it explores new manufacturing options and ideas for improved PV modules and other components, advances system and product integration, and develops new system designs, all of which will lead to overall reduced system life-cycle costs for reliable PV end products. The PVMaT Phase 4A module manufacturing R and D projects are just being completed and initial results for the work directed primarily to module manufacture are reported in this paper. Fourteen new Phase 5A subcontracts have also just been awarded and planned R and D areas for the ten focused on module manufacture are described. Finally, government funding, subcontractor cost sharing, and a comparison of the relative efforts by PV technology throughout the PVMaT project are presented.

  7. PVMaT cost reductions in the EFG high volume PV manufacturing line: Annual report, 5 August 1998--4 August 1999[PhotoVoltaic Manufacturing Technology, Edge-defined Film-fed Growth

    SciTech Connect

    Bathey, B.; Brown, B.; Cao, J.; Ebers, S.; Gonsiorawski, R.; Heath, B.; Kalejs, J.; Kardauskas, M.; Mackintosh, B.; Ouellette, M.; Piwczyk, B.; Rosenblum, M.; Southimath, B.

    1999-11-16

    This report describes work performed by ASE Americas researchers during the first year of this Photovoltaic Manufacturing Technology 5A2 program. Significant accomplishments in each of three task are as follows. Task 1--Manufacturing Systems: Researchers completed key node analysis, started statistical process control (SPC) charting, carried out design-of-experiment (DoE) matrices on the cell line to optimize efficiencies, performed a capacity and bottleneck study, prepared a baseline chemical waste analysis report, and completed writing of more than 50% of documentation and statistical sections of ISO 9000 procedures. A highlight of this task is that cell efficiencies in manufacturing were increased by 0.4%--0.5% absolute, to an average in excess of 14.2%, with the help of DoE and SPC methods. Task 2--Low-Cost Processes: Researchers designed, constructed, and tested a 50-cm-diameter, edge-defined, film-fed growth (EFG) cylinder crystal growth system to successfully produce thin cylinders up to 1.2 meters in length; completed a model for heat transfer; successfully deployed new nozzle designs and used them with a laser wafer-cutting system with the potential to decrease cutting labor costs by 75% and capital costs by 2X; achieved laser-cutting speeds of up to 8X and evaluation of this system is proceeding in production; identified laser-cutting conditions that reduce damage for both Q-switched Nd:YAG and copper-vapor lasers with the help of a breakthrough in fundamental understanding of cutting with these short-pulse-length lasers; and found that bulk EFG material lifetimes are optimized when co-firing of silicon nitride and aluminum is carried out with rapid thermal processing (RTP). Task 3--Flexible Manufacturing: Researchers improved large-volume manufacturing of 10-cm {times} 15-cm EFG wafers by developing laser-cutting fixtures, adapting carriers and fabricating adjustable racks for etching and rinsing facilities, and installing a high-speed data collection

  8. Effective seismic acceleration measurements for low-cost Structural Health Monitoring

    NASA Astrophysics Data System (ADS)

    Pentaris, Fragkiskos; Makris, John P.

    2015-04-01

    There is increasing demand on cost effective Structural Health Monitoring systems for buildings as well as important and/or critical constructions. The front end for all these systems is the accelerometer. We present a comparative study of two low cost MEMS accelaration sensors against a very sensitive, high dynamic range strong motion accelerometer of force balance type but much more expensive. A real experiment was realized by deploying the three sesnors in a reinforced concrete building of the premises of TEI of Crete at Chania Crete, an earthquake prone region. The analysis of the collected accelararion data from many seismic events indicates that all sensors are able to efficiently reveal the seismic response of the construction in terms of PSD. Furthermore, it is shown that coherence diagrams between excitation and response of the building under study, depict structural characteristics but also the seismic energy distribution. This work is supported by the Archimedes III Program of the Ministry of Education of Greece, through the Operational Program "Educational and Lifelong Learning", in the framework of the project entitled "Interdisciplinary Multi-Scale Research of Earthquake Physics and Seismotectonics at the front of the Hellenic Arc (IMPACT-ARC)" and is co-financed by the European Union (European Social Fund) and Greek national funds.

  9. New techniques in large scale metrology toolset data mining to accelerate integrated chip technology development and increase manufacturing efficiencies

    NASA Astrophysics Data System (ADS)

    Solecky, Eric; Rana, Narender; Minns, Allan; Gustafson, Carol; Lindo, Patrick; Cornell, Roger; Llanos, Paul

    2014-04-01

    Today, metrology toolsets report out more information than ever. This information applies not only to process performance but also metrology toolset and recipe performance through various diagnostic metrics. This is most evident on the Critical Dimension Scanning Electron Microscope (CD-SEM). Today state of the art CD-SEMs report out over 250 individual data points and several images per measurement. It is typical for a state of the art fab with numerous part numbers to generate at least 20TB of information over the course of a year on the CD-SEM fleet alone pushing metrology toolsets into the big data regime. Most of this comes from improvements in throughput, increased sampling and new data outputs relative to previous generations of tools. Oftentimes, these new data outputs are useful for helping to determine if the process, metrology recipe or tool is deviating from an ideal state. Many issues could be missed by singularly looking at the key process control metric like the bottom critical dimension (CD) or a small subset of this available information. By leveraging the entire data set the mean time to detect and finding the root cause of issues can be significantly reduced. In this paper a new data mining system is presented that achieves this goal. Examples are shown with a focus on the benefits realized using this new system which helps speed up development cycles of learning and reducing manufacturing cycle-time. This paper concludes discussing future directions to make this capability more effective.

  10. Solder technology in the manufacturing of electronic products

    SciTech Connect

    Vianco, P.T.

    1993-08-01

    The electronics industry has relied heavily upon the use of soldering for both package construction and circuit assembly. The solder attachment of devices onto printed circuit boards and ceramic microcircuits has supported the high volume manufacturing processes responsible for low cost, high quality consumer products and military hardware. Defects incurred during the manufacturing process are minimized by the proper selection of solder alloys, substrate materials and process parameters. Prototyping efforts are then used to evaluate the manufacturability of the chosen material systems. Once manufacturing feasibility has been established, service reliability of the final product is evaluated through accelerated testing procedures.

  11. Additive manufacturing of liquid/gas diffusion layers for low-cost and high-efficiency hydrogen production

    DOE PAGESBeta

    Mo, Jingke; Zhang, Feng -Yuan; Dehoff, Ryan R.; Peter, William H.; Toops, Todd J.; Green, Jr., Johney Boyd

    2016-01-14

    The electron beam melting (EBM) additive manufacturing technology was used to fabricate titanium liquid/gas diffusion media with high-corrosion resistances and well-controllable multifunctional parameters, including two-phase transport and excellent electric/thermal conductivities, has been first demonstrated. Their applications in proton exchange membrane eletrolyzer cells have been explored in-situ in a cell and characterized ex-situ with SEM and XRD. Compared with the conventional woven liquid/gas diffusion layers (LGDLs), much better performance with EBM fabricated LGDLs is obtained due to their significant reduction of ohmic loss. The EBM technology components exhibited several distinguished advantages in fabricating gas diffusion layer: well-controllable pore morphology and structure,more » rapid prototyping, fast manufacturing, highly customizing and economic. In addition, by taking advantage of additive manufacturing, it possible to fabricate complicated three-dimensional designs of virtually any shape from a digital model into one single solid object faster, cheaper and easier, especially for titanium. More importantly, this development will provide LGDLs with control of pore size, pore shape, pore distribution, and therefore porosity and permeability, which will be very valuable to develop modeling and to validate simulations of electrolyzers with optimal and repeatable performance. Further, it will lead to a manufacturing solution to greatly simplify the PEMEC/fuel cell components and to couple the LGDLs with other parts, since they can be easily integrated together with this advanced manufacturing process« less

  12. Efficient manufacturing technology of metal optics

    NASA Astrophysics Data System (ADS)

    Zhang, Jizhen; Wu, Yanxiong; Zhang, Xin; Zhang, Liping; Wang, Lingjie; Qu, Hemeng

    2015-10-01

    The efficient manufacturing technologies greatly accelerate the development and production process. Optical components have higher precision requirements than mechanical parts. This provides great challenge for rapid manufacturing. Metallic optical system is featured high resolution, wide spectral range, light weight, compact design, low cost and short manufacturing period. Reflective mirrors and supporting structures can be made from the same material to improve athermal performance of the system. Common materials for metal mirrors in optical applications include aluminum, copper, beryllium, aluminum beryllium alloy and so on. Their physical characteristics and relative advantages are presented. Most kinds of metals have good machinability and can be manufactured by many kinds of producing methods. This makes metallic optical system saving 30%~60% cost and time than others. The manufacturing process of metal mirror is different due to its working spectral. The metal mirror can be directly manufactured by single point diamond turning. This is an outstanding technique in point of ultra-precision as well as economical manufacture of mirrors. The roughness values and form accuracy of optical surfaces after diamond turning can satisfy the quality level for applications in the near infrared and infrared range. And for visible light spectral the turning structures must be removed with a smoothing procedure in order to minimize the scatter losses. Some smoothing methods to obtain visible quality metal mirrors are given in this paper. Some new manufacturing technology, such as 3D printing, can be used for metallic optical system and several promising techniques are presented.

  13. Smart Manufacturing.

    PubMed

    Davis, Jim; Edgar, Thomas; Graybill, Robert; Korambath, Prakashan; Schott, Brian; Swink, Denise; Wang, Jianwu; Wetzel, Jim

    2015-01-01

    Historic manufacturing enterprises based on vertically optimized companies, practices, market share, and competitiveness are giving way to enterprises that are responsive across an entire value chain to demand dynamic markets and customized product value adds; increased expectations for environmental sustainability, reduced energy usage, and zero incidents; and faster technology and product adoption. Agile innovation and manufacturing combined with radically increased productivity become engines for competitiveness and reinvestment, not simply for decreased cost. A focus on agility, productivity, energy, and environmental sustainability produces opportunities that are far beyond reducing market volatility. Agility directly impacts innovation, time-to-market, and faster, broader exploration of the trade space. These changes, the forces driving them, and new network-based information technologies offering unprecedented insights and analysis are motivating the advent of smart manufacturing and new information technology infrastructure for manufacturing. PMID:25898070

  14. Photovoltaic manufacturing technology

    SciTech Connect

    Wohlgemuth, J.H.; Whitehouse, D.; Wiedeman, S.; Catalano, A.W.; Oswald, R. )

    1991-12-01

    This report identifies steps leading to manufacturing large volumes of low-cost, large-area photovoltaic (PV) modules. Both crystalline silicon and amorphous silicon technologies were studied. Cost reductions for each step were estimated and compared to Solarex Corporation's manufacturing costs. A cost model, a simple version of the SAMICS methodology developed by the Jet Propulsion Laboratory (JPL), projected PV selling prices. Actual costs of materials, labor, product yield, etc., were used in the cost model. The JPL cost model compared potential ways of lowering costs. Solarex identified the most difficult technical challenges that, if overcome, would reduce costs. Preliminary research plans were developed to solve the technical problems. 13 refs.

  15. Photovoltaic Manufacturing Cost and Throughput Improvements for Thin-Film CIGS-Based Modules; Phase II Annual Subcontract Technical Report, July 1999 - August 2000

    SciTech Connect

    Wendt, T.G.; Wiedeman, S.

    2001-03-12

    Thin-film photovoltaics (PV) has expanded dramatically in the last five years, but commercial use remains limited by performance, cost, and reliability. Of all the thin-film systems, copper indium gallium diselenide (CIGS) has demonstrated the greatest potential for achieving high performance at a low cost. The highest-quality CIGS has been formed by multi-source co-evaporation, a technique pioneered in this country by researchers at NREL. Multi-source co-evaporation is also potentially the fastest and most cost-effective method of CIGS absorber deposition. Global Solar Energy (GSE) has adapted multi-source co-evaporation of CIGS to large-area, roll-to-roll processing on flexible substrates, enabling several manufacturing and product capability advantages. Roll-to-roll processing enables a low-cost, automated continuous manufacturing process. Flexible substrates enable product application in unique, as well as traditional, areas. The primary objectives of the GSE Photovoltaic Manufacturing Technology (PVMaT) subcontract are to reduce cost and expand the production rate of thin-film CIGS-based PV modules on flexible substrates. Improvements will be implemented in monolithic integration, CIGS deposition, contact deposition, and in-situ CIGS control and monitoring. Specific goals of the three-year contract are: - Monolithic Integration - Increase integration speed by developing high-speed, all-laser scribing processes that are more than 100% faster than the baseline process and offer clean, selective scribing; increase capacity and substantially reduce module area losses by insulating materials with high accuracy into laser scribes. - Absorber Deposition - Increase absorber-layer deposition rate by 75% in the large-area, continuous GSE process, increasing throughput and reducing labor and capital costs. Integrate a parallel detector spectroscopic ellipsometer (PDSE) with mathematical algorithms for in-situ control of the CIGS absorber, enabling runs of over 300 meters

  16. Low-cost visible-near infrared sensor for on-line monitoring of fat and fatty acids content during the manufacturing process of the milk.

    PubMed

    Villar, Alberto; Gorritxategi, Eneko; Aranzabe, Estibaliz; Fernández, Santiago; Otaduy, Deitze; Fernández, Luis A

    2012-12-15

    This paper describes the calibration, validation and testing process of a low-cost on-line visible-near infrared (400-1100 nm) sensor for the monitoring of fat and fatty acids content in milk during the manufacturing process of milk. The optical, mechanical and electronic designs of the sensor have been developed in Tekniker IK4 research centre just as its manufacturing process. The measurement range of the sensor is 400-1100 nm thus it covers the visible range (400-780 nm) and the short-wave near infrared (780-1100 nm). Chemometric techniques were applied with the purpose of obtaining a predictive model for each parameter correlating the spectra obtained by the sensor with the parameters analysed in the laboratory. The models were developed by Partial Least Squares Regression (PLS) obtaining one model for each parameter. The raw milk samples used in this work were provided by CAPSA (Asturias, Spain). PMID:22980869

  17. ACCELERATED SITE TECHNOLOGY DEPLOYMENT COST AND PERFORMANCE REPORT COMPARABILITY OF ISOCS INSTRUMENT IN RADIONUCLIDE CHARACTERICATION AT BROOKHAVEN NATIONAL LABORATORY

    SciTech Connect

    KALB,P.; LUCKETT,L.; MILLER,K.; GOGOLAK,C.; MILIAN,L.

    2001-03-01

    This report describes a DOE Accelerated Site Technology Deployment project being conducted at Brookhaven National Laboratory to deploy innovative, radiological, in situ analytical techniques. The technologies are being deployed in support of efforts to characterize the Brookhaven Graphite Research Reactor (BGRR) facility, which is currently undergoing decontamination and decommissioning. This report focuses on the deployment of the Canberra Industries In Situ Object Counting System (ISOCS) and assesses its data comparability to baseline methods of sampling and laboratory analysis. The battery-operated, field deployable gamma spectrometer provides traditional spectra of counts as a function of gamma energy. The spectra are then converted to radionuclide concentration by applying innovative efficiency calculations using monte carlo statistical methods and pre-defined geometry templates in the analysis software. Measurement of gamma emitting radionuclides has been accomplished during characterization of several BGRR components including the Pile Fan Sump, Above Ground Ducts, contaminated cooling fans, and graphite pile internals. Cs-137 is the predominant gamma-emitting radionuclide identified, with smaller quantities of Co-60 and Am-241 detected. The Project used the Multi-Agency Radiation Survey and Site Investigation Manual guidance and the Data Quality Objectives process to provide direction for survey planning and data quality assessment. Analytical results have been used to calculate data quality indicators (DQI) for the ISOCS measurements. Among the DQIs assessed in the report are sensitivity, accuracy, precision, bias, and minimum detectable concentration. The assessment of the in situ data quality using the DQIs demonstrates that the ISOCS data quality can be comparable to definitive level laboratory analysis when the field instrument is supported by an appropriate Quality Assurance Project Plan. A discussion of the results obtained by ISOCS analysis of

  18. Manufacture of ammonium sulfate fertilizer from gypsum-rich byproduct of flue gas desulfurization: A prefeasibility cost estimate

    SciTech Connect

    Chou, M.I.M.; Rostam-Abadi, M.; Lytle, J.M.

    1996-12-31

    Costs for constructing and operating a conceptual plant based on a proposed process that converts flue gas desulfurization (FGD)-gypsum to ammonium sulfate fertilizer has been calculated and used to estimate a market price for the product. The average market price of granular ammonium sulfate ($138/ton) exceeds the rough estimated cost of ammonium sulfate from the proposed process ($111/ton), by 25 percent, if granular size ammonium sulfate crystals of 1.2 to 3.3 millimeters in diameters can be produced by the proposed process. However, there was at least {+-}30% margin in the cost estimate calculations. The additional costs for compaction, if needed to create granules of the required size, would make the process uneconomical unless considerable efficiency gains are achieved to balance the additional costs. This study suggests the need both to refine the crystallization process and to find potential markets for the calcium carbonate produced by the process.

  19. Manufacture of ammonium sulfate fertilizer from gypsum-rich byproduct of flue gas desulfurization - A prefeasibility cost estimate

    USGS Publications Warehouse

    Chou, I.-Ming; Rostam-Abadi, M.; Lytle, J.M.; Achorn, F.P.

    1996-01-01

    Costs for constructing and operating a conceptual plant based on a proposed process that converts flue gas desulfurization (FGD)-gypsum to ammonium sulfate fertilizer has been calculated and used to estimate a market price for the product. The average market price of granular ammonium sulfate ($138/ton) exceeds the rough estimated cost of ammonium sulfate from the proposed process ($111/ ton), by 25 percent, if granular size ammonium sulfate crystals of 1.2 to 3.3 millimeters in diameters can be produced by the proposed process. However, there was at least ??30% margin in the cost estimate calculations. The additional costs for compaction, if needed to create granules of the required size, would make the process uneconomical unless considerable efficiency gains are achieved to balance the additional costs. This study suggests the need both to refine the crystallization process and to find potential markets for the calcium carbonate produced by the process.

  20. Advanced manufacturing technologies for reduced cost and weight in portable ruggedized VIS-IR and multi-mode optical systems for land, sea, and air

    NASA Astrophysics Data System (ADS)

    Sweeney, Michael; Spinazzola, Robert; Morrison, Donald; Macklin, Dennis; Marion, Jared

    2011-06-01

    Homeland security systems, special forces, unmanned aerial vehicles (UAV), and marine patrols require low cost, high performance, multi-mode visible through infrared (VIS-IR) wavelength optical systems to identify and neutralize potential threats that often arise at long ranges and under poor visibility conditions. Long range and wide spectral performance requirements favor reflective optical system design solutions. The limited field of view of such designs can be significantly enhanced by the use of catadioptric optical solutions that utilize molded or diamond point machined VIS-IR lenses downstream from reflective objective optics. A common optical aperture that services multiple modes of field-of-view, operating wavelength, and includes laser ranging and spotting, provides the highest utility and is most ideal for size and weight. Such a design also often requires fast, highly aspheric, reflective, refractive, and sometimes diffractive surfaces using high performance and aggressively light-weighted materials that demand the finest of manufacturing technologies. Visible wavelength performance sets the bar for component optical surface irregularity on the order of 20 nm RMS and surface finishes less than 3.0 nm RMS. Aluminum mirrors and structures can also be precision machined to yield "snap together alignment" or limited compensation assembly approaches to reduce cost and enhance interchangeability. Diamond point turning, die cast and investment cast mirror substrates and structures, computerized optical polishing, mirror replication, lens molding and other advanced manufacturing technologies can all be used to minimize the cost of this type of optical equipment. This paper discusses the tradeoffs among materials and process selection for catadioptric, multi-mode systems that are under development for a variety of DoD and Homeland Security applications. Several examples are profiled to illuminate the confluence of applicable design and manufacturing

  1. Microgravity Manufacturing

    NASA Technical Reports Server (NTRS)

    Cooper, Ken; Munafo, Paul M. (Technical Monitor)

    2002-01-01

    Manufacturing capability in outer space remains one of the critical milestones to surpass to allow humans to conduct long-duration manned space exploration. The high cost-to-orbit for leaving the Earth's gravitational field continues to be the limiting factor in carrying sufficient hardware to maintain extended life support in microgravity or on other planets. Additive manufacturing techniques, or 'chipless' fabrication, like RP are being considered as the most promising technologies for achieving in situ or remote processing of hardware components, as well as for the repair of existing hardware. At least three RP technologies are currently being explored for use in microgravity and extraterrestrial fabrication.

  2. Evaluation of the technical feasibility and effective cost of various wafer thicknesses for the manufacture of solar cells. Final report, July 15, 1978-July 15, 1979

    SciTech Connect

    Not Available

    1980-03-20

    The principal activities in the performance of this contract effort include practical evaluation of the Yasunaga YQ-100 saw in a production environment. The wafering system is a free-abrasive multiple-loop single wire machine where the number of wafers/cm is determined by the wire pitch. In addition, the effects of wire diameter and abrasive size were studied. Solar cells were manufactured from each saw run to analyze surface damage and effects varying thickness on efficiency. It was determined that surface damage was much reduced compared to fixed abrasive saws, and as little as 5 to 10 micrometers of surface removal from each side of the wafer was sufficient to obtain optimum efficiency for the particular process which was used. Since thin wafers were produced, an analysis of panel manufacture using thin cells was made with special concern for flexibility of the panels and breakage. The saw was found to be much more labor intensive than expected, and wafering system modifications are recommended which can result in effective cost reduction for the manufacture of solar cells.

  3. Workforce Development for Manufacturing

    ERIC Educational Resources Information Center

    Bernard, Rosalie

    2007-01-01

    In a recent skills gap report, the National Association of Manufacturers (NAM) noted some disturbing trends in the gap between the demand for highly skilled manufacturing workers and the potential supply. The NAM report notes that smaller manufacturers rank finding qualified workers ahead of energy costs, taxes and government regulations on the…

  4. Manufacturing technology

    SciTech Connect

    Leonard, J.A.; Floyd, H.L.; Goetsch, B.; Doran, L.

    1993-08-01

    This bulletin depicts current research on manufacturing technology at Sandia laboratories. An automated, adaptive process removes grit overspray from jet engine turbine blades. Advanced electronic ceramics are chemically prepared from solution for use in high- voltage varistors. Selective laser sintering automates wax casting pattern fabrication. Numerical modeling improves performance of photoresist stripper (simulation on Cray supercomputer reveals path to uniform plasma). And mathematical models help make dream of low- cost ceramic composites come true.

  5. Human pluripotent stem cell-derived products: Advances towards robust, scalable and cost-effective manufacturing strategies

    PubMed Central

    Jenkins, Michael J; Farid, Suzanne S

    2015-01-01

    The ability to develop cost-effective, scalable and robust bioprocesses for human pluripotent stem cells (hPSCs) will be key to their commercial success as cell therapies and tools for use in drug screening and disease modelling studies. This review outlines key process economic drivers for hPSCs and progress made on improving the economic and operational feasibility of hPSC bioprocesses. Factors influencing key cost metrics, namely capital investment and cost of goods, for hPSCs are discussed. Step efficiencies particularly for differentiation, media requirements and technology choice are amongst the key process economic drivers identified for hPSCs. Progress made to address these cost drivers in hPSC bioprocessing strategies is discussed. These include improving expansion and differentiation yields in planar and bioreactor technologies, the development of xeno-free media and microcarrier coatings, identification of optimal bioprocess operating conditions to control cell fate and the development of directed differentiation protocols that reduce reliance on expensive morphogens such as growth factors and small molecules. These approaches offer methods to further optimise hPSC bioprocessing in terms of its commercial feasibility. PMID:25524780

  6. Human pluripotent stem cell-derived products: advances towards robust, scalable and cost-effective manufacturing strategies.

    PubMed

    Jenkins, Michael J; Farid, Suzanne S

    2015-01-01

    The ability to develop cost-effective, scalable and robust bioprocesses for human pluripotent stem cells (hPSCs) will be key to their commercial success as cell therapies and tools for use in drug screening and disease modelling studies. This review outlines key process economic drivers for hPSCs and progress made on improving the economic and operational feasibility of hPSC bioprocesses. Factors influencing key cost metrics, namely capital investment and cost of goods, for hPSCs are discussed. Step efficiencies particularly for differentiation, media requirements and technology choice are amongst the key process economic drivers identified for hPSCs. Progress made to address these cost drivers in hPSC bioprocessing strategies is discussed. These include improving expansion and differentiation yields in planar and bioreactor technologies, the development of xeno-free media and microcarrier coatings, identification of optimal bioprocess operating conditions to control cell fate and the development of directed differentiation protocols that reduce reliance on expensive morphogens such as growth factors and small molecules. These approaches offer methods to further optimise hPSC bioprocessing in terms of its commercial feasibility. PMID:25524780

  7. Multiple EFG silicon ribbon technology as the basis for manufacturing low-cost terrestrial solar cells. [Epitaxial Film Growth

    NASA Technical Reports Server (NTRS)

    Mackintosh, B.; Kalejs, J. P.; Ho, C. T.; Wald, F. V.

    1981-01-01

    Mackintosh et al. (1978) have reported on the development of a multiple ribbon furnace based on the 'edge defined film fed growth' (EFG) process for the fabrication of silicon ribbon. It has been demonstrated that this technology can meet the requirements for a silicon substrate material to be used in the manufacture of solar panels which can meet requirements regarding a selling price of $0.70/Wp when certain goals in terms of throughput and quality are achieved. These goals for the multiple ribbon technology using 10 cm wide ribbon require simultaneous growth of 12 ribbons by one operator at average speeds of 4 to 4.5 cm/min, and 13% efficient solar cells. A description is presented of the progress made toward achieving these goals. It is concluded that the required performance levels have now been achieved. The separate aspects of technology must now be integrated into a single prototype furnace.

  8. Collaborative Manufacturing for Small-Medium Enterprises

    NASA Astrophysics Data System (ADS)

    Irianto, D.

    2016-02-01

    Manufacturing systems involve decisions concerning production processes, capacity, planning, and control. In a MTO manufacturing systems, strategic decisions concerning fulfilment of customer requirement, manufacturing cost, and due date of delivery are the most important. In order to accelerate the decision making process, research on decision making structure when receiving order and sequencing activities under limited capacity is required. An effective decision making process is typically required by small-medium components and tools maker as supporting industries to large industries. On one side, metal small-medium enterprises are expected to produce parts, components or tools (i.e. jigs, fixture, mold, and dies) with high precision, low cost, and exact delivery time. On the other side, a metal small- medium enterprise may have weak bargaining position due to aspects such as low production capacity, limited budget for material procurement, and limited high precision machine and equipment. Instead of receiving order exclusively, a small-medium enterprise can collaborate with other small-medium enterprise in order to fulfill requirements high quality, low manufacturing cost, and just in time delivery. Small-medium enterprises can share their best capabilities to form effective supporting industries. Independent body such as community service at university can take a role as a collaboration manager. The Laboratory of Production Systems at Bandung Institute of Technology has implemented shared manufacturing systems for small-medium enterprise collaboration.

  9. Alternative bio-based solvents for extraction of fat and oils: solubility prediction, global yield, extraction kinetics, chemical composition and cost of manufacturing.

    PubMed

    Sicaire, Anne-Gaëlle; Vian, Maryline; Fine, Frédéric; Joffre, Florent; Carré, Patrick; Tostain, Sylvain; Chemat, Farid

    2015-01-01

    The present study was designed to evaluate the performance of alternative bio-based solvents, more especially 2-methyltetrahydrofuran, obtained from crop's byproducts for the substitution of petroleum solvents such as hexane in the extraction of fat and oils for food (edible oil) and non-food (bio fuel) applications. First a solvent selection as well as an evaluation of the performance was made with Hansen Solubility Parameters and the COnductor-like Screening MOdel for Realistic Solvation (COSMO-RS) simulations. Experiments were performed on rapeseed oil extraction at laboratory and pilot plant scale for the determination of lipid yields, extraction kinetics, diffusion modeling, and complete lipid composition in term of fatty acids and micronutrients (sterols, tocopherols and tocotrienols). Finally, economic and energetic evaluations of the process were conducted to estimate the cost of manufacturing using 2-methyltetrahydrofuran (MeTHF) as alternative solvent compared to hexane as petroleum solvent. PMID:25884332

  10. Bench-Scale Silicone Process for Low-Cost CO{sub 2} Capture. Manufacturing Plan for Aminosilicone-based CO{sub 2} Absorption Material

    SciTech Connect

    Vogt, Kirkland

    2013-02-01

    A commercially cost effective manufacturing plan was developed for GAP-1m, the aminosilicone-based part of the CO{sub 2} capture solvent described in DE-FE0007502, and the small-scale synthesis of GAP-1m was confirmed. The plan utilizes a current intermediate at SiVance LLC to supply the 2013-2015 needs for GE Global Research. Material from this process was supplied to GE Global Research for evaluation and creation of specifications. GE Global Research has since ordered larger quantities (60 liters) for the larger scale evaluations that start in first quarter, 2013. For GE’s much larger future commercial needs, an improved, more economical pathway to make the product was developed after significant laboratory and literature research. Suppliers were identified for all raw materials.

  11. Alternative Bio-Based Solvents for Extraction of Fat and Oils: Solubility Prediction, Global Yield, Extraction Kinetics, Chemical Composition and Cost of Manufacturing

    PubMed Central

    Sicaire, Anne-Gaëlle; Vian, Maryline; Fine, Frédéric; Joffre, Florent; Carré, Patrick; Tostain, Sylvain; Chemat, Farid

    2015-01-01

    The present study was designed to evaluate the performance of alternative bio-based solvents, more especially 2-methyltetrahydrofuran, obtained from crop’s byproducts for the substitution of petroleum solvents such as hexane in the extraction of fat and oils for food (edible oil) and non-food (bio fuel) applications. First a solvent selection as well as an evaluation of the performance was made with Hansen Solubility Parameters and the COnductor-like Screening MOdel for Realistic Solvation (COSMO-RS) simulations. Experiments were performed on rapeseed oil extraction at laboratory and pilot plant scale for the determination of lipid yields, extraction kinetics, diffusion modeling, and complete lipid composition in term of fatty acids and micronutrients (sterols, tocopherols and tocotrienols). Finally, economic and energetic evaluations of the process were conducted to estimate the cost of manufacturing using 2-methyltetrahydrofuran (MeTHF) as alternative solvent compared to hexane as petroleum solvent. PMID:25884332

  12. Manufacturing a low-cost ceramic water filter and filter system for the elimination of common pathogenic bacteria

    NASA Astrophysics Data System (ADS)

    Simonis, J. J.; Basson, A. K.

    Africa is one of the most water-scarce continents in the world but it is the lack of potable water which results in diarrhoea being the leading cause of death amongst children under the age of five in Africa (696 million children under 5 years old in Africa contract diarrhoea resulting in 2000 deaths per day: WHO and UNICEF, 2009). Most potable water treatment methods use bulk water treatment not suitable or available to the majority of rural poor in Sub-Saharan Africa. One simple but effective way of making sure that water is of good quality is by purifying it by means of a household ceramic water filter. The making and supply of water filters suitable for the removal of suspended solids, pathogenic bacteria and other toxins from drinking water is therefore critical. A micro-porous ceramic water filter with micron-sized pores was developed using the traditional slip casting process. This locally produced filter has the advantage of making use of less raw materials, cost, labour, energy and expertise and being more effective and efficient than other low cost produced filters. The filter is fitted with a silicone tube inserted into a collapsible bag that acts as container and protection for the filter. Enhanced flow is obtained through this filter system. The product was tested using water inoculated with high concentrations of different bacterial cultures as well as with locally polluted stream water. The filter is highly effective (log10 > 4 with 99.99% reduction efficiency) in providing protection from bacteria and suspended solids found in natural water. With correct cleaning and basic maintenance this filter technology can effectively provide drinking water to rural families affected by polluted surface water sources. This is an African solution for the more than 340 million people in Africa without access to clean drinking water (WHO and UNICEF, 2008).

  13. Individualized Positron Emission Tomography–Based Isotoxic Accelerated Radiation Therapy Is Cost-Effective Compared With Conventional Radiation Therapy: A Model-Based Evaluation

    SciTech Connect

    Bongers, Mathilda L.; Coupé, Veerle M.H.; De Ruysscher, Dirk; Oberije, Cary; Lambin, Philippe; Uyl-de Groot, Cornelia A.

    2015-03-15

    Purpose: To evaluate long-term health effects, costs, and cost-effectiveness of positron emission tomography (PET)-based isotoxic accelerated radiation therapy treatment (PET-ART) compared with conventional fixed-dose CT-based radiation therapy treatment (CRT) in non-small cell lung cancer (NSCLC). Methods and Materials: Our analysis uses a validated decision model, based on data of 200 NSCLC patients with inoperable stage I-IIIB. Clinical outcomes, resource use, costs, and utilities were obtained from the Maastro Clinic and the literature. Primary model outcomes were the difference in life-years (LYs), quality-adjusted life-years (QALYs), costs, and the incremental cost-effectiveness and cost/utility ratio (ICER and ICUR) of PET-ART versus CRT. Model outcomes were obtained from averaging the predictions for 50,000 simulated patients. A probabilistic sensitivity analysis and scenario analyses were carried out. Results: The average incremental costs per patient of PET-ART were €569 (95% confidence interval [CI] €−5327-€6936) for 0.42 incremental LYs (95% CI 0.19-0.61) and 0.33 QALYs gained (95% CI 0.13-0.49). The base-case scenario resulted in an ICER of €1360 per LY gained and an ICUR of €1744 per QALY gained. The probabilistic analysis gave a 36% probability that PET-ART improves health outcomes at reduced costs and a 64% probability that PET-ART is more effective at slightly higher costs. Conclusion: On the basis of the available data, individualized PET-ART for NSCLC seems to be cost-effective compared with CRT.

  14. Innovative Approaches to Low Cost Module Manufacturing of String Ribbon Si PV Modules: Phase II, Annual Technical Progress Report, 1 April 2003--31 May 2004

    SciTech Connect

    Hanoka, J. I.

    2004-10-01

    This subcontract resulted in a number of important advances for Evergreen Solar Inc. Foremost amongst these is the production implementation of dual ribbon growth from a single crucible (Gemini) using the String Ribbon continuous ribbon technology. This project has resulted in the flattest ribbon and the highest yields and machine uptime ever seen at Evergreen Solar. This then has resulted in significantly lowered consumables costs and lower overall direct manufacturing costs. In addition, methods to control the as-grown surface of Gemini ribbon have permitted the usage of the so-called no-etch process that allows for direct transfer of as-grown ribbon to diffusion without any intermediate etching step. In-line diagnostics for Gemini were further developed--these included more accurate methods for measuring and controlling melt depth and more accurate means to measure and control ribbon thickness. Earlier in the project, the focus was on monolithic module development. With the Gemini advances described above, monolithic module work was brought to a close during this second year of the overall three year project. A significant advance in this technology was the development of a conductive adhesive in combination with Evergreen's proprietary backskin and encapsulant. 25-W size experimental monolithic modules have been tested and found to be able to withstand up to 1400 thermal cycles.

  15. Manufacturing Planning Guide

    NASA Technical Reports Server (NTRS)

    Waid, Michael

    2011-01-01

    Manufacturing process, milestones and inputs are unknowns to first-time users of the manufacturing facilities. The Manufacturing Planning Guide aids in establishing expectations for both NASA and non-NASA facility customers. The potential audience for this guide includes both internal and commercial spaceflight hardware/software developers. It is intended to assist their project engineering personnel in manufacturing planning and execution. Material covered includes a roadmap of the manufacturing process, roles and responsibilities of facility and user, major milestones, facility capabilities, and inputs required by the facility. Samples of deliverables, products, and inputs necessary to define test scope, cost, and schedule are included as an appendix to the guide.

  16. High intensity accelerator for a wide range of applications

    NASA Astrophysics Data System (ADS)

    Conard, E. Milo

    1994-12-01

    When looking at commercial applications of accelerators from a market point of view, it appears that a common accelerator design could meet different users' needs. This would benefit both the manufacturer and the user by multiplying the number of machines sold, thus lowering their cost and improving their quality. These applications include: radioisotope production for medical imaging (positron emission tomography), industrial imaging and non-destructive testing (e.g. neutron radiography, explosive and drug detection in luggage or freight). This paper investigates the needs of the various applications and defines their common denominator to establish suitable specifications (type of particles, energy, intensity). Different accelerator types (cyclotrons, linear accelerators and electrostatic machines) are reviewed and compared on performance and estimated costs. A high intensity tandem accelerator design is studied in more detail as it seems the most appropriate candidate.

  17. Accelerated/abbreviated test methods of the low-cost silicon solar array project. Study 4, task 3: Encapsulation

    NASA Technical Reports Server (NTRS)

    Kolyer, J. M.; Mann, N. R.

    1977-01-01

    Methods of accelerated and abbreviated testing were developed and applied to solar cell encapsulants. These encapsulants must provide protection for as long as 20 years outdoors at different locations within the United States. Consequently, encapsulants were exposed for increasing periods of time to the inherent climatic variables of temperature, humidity, and solar flux. Property changes in the encapsulants were observed. The goal was to predict long term behavior of encapsulants based upon experimental data obtained over relatively short test periods.

  18. Photovoltaic manufacturing cost and throughput improvements for thin-film CIGS-based modules: Phase 1 technical report, July 1998--July 1999

    SciTech Connect

    Wiedeman, S.; Wendt, R.G.

    2000-03-01

    The primary objectives of the Global Solar Energy (GSE) Photovoltaic Manufacturing Technology (PVMaT) subcontract are directed toward reducing cost and expanding the production rate of thin-film CuInGaSe{sub 2} (CIGS)-based PV modules on flexible substrates. Improvements will be implemented in monolithic integration, CIGS deposition, contact deposition, and in-situ CIGS control and monitoring. In Phase 1, GSE has successfully attacked many of the highest risk aspects of each task. All-laser, selective scribing processes for CIGS have been developed, and many end-of-contract goals for scribing speed have been exceeded in the first year. High-speed ink-jet deposition of insulating material in the scribes now appears to be a viable technique, again exceeding some end-of-contract goals in the first year. Absorber deposition of CIGS was reduced corresponding to throughput speeds of up to 24-in/min, also exceeding an end-of-contract goal. Alternate back-contact materials have been identified that show potential as candidates for replacement of higher-cost molybdenum, and a novel, real-time monitoring technique (parallel-detector spectroscopic ellipsometry) has shown remarkable sensitivity to relevant properties of the CIGS absorber layer for use as a diagnostic tool. Currently, one of the bilayers has been baselined by GSE for flexible CIGS on polymeric substrates. Resultant back-contacts meet sheet-resistance goals and exhibit much less intrinsic stress than Mo. CIGS has been deposited, and resultant devices are comparable in performance to pure Mo back-contacts. Debris in the chamber has been substantially reduced, allowing longer roll-length between system cleaning.

  19. Updating the evidence base on the operational costs of supplementary immunization activities for current and future accelerated disease control, elimination and eradication efforts

    PubMed Central

    2014-01-01

    Background To achieve globally or regionally defined accelerated disease control, elimination and eradication (ADC/E/E) goals against vaccine-preventable diseases requires complementing national routine immunization programs with intensive, time-limited, and targeted Supplementary Immunization Activities (SIAs). Many global and country-level SIA costing efforts have historically relied on what are now outdated benchmark figures. Mobilizing adequate resources for successful implementation of SIAs requires updated estimates of non-vaccine costs per target population. Methods This assessment updates the evidence base on the SIA operational costs through a review of literature between 1992 and 2012, and an analysis of actual expenditures from 142 SIAs conducted between 2004 and 2011 and documented in country immunization plans. These are complemented with an analysis of budgets from 31 SIAs conducted between 2006 and 2011 in order to assess the proportion of total SIA costs per person associated with various cost components. All results are presented in 2010 US dollars. Results Existing evidence indicate that average SIA operational costs were usually less than US$0.50 per person in 2010 dollars. However, the evidence is sparse, non-standardized, and largely out of date. Average operational costs per person generated from our analysis of country immunization plans are consistently higher than published estimates, approaching US$1.00 for injectable vaccines. The results illustrate that the benchmarks often used to project needs underestimate the true costs of SIAs and the analysis suggests that SIA operational costs have been increasing over time in real terms. Our assessment also illustrates that operational costs vary across several dimensions. Variations in the actual costs of SIAs likely to reflect the extents to which economies of scale associated with campaign-based delivery can be attained, the underlying strength of the immunization program, sensitivities to the

  20. Manufacturing Success

    ERIC Educational Resources Information Center

    Reese, Susan

    2007-01-01

    According to the National Association of Manufacturers (NAM), "manufacturing is the engine that drives American prosperity". When NAM and its research and education arm, The Manufacturing Institute, released the handbook, "The Facts About Modern Manufacturing," in October 2006, NAM President John Engler noted, that manufacturing output in America…

  1. Accelerated/abbreviated test methods, study 4 of task 3 (encapsulation) of the low-cost silicon solar array project

    NASA Technical Reports Server (NTRS)

    Kolyer, J. M.; Mann, N. R.

    1978-01-01

    Inherent weatherability is controlled by the three weather factors common to all exposure sites: insolation, temperature, and humidity. Emphasis was focused on the transparent encapsulant portion of miniature solar cell arrays by eliminating weathering effects on the substrate and circuitry (which are also parts of the encapsulant system). The most extensive data were for yellowing, which were measured conveniently and precisely. Considerable data also were obtained on tensile strength. Changes in these two properties after outdoor exposure were predicted very well from accelerated exposure data.

  2. Solid state laser applications in photovoltaics manufacturing

    NASA Astrophysics Data System (ADS)

    Dunsky, Corey; Colville, Finlay

    2008-02-01

    Photovoltaic energy conversion devices are on a rapidly accelerating growth path driven by increasing government and societal pressure to use renewable energy as part of an overall strategy to address global warming attributed to greenhouse gas emissions. Initially supported in several countries by generous tax subsidies, solar cell manufacturers are relentlessly pushing the performance/cost ratio of these devices in a quest to reach true cost parity with grid electricity. Clearly this eventual goal will result in further acceleration in the overall market growth. Silicon wafer based solar cells are currently the mainstay of solar end-user installations with a cost up to three times grid electricity. But next-generation technology in the form of thin-film devices promises streamlined, high-volume manufacturing and greatly reduced silicon consumption, resulting in dramatically lower per unit fabrication costs. Notwithstanding the modest conversion efficiency of thin-film devices compared to wafered silicon products (around 6-10% versus 15-20%), this cost reduction is driving existing and start-up solar manufacturers to switch to thin-film production. A key aspect of these devices is patterning large panels to create a monolithic array of series-interconnected cells to form a low current, high voltage module. This patterning is accomplished in three critical scribing processes called P1, P2, and P3. Lasers are the technology of choice for these processes, delivering the desired combination of high throughput and narrow, clean scribes. This paper examines these processes and discusses the optimization of industrial lasers to meet their specific needs.

  3. Determining position, velocity and acceleration of free-ranging animals with a low-cost unmanned aerial system.

    PubMed

    Harvey, Richard J; Roskilly, Kyle; Buse, Chris; Evans, Hannah K; Hubel, Tatjana Y; Wilson, Alan M

    2016-09-01

    Unmanned aerial systems (UASs), frequently referred to as 'drones', have become more common and affordable and are a promising tool for collecting data on free-ranging wild animals. We used a Phantom-2 UAS equipped with a gimbal-mounted camera to estimate position, velocity and acceleration of a subject on the ground moving through a grid of GPS surveyed ground control points (area ∼1200 m(2)). We validated the accuracy of the system against a dual frequency survey grade GPS system attached to the subject. When compared with GPS survey data, the estimations of position, velocity and acceleration had a root mean square error of 0.13 m, 0.11 m s(-1) and 2.31 m s(-2), respectively. The system can be used to collect locomotion and localisation data on multiple free-ranging animals simultaneously. It does not require specialist skills to operate, is easily transported to field locations, and is rapidly and easily deployed. It is therefore a useful addition to the range of methods available for field data collection on free-ranging animal locomotion. PMID:27353230

  4. Heat pipe manufacturing study

    NASA Technical Reports Server (NTRS)

    Edelstein, F.

    1974-01-01

    Heat pipe manufacturing methods are examined with the goal of establishing cost effective procedures that will ultimately result in cheaper more reliable heat pipes. Those methods which are commonly used by all heat pipe manufacturers have been considered, including: (1) envelope and wick cleaning, (2) end closure and welding, (3) mechanical verification, (4) evacuation and charging, (5) working fluid purity, and (6) charge tube pinch off. The study is limited to moderate temperature aluminum and stainless steel heat pipes with ammonia, Freon-21 and methanol working fluids. Review and evaluation of available manufacturers techniques and procedures together with the results of specific manufacturing oriented tests have yielded a set of recommended cost-effective specifications which can be used by all manufacturers.

  5. A single pass electron accelerator

    NASA Astrophysics Data System (ADS)

    Schuetz, Marlin N.; Vroom, David A.

    1995-02-01

    Higher volumes, increasing competition and the need to improve quality have led us to re-examine the process for irradiation of tubing and wire. Traditionallyin Raychem, product irradiation has involved the use of large multi-purpose facilities that were designed to handle relatively small volumes of a large variety of products as a separate process. Today, with larger volumes of certain products, there is an interest in combining processes to improve quality and reduce cost. We have recently designed and constructed a small, low voltage accelerator system that can be placed in-line with another manufacturing process and can uniformly irradiate a tube or wire product in a single pass. The system is comprised of two conventional accelerator systems having elongated filaments and placed on opposite sides of a linear product path. The ribbon shaped electron beams from these two accelerators are scanned, after acceleration toward the product path, in a conventional manner and 180 degrees out of phase from each other. The two accelerated electron beams then enter a third magnetic field that is synchronous with the scanning magnets and whose oscillating polarity is such that the ribbon beams are converged onto a tubular shaped window close to and around a segment of the product path. Trials with a prototype system have produced tubing having a dose concentricity of better than ± 10 percent on a single pass through the system.

  6. Blade Manufacturing Improvement: Remote Blade Manufacturing Demonstration

    SciTech Connect

    ASHWILL, THOMAS D.

    2003-05-01

    The objective of this program was to investigate manufacturing improvements for wind turbine blades. The program included a series of test activities to evaluate the strength, deflection, performance, and loading characteristics of the prototype blades. The original contract was extended in order to continue development of several key blade technologies identified in the project. The objective of the remote build task was to demonstrate the concept of manufacturing wind turbine blades at a temporary manufacturing facility in a rural environment. TPI Composites successfully completed a remote manufacturing demonstration in which four blades were fabricated. The remote demonstration used a manufacturing approach which relied upon material ''kits'' that were organized in the factory and shipped to the site. Manufacturing blades at the wind plant site presents serious logistics difficulties and does not appear to be the best approach. A better method appears to be regional manufacturing facilities, which will eliminate most of the transportation cost, without incurring the logistical problems associated with fabrication directly onsite. With this approach the remote facilities would use commonly available industrial infrastructure such as enclosed workbays, overhead cranes, and paved staging areas. Additional fatigue testing of the M20 root stud design was completed with good results. This design provides adhesive bond strength under fatigue loading that exceeds that of the fastener. A new thru-stud bonding concept was developed for the M30 stud design. This approach offers several manufacturing advantages; however, the test results were inconclusive.

  7. Turbine Manufacture

    NASA Technical Reports Server (NTRS)

    1979-01-01

    The machinery pictured is a set of Turbodyne steam turbines which power a sugar mill at Bell Glade, Florida. A NASA-developed computer program called NASTRAN aided development of these and other turbines manufactured by Turbodyne Corporation's Steam Turbine Division, Wellsville, New York. An acronym for NASA Structural Analysis Program, NASTRAN is a predictive tool which advises development teams how a structural design will perform under service use conditions. Turbodyne uses NASTRAN to analyze the dynamic behavior of steam turbine components, achieving substantial savings in development costs. One of the most widely used spinoffs, NASTRAN is made available to private industry through NASA's Computer Software Management Information Center (COSMIC) at the University of Georgia.

  8. Low cost back contact heterojunction solar cells on thin c-Si wafers. integrating laser and thin film processing for improved manufacturability

    SciTech Connect

    Hegedus, Steven S.

    2015-09-08

    An interdigitated back contact (IBC) Si wafer solar cell with deposited a-Si heterojunction (HJ) emitter and contacts is considered the ultimate single junction Si solar cell design. This was confirmed in 2014 by both Panasonic and Sharp Solar producing IBC-HJ cells breaking the previous record Si solar cell efficiency of 25%. But manufacturability at low cost is a concern for the complex IBC-HJ device structure. In this research program, our goals were to addressed the broad industry need for a high-efficiency c-Si cell that overcomes the dominant module cost barriers by 1) developing thin Si wafers synthesized by innovative, kerfless techniques; 2) integrating laser-based processing into most aspects of solar cell fabrication, ensuring high speed and low thermal budgets ; 3) developing an all back contact cell structure compatible with thin wafers using a simplified, low-temperature fabrication process; and 4) designing the contact patterning to enable simplified module assembly. There were a number of significant achievements from this 3 year program. Regarding the front surface, we developed and applied new method to characterize critical interface recombination parameters including interface defect density Dit and hole and electron capture cross-section for use as input for 2D simulation of the IBC cell to guide design and loss analysis. We optimized the antireflection and passivation properties of the front surface texture and a-Si/a-SiN/a-SiC stack depositions to obtain a very low (< 6 mA/cm2) front surface optical losses (reflection and absorption) while maintaining excellent surface passivation (SRV<5 cm/s). We worked with kerfless wafer manufacturers to apply defect-engineering techniques to improve bulk minority-carrier lifetime of thin kerfless wafers by both reducing initial impurities during growth and developing post-growth gettering techniques. This led insights about the kinetics of nickel, chromium, and dislocations in PV-grade silicon and to

  9. Low cost back contact heterojunction solar cells on thin c-Si wafers. Integrating laser and thin film processing for improved manufacturability

    SciTech Connect

    Hegedus, Steven S.

    2015-09-08

    An interdigitated back contact (IBC) Si wafer solar cell with deposited a-Si heterojunction (HJ) emitter and contacts is considered the ultimate single junction Si solar cell design. This was confirmed in 2014 by both Panasonic and Sharp Solar producing IBC-HJ cells breaking the previous record Si solar cell efficiency of 25%. But manufacturability at low cost is a concern for the complex IBC-HJ device structure. In this research program, our goals were to addressed the broad industry need for a high-efficiency c-Si cell that overcomes the dominant module cost barriers by 1) developing thin Si wafers synthesized by innovative, kerfless techniques; 2) integrating laser-based processing into most aspects of solar cell fabrication, ensuring high speed and low thermal budgets ; 3) developing an all back contact cell structure compatible with thin wafers using a simplified, low-temperature fabrication process; and 4) designing the contact patterning to enable simplified module assembly. There were a number of significant achievements from this 3 year program. Regarding the front surface, we developed and applied new method to characterize critical interface recombination parameters including interface defect density Dit and hole and electron capture cross-section for use as input for 2D simulation of the IBC cell to guide design and loss analysis. We optimized the antireflection and passivation properties of the front surface texture and a-Si/a-SiN/a-SiC stack depositions to obtain a very low (< 6 mA/cm2) front surface optical losses (reflection and absorption) while maintaining excellent surface passivation (SRV<5 cm/s). We worked with kerfless wafer manufacturers to apply defect-engineering techniques to improve bulk minority-carrier lifetime of thin kerfless wafers by both reducing initial impurities during growth and developing post-growth gettering techniques. This led insights about the kinetics of nickel, chromium, and dislocations in PV-grade silicon and to

  10. Management of end-of-life electronic products within environmental benign manufacturing framework: Analysis of infrastructure, cost, materials flow, and decision-making

    NASA Astrophysics Data System (ADS)

    Kang, Hai-Yong

    This research addresses a management of end-of-life (EOL) electronic products within the boundary of Environmentally Benign Manufacturing (EBM). For the comprehensive evaluation of EOL electronic products, existing recycling programs, the roles of each stakeholder in e-waste recycling, and technologies are identified. The results show that to increase the recycling rate a steady supply of collected materials is needed, as well as effective sorting techniques, proper incorporation of Design for the Environment in early product design, and valued secondary markets for recycled goods. Technical cost modeling (TCM) results provide guidance to the recycling industry on how to maximize revenue and ensure the robust economic viability of e-waste Materials Recycling Facilities. Revenue sources with higher profit-efficiency ratios are an example. Also, process automation is demonstrated to be a major hurdle to overcome because of the high labor cost in the recycling industry combined with the randomness factor associated with the input stream. The results of the materials flow analysis (MFA) indicate that the pattern of outflow and the amount do not simply depend on the inflow pattern and amount. Also, the behavior of consumers, especially of the first user, is the most critical factor that determines the outflow of personal computer systems at the EOL stage. The combination of TCM and MFA provide a tool for estimating the infrastructure needed to treat future e-waste, such as the number of treatment facilities and the total capital investment needed. Laws that are designed to minimize the generation of toxic waste and the use of toxic substances in the U.S. and Europe are reviewed. And electronic and electrical industries in California and Massachusetts are analyzed in terms of the generation of toxic waste, the size of these industries. The results of the Analytic Hierarchy Process decision-making study indicate that the current toxic waste treatment methods practiced in

  11. Designing MEMS for manufacturing

    NASA Astrophysics Data System (ADS)

    Wolter, Alexander; Herrmann, Andreas; Yildiz, Goekhan; Schenk, Harald; Lakner, Hubert

    2004-10-01

    MEMS (micro electro-mechanical systems) are often expected to take a development as microelectronics did in the last 35 years. Several devices are already established in mass markets like acceleration sensors, gyros, pressure sensors, ink jet heads and the DLP micromirror array. On the other hand many companies have stopped their business after the telecom bubble. Others are struggling. Many dreams based on MEMS-devices that were not at all mature and could not be manufactured in high numbers. When a commercial product is the goal, several questions must be answered already in concept phase. The specifications must clearly reflect the requirements of the application. Performance and price must be competitive to any other technology. The relation between fabrication process and design is strong and mutual. The process must create all features of the device and the design must consider the limitations of the process. Only if the design is tolerant against all process variations reproducible performance can be achieved. And only if the design is robust in all process steps the devices can survive. Regarding the time and cost frame it is always preferable to change the layout rather than the process. This article looks at MEMS technology and identifies what has been adopted from CMOS, what is desirable to adopt and what needs new solutions. Examples are given in the fields of design, modeling layout, process, test, and packaging.

  12. Photovoltaic Manufacturing Technology

    NASA Astrophysics Data System (ADS)

    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.

  13. SMART 3D SUBSURFACE CONTAMINANT CHARACTERIZATION AT THE BGRR DECOMMISSIONING PROJECT. ACCELERATED SITE TECHNOLOGY DEPLOYMENT COST AND PERFORMANCE REPORT.

    SciTech Connect

    HEISER,J.; KALB,P.; SULLIVAN,T.; MILIAN,L.

    2001-12-01

    The BGRR was the world's first nuclear reactor dedicated to the peaceful exploration of atomic energy. The reactor pile consisted of a 700-ton, 25-foot cube of graphite fueled by uranium. A total of 1,369 fuel channels were available with roughly half in use at any given time. Insertion and removal of boron steel control rods controlled reactor power levels. One or more of five fans powered air-cooling. Air was brought in through two filtered plenums, flowed through and around the reactor core, through an exhaust duct containing filters, and finally out through the 320-foot high exhaust stack. Spent fuel was temporarily stored in the spent-fuel canal, and then sent to the Department of Energy's Savannah River Site (SRS). Access to the canal for removing spent fuel was through the Canal House (Building 709). The BGRR ceased operation in 1968 and was placed in a shutdown mode in which all fuel was removed and sent to SRS. Penetrations in the biological shield around the graphite cube and fuel channels were sealed. The final decontamination and decommissioning (D and D) process was initiated in 1999 and is scheduled for completion in 2005. An accelerated schedule was developed that combines characterization with removal actions for the various systems and structures. Before D and D work on a section of the BGRR facility begins, contaminant characterization is conducted to determine the types and amounts of contaminants present. The data are then used for project planning, including decisions affecting the extent of removal, waste designation, and health and safety plans.

  14. An Accelerated Development, Reduced Cost Approach to Lunar/Mars Exploration Using a Modular NTR-Based Space Transportation System

    NASA Technical Reports Server (NTRS)

    Borowski, S.; Clark, J.; Sefcik, R.; Corban, R.; Alexander, S.

    1995-01-01

    The results of integrated systems and mission studies are presented which quantify the benefits and rationale for developing a common, modular lunar/Mars space transportation system (STS) based on nuclear thermal rocket (NTR) technology. At present NASA's Exploration Program Office (ExPO) is considering chemical propulsion for an 'early return to the Moon' and NTR propulsion for the more demanding Mars missions to follow. The time and cost to develop these multiple systems are expected to be significant. The Nuclear Propulsion Office (NPO) has examined a variety of lunar and Mars missions and heavy lift launch vehicle (HLLV) options in an effort to determine a 'standardized' set of engine and stage components capable of satisfying a wide range of Space Exploration Initiative (SEI) missions. By using these components in a 'building block' fashion, a variety of single and multi-engine lunar and Mars vehicles can be configured. For NASA's 'First Lunar Outpost' (FLO) mission, an expendable NTR stage powered by two 50 klbf engines can deliver approximately 96 metric tons (t) to translunar injection (TLI) conditions for an initial mass in low earth orbit (IMLEO) of approximately 198 t compared to 250 t for a cryogenic chemical TLI stage. The NTR stage liquid hydrogen (LH2) tank has a 10 m diameter, 14.5 m length, and 66 t LH2 capacity. The NTR utilizes a UC-ZrC-graphite 'composite' fuel with a specific impulse (Isp) capability of approximately 900 s and an engine thrust-to-weight ratio of approximately 4.3. By extending the size and LH2 capacity of the lunar NTR stage to approximately 20 m and 96 t, respectively, a single launch Mars cargo vehicle capable of delivering approximately 50 t of surface payload is possible. Three 50 klbf NTR engines and the two standardized LH2 tank sizes developed for lunar and Mars cargo vehicle applications would be used to configure the Mars piloted vehicle for a mission as early as 2010. The paper describes the features of the 'common

  15. Accelerating Influenza Research: Vaccines, Antivirals, Immunomodulators and Monoclonal Antibodies. The Manufacture of a New Wild-Type H3N2 Virus for the Human Viral Challenge Model

    PubMed Central

    Fullen, Daniel J.; Noulin, Nicolas; Catchpole, Andrew; Fathi, Hosnieh; Murray, Edward J.; Mann, Alex; Eze, Kingsley; Balaratnam, Ganesh; Borley, Daryl W.; Gilbert, Anthony; Lambkin-Williams, Rob

    2016-01-01

    Background Influenza and its associated diseases are a major cause of morbidity and mortality. The United States Advisory Committee on Immunization Practices recommends influenza vaccination for everyone over 6 months of age. The failure of the flu vaccine in 2014–2015 demonstrates the need for a model that allows the rapid development of novel antivirals, universal/intra-seasonal vaccines, immunomodulators, monoclonal antibodies and other novel treatments. To this end we manufactured a new H3N2 influenza virus in compliance with Good Manufacturing Practice for use in the Human Viral Challenge Model. Methods and Strain Selection We chose an H3N2 influenza subtype, rather than H1N1, given that this strain has the most substantial impact in terms of morbidity or mortality annually as described by the Centre for Disease Control. We first subjected the virus batch to rigorous adventitious agent testing, confirmed the virus to be wild-type by Sanger sequencing and determined the virus titres appropriate for human use via the established ferret model. We built on our previous experience with other H3N2 and H1N1 viruses to develop this unique model. Human Challenge and Conclusions We conducted an initial safety and characterisation study in healthy adult volunteers, utilising our unique clinical quarantine facility in London, UK. In this study we demonstrated this new influenza (H3N2) challenge virus to be both safe and pathogenic with an appropriate level of disease in volunteers. Furthermore, by inoculating volunteers with a range of different inoculum titres, we established the minimum infectious titre required to achieve reproducible disease whilst ensuring a sensitive model that can be translated to design of subsequent field based studies. Trial Registration ClinicalTrials.gov NCT02525055 PMID:26761707

  16. Financial impact of technology acceleration on semiconductor masks

    NASA Astrophysics Data System (ADS)

    Trybula, Walter J.; Kimmel, Kurt R.; Grenon, Brian J.

    2002-03-01

    The Semiconductor Industry has been on a historic productivity growth curve that is due to the feature increase based on size reductions. The pace of technology introduction is accelerating as evidenced by the shortening of time from the introduction of the 180nm node and the introduction of the 130nm node. Historically, the introduction of new nodes had been on a three-year cycle. This raises the question of the impact of this acceleration on the manufacture of masks. This paper examines the impact on semiconductor masks by considering the process steps involved in manufacturing masks and the related cots and cycle time. As technology accelerates, the tools available may not maintain a similar pace of introduction. The consequences of this possible non-compliance with the technology acceleration will have an impact on the cost of masks. An example is employed to demonstrate the financial impact of the technology acceleration. Projections can be made of the continuing impact of technology acceleration on the mask manufacturing process. The conclusions drawn are that several identified, critical processes must be the focus of improvement to allow the industry to continue on the productivity growth curve.

  17. Overview of the Photovoltaic Manufacturing Technology (PVMaT) project

    SciTech Connect

    Witt, C E; Mitchell, R L; Mooney, G D

    1993-08-01

    The Photovoltaic Manufacturing Technology (PVMaT) project is a historic government/industry photovoltaic (PV) manufacturing R&D partnership composed of joint efforts between the federal government (through the US Department of Energy) and members of the US PV industry. The project`s ultimate goal is to ensure that the US industry retains and extends its world leadership role in the manufacture and commercial development of PV components and systems. PVMaT is designed to do this by helping the US PV industry improve manufacturing processes, accelerate manufacturing cost reductions for PV modules, improve commercial product performance, and lay the groundwork for a substantial scale-up of US-based PV manufacturing capacities. Phase 1 of the project, the problem identification phase, was completed in early 1991. Phase 2, the problem solution phase, which addresses process-specific problems of specific manufacturers, is now underway with an expected duration of 5 years. Phase 3 addresses R&D problems that are relatively common to a number of PV companies or the PV industry as a whole. These ``generic`` problem areas are being addressed through a teamed research approach.

  18. Development of A Real-Time Shaking Map System Using Low Cost Acceleration Sensors and Its Application for Earthquake Early Warning

    NASA Astrophysics Data System (ADS)

    Kuo, K.; Wu, Y.; Lin, T.; Hsiao, N.; Chen, D.

    2013-12-01

    Real-time signals from Palert (low-cost MEMS acceleration sensor) network are used to develop a real-time shaking map system based on the Earthworm environment in Taiwan. This system could provide real-time intensity map and estimate magnitude which is determined by shaking covered areas without earthquake location process. In order to derive an empirical strong motion attenuation relationship between the shaking covered areas and their corresponding earthquake magnitudes, we collected the strong motion records from 42 large crustal earthquakes recorded by the Taiwan Strong Motion Instrumentation Program (TSMIP) stations. The shaking covered areas (A) of certain peak ground acceleration (PGA) could be related to MA as follow: MA=0.002*(PGA)*log(A)+0.279*log(A)+4.236 Records of three earthquakes are used to test our system performance, they are the Hualien earthquake (ML 5.6, MW 5.5) occurred on 7th March 2013, the Nantou earthquake (ML 6.1, MW 5.9) occurred on 27th March 2013, and the Nantou earthquake (ML 6.3, MW 6.2) occurred on 2nd June 2013. Results show that the first report could be provided at about 10 seconds after the earthquake occurrence and the magnitudes are reported as 5.7, 5.7 and 5.8 for Hualien and two Nantou events, respectively. Finally, the stable report could be obtained at about 20, 19 and 17 seconds after the earthquake occurred and the magnitudes are reported as 5.5, 5.9 and 6.0 for Hualien and two Nantou events, respectively. Base on the result from this study, the real-time shaking map system could provide rapidly real-time shaking map and estimate earthquake magnitude within 1 minute even tens of seconds. It will play an important role in seismic hazard mitigation.

  19. 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.

  20. Metal Additive Manufacturing: A Review

    NASA Astrophysics Data System (ADS)

    Frazier, William E.

    2014-06-01

    This paper reviews the state-of-the-art of an important, rapidly emerging, manufacturing technology that is alternatively called additive manufacturing (AM), direct digital manufacturing, free form fabrication, or 3D printing, etc. A broad contextual overview of metallic AM is provided. AM has the potential to revolutionize the global parts manufacturing and logistics landscape. It enables distributed manufacturing and the productions of parts-on-demand while offering the potential to reduce cost, energy consumption, and carbon footprint. This paper explores the material science, processes, and business consideration associated with achieving these performance gains. It is concluded that a paradigm shift is required in order to fully exploit AM potential.

  1. The photovoltaic manufacturing technology project: A government/industry partnership

    SciTech Connect

    Mitchell, R.L.; Witt, C.E.; Mooney, G.D.

    1991-12-01

    The Photovoltaic Manufacturing Technology (PVMaT) project is a government/industry photovoltaic manufacturing research and development (R D) project composed of partnerships between the federal government (through the US Department of Energy) and members of the US photovoltaic (PV) industry. It is designed to assist the US PV industry in improving manufacturing processes, accelerating manufacturing cost reductions for PV modules, increasing commercial product performance, and generally laying the groundwork for a substantial scale-up of US-based PV manufacturing plant capabilities. The project is being carried out in three separate phases, each focused on a specific approach to solving the problems identified by the industrial participants. These participants are selected through competitive procurements. Furthermore, the PVMaT project has been specifically structured to ensure that these PV manufacturing R D subcontract awards are selected with no intention of either directing funding toward specific PV technologies (e.g., amorphous silicon, polycrystalline thin films, etc.), or spreading the awards among a number of technologies (e.g., one subcontract in each area). Each associated subcontract under any phase of this project is, and will continue to be, selected for funding on its own technical and cost merits. Phase 1, the problem identification phase, was completed early in 1991. Phase 2 is now under way. This is the solution phase of the project and addresses problems of specific manufacturers. The envisioned subcontracts under Phase 2 may be up to three years in duration and will be highly cost-shared between the US government and US industrial participants. Phase 3, is also under way. General issues related to PV module development will be studied through various teaming arrangements. 25 refs.

  2. The photovoltaic manufacturing technology project: A government/industry partnership

    SciTech Connect

    Mitchell, R.L.; Witt, C.E.; Mooney, G.D.

    1991-12-01

    The Photovoltaic Manufacturing Technology (PVMaT) project is a government/industry photovoltaic manufacturing research and development (R&D) project composed of partnerships between the federal government (through the US Department of Energy) and members of the US photovoltaic (PV) industry. It is designed to assist the US PV industry in improving manufacturing processes, accelerating manufacturing cost reductions for PV modules, increasing commercial product performance, and generally laying the groundwork for a substantial scale-up of US-based PV manufacturing plant capabilities. The project is being carried out in three separate phases, each focused on a specific approach to solving the problems identified by the industrial participants. These participants are selected through competitive procurements. Furthermore, the PVMaT project has been specifically structured to ensure that these PV manufacturing R&D subcontract awards are selected with no intention of either directing funding toward specific PV technologies (e.g., amorphous silicon, polycrystalline thin films, etc.), or spreading the awards among a number of technologies (e.g., one subcontract in each area). Each associated subcontract under any phase of this project is, and will continue to be, selected for funding on its own technical and cost merits. Phase 1, the problem identification phase, was completed early in 1991. Phase 2 is now under way. This is the solution phase of the project and addresses problems of specific manufacturers. The envisioned subcontracts under Phase 2 may be up to three years in duration and will be highly cost-shared between the US government and US industrial participants. Phase 3, is also under way. General issues related to PV module development will be studied through various teaming arrangements. 25 refs.

  3. Manufacturing information system

    NASA Astrophysics Data System (ADS)

    Allen, D. K.; Smith, P. R.; Smart, M. J.

    1983-12-01

    The size and cost of manufacturing equipment has made it extremely difficult to perform realistic modeling and simulation of the manufacturing process in university research laboratories. Likewise the size and cost factors, coupled with many uncontrolled variables of the production situation has even made it difficult to perform adequate manufacturing research in the industrial setting. Only the largest companies can afford manufacturing research laboratories; research results are often held proprietary and seldom find their way into the university classroom to aid in education and training of new manufacturing engineers. It is the purpose for this research to continue the development of miniature prototype equipment suitable for use in an integrated CAD/CAM Laboratory. The equipment being developed is capable of actually performing production operations (e.g. drilling, milling, turning, punching, etc.) on metallic and non-metallic workpieces. The integrated CAD/CAM Mini-Lab is integrating high resolution, computer graphics, parametric design, parametric N/C parts programmings, CNC machine control, automated storage and retrieval, with robotics materials handling. The availability of miniature CAD/CAM laboratory equipment will provide the basis for intensive laboratory research on manufacturing information systems.

  4. Integrating post-manufacturing issues into design and manufacturing decisions

    NASA Technical Reports Server (NTRS)

    Eubanks, Charles F.

    1996-01-01

    An investigation is conducted on research into some of the fundamental issues underlying the design for manufacturing, service and recycling that affect engineering decisions early in the conceptual design phase of mechanical systems. The investigation focuses on a system-based approach to material selection, manufacturing methods and assembly processes related to overall product requirements, performance and life-cycle costs. Particular emphasis is placed on concurrent engineering decision support for post-manufacturing issues such as serviceability, recyclability, and product retirement.

  5. Productization and Manufacturing Scaling of High-Efficiency Solar Cell and Module Products Based on a Disruptive Low-Cost, Mono-Crystalline Technology: Final Technical Progress Report, April 1, 2009 - December 30, 2010

    SciTech Connect

    Fatemi, H.

    2012-07-01

    Final report for PV incubator subcontract with Solexel, Inc. The purpose of this project was to develop Solexel's Unique IP, productize it, and transfer it to manufacturing. Silicon constitutes a significant fraction of the total solar cell cost, resulting in an industry-wide drive to lower silicon usage. Solexel's disruptive Solar cell structure got around these challenges and promised superior light trapping, efficiency and mechanical strength, despite being significantly thinner than commercially available cells. Solexel's successful participation in this incubator project became evident as the company is now moving into commercial production and position itself to be competitive for the next Technology Pathway Partnerships (TPP) funding opportunity.

  6. Manufacturing technologies

    SciTech Connect

    1995-09-01

    The Manufacturing Technologies Center is an integral part of Sandia National Laboratories, a multiprogram engineering and science laboratory, operated for the Department of Energy (DOE) with major facilities at Albuquerque, New Mexico, and Livermore, California. Our Center is at the core of Sandia`s Advanced Manufacturing effort which spans the entire product realization process.

  7. Manufacturing Technology.

    ERIC Educational Resources Information Center

    Barnes, James L.

    This curriculum guide is designed to assist junior high school industrial arts teachers in planning new courses and revising existing courses in manufacturing technology. Addressed in the individual units of the guide are the following topics: introduction to manufacturing, materials processing, personnel management, production management,…

  8. Relativistic klystron driven compact high gradient accelerator as an injector to an X-ray synchrotron radiation ring

    DOEpatents

    Yu, David U. L.

    1990-01-01

    A compact high gradient accelerator driven by a relativistic klystron is utilized to inject high energy electrons into an X-ray synchrotron radiation ring. The high gradients provided by the relativistic klystron enables accelerator structure to be much shorter (typically 3 meters) than conventional injectors. This in turn enables manufacturers which utilize high energy, high intensity X-rays to produce various devices, such as computer chips, to do so on a cost effective basis.

  9. Breakthrough: Fermilab Accelerator Technology

    ScienceCinema

    None

    2014-08-12

    There are more than 30,000 particle accelerators in operation around the world. At Fermilab, scientists are collaborating with other laboratories and industry to optimize the manufacturing processes for a new type of powerful accelerator that uses superconducting niobium cavities. Experimenting with unique polishing materials, a Fermilab team has now developed an efficient and environmentally friendly way of creating cavities that can propel particles with more than 30 million volts per meter.

  10. Breakthrough: Fermilab Accelerator Technology

    SciTech Connect

    2012-04-23

    There are more than 30,000 particle accelerators in operation around the world. At Fermilab, scientists are collaborating with other laboratories and industry to optimize the manufacturing processes for a new type of powerful accelerator that uses superconducting niobium cavities. Experimenting with unique polishing materials, a Fermilab team has now developed an efficient and environmentally friendly way of creating cavities that can propel particles with more than 30 million volts per meter.

  11. Correlated histogram representation of Monte Carlo derived medical accelerator photon-output phase space

    DOEpatents

    Schach Von Wittenau, Alexis E.

    2003-01-01

    A method is provided to represent the calculated phase space of photons emanating from medical accelerators used in photon teletherapy. The method reproduces the energy distributions and trajectories of the photons originating in the bremsstrahlung target and of photons scattered by components within the accelerator head. The method reproduces the energy and directional information from sources up to several centimeters in radial extent, so it is expected to generalize well to accelerators made by different manufacturers. The method is computationally both fast and efficient overall sampling efficiency of 80% or higher for most field sizes. The computational cost is independent of the number of beams used in the treatment plan.

  12. Graphical simulation for aerospace manufacturing

    NASA Technical Reports Server (NTRS)

    Babai, Majid; Bien, Christopher

    1994-01-01

    Simulation software has become a key technological enabler for integrating flexible manufacturing systems and streamlining the overall aerospace manufacturing process. In particular, robot simulation and offline programming software is being credited for reducing down time and labor cost, while boosting quality and significantly increasing productivity.

  13. Manufacturing technology

    SciTech Connect

    Blaedel, K.L.

    1997-02-01

    The specific goals of the Manufacturing Technology thrust area are to develop an understanding of fundamental fabrication processes, to construct general purpose process models that will have wide applicability, to document our findings and models in journals, to transfer technology to LLNL programs, industry, and colleagues, and to develop continuing relationships with industrial and academic communities to advance our collective understanding of fabrication processes. Advances in four projects are described here, namely Design of a Precision Saw for Manufacturing, Deposition of Boron Nitride Films via PVD, Manufacturing and Coating by Kinetic Energy Metallization, and Magnet Design and Application.

  14. Metaldyne. Plant-Wide Assessment at Royal Oak Finds Opportunities to Improve Manufacturing Effciency, Reduce Energy Use, and Achieve Sigificant Cost Savings

    SciTech Connect

    none,

    2005-05-01

    This case study prepared for the U.S. Department of Energy's Industrial Technologies Program describes a plant-wide energy assessment conducted at the Metaldyne, Inc., forging plant in Royal Oak, Michigan. The assessment focused on reducing the plant's operating costs, inventory, and energy use. If the company were to implement all the recommendations that came out of the assessment, its total annual energy savings for electricity would be about 11.5 million kWh and annual cost savings would be $12.6 million.

  15. Metaldyne: Plant-Wide Assessment at Royal Oak Finds Opportunities to Improve Manufacturing Efficiency, Reduce Energy Use, and Achieve Significant Cost Savings

    SciTech Connect

    Not Available

    2005-05-01

    This case study prepared for the U.S. Department of Energy's Industrial Technologies Program describes a plant-wide energy assessment conducted at the Metaldyne, Inc., forging plant in Royal Oak, Michigan. The assessment focused on reducing the plant's operating costs, inventory, and energy use. If the company were to implement all the recommendations that came out of the assessment, its total annual energy savings for electricity would be about 11.5 million kWh and annual cost savings would be $12.6 million.

  16. 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.

  17. Ohio Advanced Energy Manufacturing Center

    SciTech Connect

    Kimberly Gibson; Mark Norfolk

    2012-07-30

    The program goal of the Ohio Advanced Energy Manufacturing Center (OAEMC) is to support advanced energy manufacturing and to create responsive manufacturing clusters that will support the production of advanced energy and energy-efficient products to help ensure the nation's energy and environmental security. This goal cuts across a number of existing industry segments critical to the nation's future. Many of the advanced energy businesses are starting to make the transition from technology development to commercial production. Historically, this transition from laboratory prototypes through initial production for early adopters to full production for mass markets has taken several years. Developing and implementing manufacturing technology to enable production at a price point the market will accept is a key step. Since these start-up operations are configured to advance the technology readiness of the core energy technology, they have neither the expertise nor the resources to address manufacturing readiness issues they encounter as the technology advances toward market entry. Given the economic realities of today's business environment, finding ways to accelerate this transition can make the difference between success and failure for a new product or business. The advanced energy industry touches a wide range of industry segments that are not accustomed to working together in complex supply chains to serve large markets such as automotive and construction. During its first three years, the Center has catalyzed the communication between companies and industry groups that serve the wide range of advanced energy markets. The Center has also found areas of common concern, and worked to help companies address these concerns on a segment or industry basis rather than having each company work to solve common problems individually. EWI worked with three industries through public-private partnerships to sew together disparate segments helping to promote overall industry

  18. Energy consumption in manufacturing

    NASA Astrophysics Data System (ADS)

    Schmid, S. R.

    2012-04-01

    Energy sources, in the form of coal, oil, natural gas, solar or nuclear power, are global commodities, and as demand is projected to rise in the coming decades, so will costs. As such, an understanding of the energy needs of manufacturing processes and the ability to reduce the energy and carbon footprints are essential for sustainability reasons. Energy source effects are quantified in a number of measures. Models of energy needs by manufacturing processes are then examined, along with models incorporating the use of ancillary equipment such as pumps, filters, blowers, lighting, etc. Finally, the successful application of the tribological principles to influence energy consumption is discussed.

  19. Manufacturing and producibility technology

    NASA Technical Reports Server (NTRS)

    Hankins, J. D.; Dreshfield, R. L.

    1985-01-01

    Activities of the manufacturing/producibility working group within the Advanced High-Pressure O2/H2 Technology Program are summarized. The objectives of the M/P working group are: to develop and evaluate process and manufacturing techniques for advanced propulsion hardware design and selected materials; and to optimize the producibility of (SSME) components and assemblies by improved performance, increased life, greater reliability, and/or reduced cost. The technologies being developed include: plasma arc, laser, and inertia welding; combustion chamber and turbine blade coatings; coating processes; high performance alloy electroforming; and process control technology.

  20. Linear Accelerators

    NASA Astrophysics Data System (ADS)

    Sidorin, Anatoly

    2010-01-01

    In linear accelerators the particles are accelerated by either electrostatic fields or oscillating Radio Frequency (RF) fields. Accordingly the linear accelerators are divided in three large groups: electrostatic, induction and RF accelerators. Overview of the different types of accelerators is given. Stability of longitudinal and transverse motion in the RF linear accelerators is briefly discussed. The methods of beam focusing in linacs are described.

  1. Linear Accelerators

    SciTech Connect

    Sidorin, Anatoly

    2010-01-05

    In linear accelerators the particles are accelerated by either electrostatic fields or oscillating Radio Frequency (RF) fields. Accordingly the linear accelerators are divided in three large groups: electrostatic, induction and RF accelerators. Overview of the different types of accelerators is given. Stability of longitudinal and transverse motion in the RF linear accelerators is briefly discussed. The methods of beam focusing in linacs are described.

  2. 78 FR 34346 - Proposed Information Collection; Comment Request; NIST MEP Advanced Manufacturing Jobs and...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2013-06-07

    ... Advanced Manufacturing Jobs and Innovation Accelerator Challenge (AMJIAC) Client Impact Survey AGENCY... information collection. The purpose of the Advanced Manufacturing Jobs and Innovation Accelerator Challenge... to support job creation, encourage economic development, and enhance the competitiveness of...

  3. The use of a low cost 3D scanning and printing tool in the manufacture of custom-made foot orthoses: a preliminary study

    PubMed Central

    2014-01-01

    Background Custom foot orthoses are currently recognized as the gold standard for treatment of foot and lower limb pathology. While foam and plaster casting methods are most widely used in clinical practice, technology has emerged, permitting the use of 3D scanning, computer aided design (CAD) and computer aided manufacturing (CAM) for fabrication of foot molds and custom foot orthotic components. Adoption of 3D printing, as a form of CAM, requires further investigation for use as a clinical tool. This study provides a preliminary description of a new method to manufacture foot orthoses using a novel 3D scanner and printer and compare gait kinematic outputs from shod and traditional plaster casted orthotics. Findings One participant (male, 25 years) was included with no lower extremity injuries. Foot molds were created from both plaster casting and 3D scanning/printing methods. Custom foot orthoses were then fabricated from each mold. Lower body plug-in-gait with the Oxford Foot Model on the right foot was collected for both orthotic and control (shod) conditions. The medial longitudinal arch was measured using arch height index (AHI) where a decrease in AHI represented a drop in arch height. The lowest AHI was 21.2 mm in the running shoes, followed by 21.4 mm wearing the orthoses made using 3D scanning and printing, with the highest AHI of 22.0 mm while the participant wore the plaster casted orthoses. Conclusion This preliminary study demonstrated a small increase in AHI with the 3D printing orthotic compared to the shod condition. A larger sample size may demonstrate significant patterns for the tested conditions. PMID:25015013

  4. High frequency planar accelerating structures for future linear colliders

    SciTech Connect

    Yu, D.; Ben-Menahem, S.; Wilson, P.; Miller, R.; Ruth, R.; Nassiri, A.

    1994-12-31

    machined in the same process with the cavities. The new fabrication technique should substantially reduce the manufacturing cost of such accelerating structures.

  5. 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.

  6. Space Technology Mission Directorate Game Changing Development Program FY2015 Annual Program Review: Advanced Manufacturing Technology

    NASA Technical Reports Server (NTRS)

    Vickers, John; Fikes, John

    2015-01-01

    The Advance Manufacturing Technology (AMT) Project supports multiple activities within the Administration's National Manufacturing Initiative. A key component of the Initiative is the Advanced Manufacturing National Program Office (AMNPO), which includes participation from all federal agencies involved in U.S. manufacturing. In support of the AMNPO the AMT Project supports building and Growing the National Network for Manufacturing Innovation through a public-private partnership designed to help the industrial community accelerate manufacturing innovation. Integration with other projects/programs and partnerships: STMD (Space Technology Mission Directorate), HEOMD, other Centers; Industry, Academia; OGA's (e.g., DOD, DOE, DOC, USDA, NASA, NSF); Office of Science and Technology Policy, NIST Advanced Manufacturing Program Office; Generate insight within NASA and cross-agency for technology development priorities and investments. Technology Infusion Plan: PC; Potential customer infusion (TDM, HEOMD, SMD, OGA, Industry); Leverage; Collaborate with other Agencies, Industry and Academia; NASA roadmap. Initiatives include: Advanced Near Net Shape Technology Integrally Stiffened Cylinder Process Development (launch vehicles, sounding rockets); Materials Genome; Low Cost Upper Stage-Class Propulsion; Additive Construction with Mobile Emplacement (ACME); National Center for Advanced Manufacturing.

  7. Optimising the manufacture, formulation, and dose of antiretroviral drugs for more cost-efficient delivery in resource-limited settings: a consensus statement.

    PubMed

    Crawford, Keith W; Ripin, David H Brown; Levin, Andrew D; Campbell, Jennifer R; Flexner, Charles

    2012-07-01

    It is expected that funding limitations for worldwide HIV treatment and prevention in resource-limited settings will continue, and, because the need for treatment scale-up is urgent, the emphasis on value for money has become an increasing priority. The Conference on Antiretroviral Drug Optimization--a collaborative project between the Clinton Health Access Initiative, the Johns Hopkins University School of Medicine, and the Bill & Melinda Gates Foundation--brought together process chemists, clinical pharmacologists, pharmaceutical scientists, physicians, pharmacists, and regulatory specialists to explore strategies for the reduction of antiretroviral drug costs. The antiretroviral drugs discussed were prioritised for consideration on the basis of their market impact, and the objectives of the conference were framed as discussion questions generated to guide scientific assessment of potential strategies. These strategies included modifications to the synthesis of the active pharmaceutical ingredient (API) and use of cheaper sources of raw materials in synthesis of these ingredients. Innovations in product formulation could improve bioavailability thus needing less API. For several antiretroviral drugs, studies show efficacy is maintained at doses below the approved dose (eg, efavirenz, lopinavir plus ritonavir, atazanavir, and darunavir). Optimising pharmacoenhancement and extending shelf life are additional strategies. The conference highlighted a range of interventions; optimum cost savings could be achieved through combining approaches. PMID:22742638

  8. Can Accelerators Accelerate Learning?

    NASA Astrophysics Data System (ADS)

    Santos, A. C. F.; Fonseca, P.; Coelho, L. F. S.

    2009-03-01

    The 'Young Talented' education program developed by the Brazilian State Funding Agency (FAPERJ) [1] makes it possible for high-schools students from public high schools to perform activities in scientific laboratories. In the Atomic and Molecular Physics Laboratory at Federal University of Rio de Janeiro (UFRJ), the students are confronted with modern research tools like the 1.7 MV ion accelerator. Being a user-friendly machine, the accelerator is easily manageable by the students, who can perform simple hands-on activities, stimulating interest in physics, and getting the students close to modern laboratory techniques.

  9. PARTICLE ACCELERATOR

    DOEpatents

    Teng, L.C.

    1960-01-19

    ABS>A combination of two accelerators, a cyclotron and a ring-shaped accelerator which has a portion disposed tangentially to the cyclotron, is described. Means are provided to transfer particles from the cyclotron to the ring accelerator including a magnetic deflector within the cyclotron, a magnetic shield between the ring accelerator and the cyclotron, and a magnetic inflector within the ring accelerator.

  10. Additive Manufacturing Infrared Inspection

    NASA Technical Reports Server (NTRS)

    Gaddy, Darrell

    2014-01-01

    Additive manufacturing is a rapid prototyping technology that allows parts to be built in a series of thin layers from plastic, ceramics, and metallics. Metallic additive manufacturing is an emerging form of rapid prototyping that allows complex structures to be built using various metallic powders. Significant time and cost savings have also been observed using the metallic additive manufacturing compared with traditional techniques. Development of the metallic additive manufacturing technology has advanced significantly over the last decade, although many of the techniques to inspect parts made from these processes have not advanced significantly or have limitations. Several external geometry inspection techniques exist such as Coordinate Measurement Machines (CMM), Laser Scanners, Structured Light Scanning Systems, or even traditional calipers and gages. All of the aforementioned techniques are limited to external geometry and contours or must use a contact probe to inspect limited internal dimensions. This presentation will document the development of a process for real-time dimensional inspection technique and digital quality record of the additive manufacturing process using Infrared camera imaging and processing techniques.

  11. Evaporation in space manufacturing

    NASA Technical Reports Server (NTRS)

    Li, C. H.

    1974-01-01

    'Normal evaporation' equations for predicting the compositional changes with time and temperature have been developed and correlated with actual experimental data. An evaporative congruent temperature is defined and used to explain, predict, or plan space experiments on anomalous constitutional melting (on cooling) or solidification (on heating). Uneven evaporation causes reactive jetting forces capable of initiating new convection currents, nongravitational accelerations, surface vibrations, or other disturbances. Applications of evaporation to space manufacturing are described concerning evaporative purification, surface cooling, specimen selection, particles splitting, freezing data interpretation, material loss and dimensional control, and surface contamination or compositional changes.

  12. Troubleshooting Costs

    NASA Astrophysics Data System (ADS)

    Kornacki, Jeffrey L.

    Seventy-six million cases of foodborne disease occur each year in the United States alone. Medical and lost productivity costs of the most common pathogens are estimated to be 5.6-9.4 billion. Product recalls, whether from foodborne illness or spoilage, result in added costs to manufacturers in a variety of ways. These may include expenses associated with lawsuits from real or allegedly stricken individuals and lawsuits from shorted customers. Other costs include those associated with efforts involved in finding the source of the contamination and eliminating it and include time when lines are shut down and therefore non-productive, additional non-routine testing, consultant fees, time and personnel required to overhaul the entire food safety system, lost market share to competitors, and the cost associated with redesign of the factory and redesign or acquisition of more hygienic equipment. The cost associated with an effective quality assurance plan is well worth the effort to prevent the situations described.

  13. Low cost MCFC anodes

    SciTech Connect

    Erickson, D.S.

    1996-12-31

    This paper outlines a project, funded under a DOE SBIR grant, which tested a potentially lower cost method of manufacturing MCFC stack anodes and evaluated the feasibility of using the technology in the existing M-C Power Corp. manufacturing facility. The procedure involves adding activator salts to the anode tape casting slurry with the Ni and Cr or Al powders. Two different processes occur during heat treatment in a reducing environment: sintering of the base Ni structure, and alloying or cementation of the Cr or Al powders. To determine whether it was cost-effective to implement the cementation alloying manufacturing process, the M-C Power manufacturing cost model was used to determine the impact of different material costs and processing parameters on total anode cost. Cost analysis included equipment expenditures and facility modifications required by the cementation alloying process.

  14. Synchronized manufacture of composites knowledge study (SMACKS)

    NASA Astrophysics Data System (ADS)

    Strickland, B.; Oliver, M.

    1990-06-01

    The need for a competitive manufacturing knowledge base for the composites industry, encompasses a change from a 'functionally' organized factory to a product-based organization, and has led to major reductions in inventories, manufacturing costs and cycle times. The net effect was that products became more price- and delivery-competitive. It is believed that composite manufacturers have an equal need to improve their competitive edge, particularly as the demand for composite products grows and more manufacturers enter the marketplace. 'SMACKS' has begun to establish these needs and market trends, with a view to establishing the advantages offered to composite manufacturers by synchronized manufacturing methods.

  15. The Economics of Big Area Addtiive Manufacturing

    SciTech Connect

    Post, Brian; Lloyd, Peter D; Lindahl, John; Lind, Randall F; Love, Lonnie J; Kunc, Vlastimil

    2016-01-01

    Case studies on the economics of Additive Manufacturing (AM) suggest that processing time is the dominant cost in manufacturing. Most additive processes have similar performance metrics: small part sizes, low production rates and expensive feedstocks. Big Area Additive Manufacturing is based on transitioning polymer extrusion technology from a wire to a pellet feedstock. Utilizing pellets significantly increases deposition speed and lowers material cost by utilizing low cost injection molding feedstock. The use of carbon fiber reinforced polymers eliminates the need for a heated chamber, significantly reducing machine power requirements and size constraints. We hypothesize that the increase in productivity coupled with decrease in feedstock and energy costs will enable AM to become more competitive with conventional manufacturing processes for many applications. As a test case, we compare the cost of using traditional fused deposition modeling (FDM) with BAAM for additively manufacturing composite tooling.

  16. The Platinum Bullet: An Experimental Evaluation of CUNY's Accelerated Study in Associate Program (ASAP)--New Three-Year Impacts, Cost Analyses, and Implementation Findings

    ERIC Educational Resources Information Center

    Weiss, Michael; Scrivener, Susan; Fresques, Hannah; Ratledge, Alyssa; Rudd, Tim; Sommo, Colleen

    2014-01-01

    The City University of New York's (CUNY's) Accelerated Study in Associate Programs (ASAP) combines many of the ideas from a range of programs into a comprehensive model that requires students to attend school full-time, and provides supports and incentives for three years. ASAP's financial aid reforms, enhanced student services, and scheduling…

  17. Apparel Manufacture

    NASA Technical Reports Server (NTRS)

    1995-01-01

    Marshall Space Flight Center teamed with the University of Alabama in Huntsville (UAH) in 1989 on a program involving development of advanced simulation software. Concurrently, the State of Alabama chartered UAH to conduct a technology advancement program in support of the state's apparel manufacturers. In 1992, under contract to Marshall, UAH developed an apparel-specific software package that allows manufacturers to design and analyze modules without making an actual investment -- it functions on ordinary PC equipment. By 1995, Marshall had responded to requests for the package from more than 400 companies in 36 states; some of which reported savings up to $2 million. The National Garment Company of Missouri, for example, uses the system to design and balance a modular line before committing to expensive hardware; for setting up sewing lines; and for determining the composition of a new team.

  18. Magnet cable manufacturing

    SciTech Connect

    Royet, J.

    1990-10-01

    The cable is the heart of a superconducting accelerator magnet. Since the initial development of the Rutherford Cable more than twenty years ago, many improvements in manufacturing techniques have increased the current carrying capacity. When the Tevatron cable was specified fifteen years ago the current carrying capacity was 1800 A/mm{sup 2} at a field of 5.3T. During the intervening years it has been increased to 3000 A/mm{sup 2}. These improvements were due to refinements in the fabrication of the strands and the formation of the cable from the strands. The metallurgists were able to impart significant gains in performance by improving the homogeneity of the conductor. The engineers and technicians who designed and built the modern cabling machines made an enormous contribution by significantly reducing the degradation of wire performance that occurs when the wire was cabled. The fact that these gains were made while increasing the speed of cabling is one of the technological advances that made accelerators like the SSC possible. This article describes the cabling machines that were built to manufacture the cable for the full scale SSC prototype magnets and the low beta quadrupoles for the Fermilab Tevatron. This article also presents a compendium of the knowledge that was gained in the struggle to make high performance cable to exacting dimensional standards and at the throughput needed for the SSC. The material is an important part of the technology transfer from the Department of energy Laboratories to Industry.

  19. Green Manufacturing

    SciTech Connect

    Patten, John

    2013-12-31

    Green Manufacturing Initiative (GMI): The initiative provides a conduit between the university and industry to facilitate cooperative research programs of mutual interest to support green (sustainable) goals and efforts. In addition to the operational savings that greener practices can bring, emerging market demands and governmental regulations are making the move to sustainable manufacturing a necessity for success. The funding supports collaborative activities among universities such as the University of Michigan, Michigan State University and Purdue University and among 40 companies to enhance economic and workforce development and provide the potential of technology transfer. WMU participants in the GMI activities included 20 faculty, over 25 students and many staff from across the College of Engineering and Applied Sciences; the College of Arts and Sciences' departments of Chemistry, Physics, Biology and Geology; the College of Business; the Environmental Research Institute; and the Environmental Studies Program. Many outside organizations also contribute to the GMI's success, including Southwest Michigan First; The Right Place of Grand Rapids, MI; Michigan Department of Environmental Quality; the Michigan Department of Energy, Labor and Economic Growth; and the Michigan Manufacturers Technical Center.

  20. Accelerated/abbreviated test methods for predicting life of solar cell encapsulants to Jet Propulsion Laboratory California Institute of Technology for the encapsulation task of the low-cost solar array project

    NASA Technical Reports Server (NTRS)

    Kolyer, J. M.

    1978-01-01

    An important principle is that encapsulants should be tested in a total array system allowing realistic interaction of components. Therefore, micromodule test specimens were fabricated with a variety of encapsulants, substrates, and types of circuitry. One common failure mode was corrosion of circuitry and solar cell metallization due to moisture penetration. Another was darkening and/or opacification of encapsulant. A test program plan was proposed. It includes multicondition accelerated exposure. Another method was hyperaccelerated photochemical exposure using a solar concentrator. It simulates 20 year of sunlight exposure in a short period of one to two weeks. The study was beneficial in identifying some cost effective encapsulants and array designs.

  1. Manufactured Homes Tool

    2005-03-09

    The MH Tool software is designed to evaluate existing and new manufactured homes for structural adequacy in high winds. Users define design elements of a manufactured home and then select the hazard(s) for analysis. MH Tool then calculates and reports structural analysis results for the specified design and hazard Method of Solution: Design engineers input information (geometries, materials, etc.) describing the structure of a manufactured home, from which the software automatically creates a mathematical model.more » Windows, doors, and interior walls can be added to the initial design. HUD Code loads (wind, snow loads, interior live loads, etc.) are automatically applied. A finite element analysis is automatically performed using a third party solver to find forces and stresses throughout the structure. The designer may then employ components of strength (and cost) most appropriate for the loads that must be carried at each location, and then re-run the analysis for verification. If forces and stresses are still within tolerable limits (such as the HUD requirements), construction costs would be reduced without sacrificing quality.« less

  2. Manufactured Homes Tool

    SciTech Connect

    2005-03-09

    The MH Tool software is designed to evaluate existing and new manufactured homes for structural adequacy in high winds. Users define design elements of a manufactured home and then select the hazard(s) for analysis. MH Tool then calculates and reports structural analysis results for the specified design and hazard Method of Solution: Design engineers input information (geometries, materials, etc.) describing the structure of a manufactured home, from which the software automatically creates a mathematical model. Windows, doors, and interior walls can be added to the initial design. HUD Code loads (wind, snow loads, interior live loads, etc.) are automatically applied. A finite element analysis is automatically performed using a third party solver to find forces and stresses throughout the structure. The designer may then employ components of strength (and cost) most appropriate for the loads that must be carried at each location, and then re-run the analysis for verification. If forces and stresses are still within tolerable limits (such as the HUD requirements), construction costs would be reduced without sacrificing quality.

  3. Rapid response manufacturing (RRM)

    SciTech Connect

    Cain, W.D.; Waddell, W.L.

    1997-02-18

    US industry is fighting to maintain its competitive edge in the global market place. Today markets fluctuate rapidly. Companies, to survive, have to be able to respond with quick-to-market, improved, high quality, cost efficient products. The way products are developed and brought to market can be improved and made more efficient through the proper incorporation of emerging technologies. The RRM project was established to leverage the expertise and resources of US private industries and federal agencies to develop, integrate, and deploy new technologies that meet critical needs for effective product realization. The RRM program addressed a needed change in the US Manufacturing infrastructure that will ensure US competitiveness in world market typified by mass customization. This project provided the effort needed to define, develop and establish a customizable infrastructure for rapid response product development design and manufacturing. A major project achievement was the development of a broad-based framework for automating and integrating the product and process design and manufacturing activities involved with machined parts. This was accomplished by coordinating and extending the application of feature-based product modeling, knowledge-based systems, integrated data management, and direct manufacturing technologies in a cooperative integrated computing environment. Key technological advancements include a product model that integrates product and process data in a consistent, minimally redundant manner, an advanced computer-aided engineering environment, knowledge-based software aids for design and process planning, and new production technologies to make products directly from design application software.

  4. Photovoltaic manufacturing technology, Phase 1

    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. Manufacturing technology

    SciTech Connect

    Blaedel, K L

    1998-01-01

    The mission of the Manufacturing Technology thrust area at Lawrence Livermore National Laboratory (LLNL) has been to have an adequate base of manufacturing technology, not necessarily resident at LLNL, to conduct their future business. The specific goals were (1) to develop an understanding of fundamental fabrication processes; (2) to construct general purpose process models that have wide applicability; (3) to document their findings and models in journals; (4) to transfer technology to LLNL programs, industry, and colleagues; and (5) to develop continuing relationships with the industrial and academic communities to advance their collective understanding of fabrication processes. In support of this mission, two projects were reported here, each of which explores a way to bring higher precision to the manufacturing challenges that we face over the next few years. The first, ''A Spatial-Frequency-Domain Approach to Designing a Precision Machine Tools,'' is an overall view of how they design machine tools and instruments to make or measure workpieces that are specified in terms of the spatial frequency content of the residual errors of the workpiece surface. This represents an improvement of an ''error budget,'' a design tool that saw significant development in the early 1980's, and has been in active use since then. The second project, ''Micro-Drilling of ICF Capsules,'' is an attempt to define the current state in commercial industry for drilling small holes, particularly laser-drilling. The report concludes that 1-{micro}m diameter holes cannot currently be drilled to high aspect ratios, and then defines the engineering challenges that will have to be overcome to machine holes small enough for NIF capsules.

  6. 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.

  7. Computers in manufacturing

    NASA Astrophysics Data System (ADS)

    Hudson, C. A.

    1982-02-01

    CAD/CAM advances and applications for enhancing productivity in industry are explored. Wide-spread use of CAD/CAM devices are projected to occur by the time period 1992-1997, resulting in a higher percentage of technicians in the manufacturing process, while the cost of computers and software will continue to fall and become more widely available. Computer aided design is becoming a commercially viable system for design and geometric modeling, engineering analysis, kinematics, and drafting, and efforts to bridge the gap between CAD and CAM are indicated, with particular attention given to layering, wherein individual monitoring of different parts of the manufacturing process can be effected without crossover of unnecessary information. The potentials and barriers to the use of robotics are described, with the added optimism that displaced workers to date have moved up to jobs of higher skill and interest.

  8. Plasma accelerators

    SciTech Connect

    Ruth, R.D.; Chen, P.

    1986-03-01

    In this paper we discuss plasma accelerators which might provide high gradient accelerating fields suitable for TeV linear colliders. In particular we discuss two types of plasma accelerators which have been proposed, the Plasma Beat Wave Accelerator and the Plasma Wake Field Accelerator. We show that the electric fields in the plasma for both schemes are very similar, and thus the dynamics of the driven beams are very similar. The differences appear in the parameters associated with the driving beams. In particular to obtain a given accelerating gradient, the Plasma Wake Field Accelerator has a higher efficiency and a lower total energy for the driving beam. Finally, we show for the Plasma Wake Field Accelerator that one can accelerate high quality low emittance beams and, in principle, obtain efficiencies and energy spreads comparable to those obtained with conventional techniques.

  9. DFM for manufacturers and designers

    NASA Astrophysics Data System (ADS)

    Hurat, Philippe; Cote, Michel

    2005-11-01

    At 90nm and 65nm, the semiconductor industry is condemned to use 193nm steppers and an overwhelming amount of resolution enhancement techniques (RET). Even when using the best RET solution available, some designs are more amenable to manufacturing than others and their initial yield or startup yield is higher. Design for manufacturing (DFM) has been a hotly discussed topic in both electronic design automation (EDA) and manufacturing communities, and to date much debate remains regarding its precise definition, let alone the solution. However, it is rather intuitive that, whatever the solution is, DFM needs to simultaneously satisfy several objectives in terms of optimizing yield, manufacturing cost and manufacturing friendliness; being transparent to the designer; protecting manufacturing intellectual property (IP); and having a sensible implementation. In this paper, we will describe a suitable technology that satisfies the data information sharing to ensure that both designers and manufacturers fulfill the expected initial and volume yield expectations. We describe how this technology may be applied pre- and post-tapeout to fulfill both designer and manufactures requirements.

  10. Cellular Manufacturing Internet Performance Support System

    SciTech Connect

    Bohley, M.C.; Schwartz, M.E.

    1998-03-04

    The objective of this project was to develop an Internet-based electronic performance support system (EPSS) for cellular manufacturing providing hardware/software specifications, process descriptions, estimated cost savings, manufacturing simulations, training information, and service resources for government and industry users of Cincinnati Milacron machine tools and products. AlliedSignal Federal Manufacturing and Technologies (ASFM and T) used expertise in the areas of Internet design and multimedia creation to develop a performance support system (PSS) for the Internet with assistance from CM's subject matter experts from engineering, manufacturing, and technical support. Reference information was both created and re-purposed from other existing formats, then made available on the Internet. On-line references on cellular manufacturing operations include: definitions of cells and cellular manufacturing; illustrations on how cellular manufacturing improves part throughput, resource utilization, part quality, and manufacturing flexibility; illustrations on how cellular manufacturing reduces labor and overhead costs; identification of critical factors driving decisions toward cellular manufacturing; a method for identifying process improvement areas using cellular manufacturing; a method for customizing the size of cells for a specific site; a simulation for making a part using cellular manufacturing technology; and a glossary of terms and concepts.

  11. 10 CFR 51.54 - Environmental report-manufacturing license.

    Code of Federal Regulations, 2012 CFR

    2012-01-01

    ... 10 Energy 2 2012-01-01 2012-01-01 false Environmental report-manufacturing license. 51.54 Section... report—manufacturing license. (a) Each applicant for a manufacturing license under subpart F of part 52... Environmental Report—Manufacturing License.” The environmental report must address the costs and benefits...

  12. Research on advanced photovoltaic manufacturing technology

    SciTech Connect

    Jester, T.; Eberspacher, C. )

    1991-11-01

    This report outlines opportunities for significantly advancing the scale and economy of high-volume manufacturing of high-efficiency photovoltaic (PV) modules. We propose to pursue a concurrent effort to advance existing crystalline silicon module manufacturing technology and to implement thin film CuInSe{sub 2} (CIS) module manufacturing. This combination of commercial-scale manufacturing of high-efficiency crystalline silicon modules and of pilot-scale manufacturing of low-cost thin film CIS technology will support continued, rapid growth of the US PV industry.

  13. Accelerator physics: Surf's up at SLAC

    NASA Astrophysics Data System (ADS)

    Downer, Mike; Zgadzaj, Rafal

    2014-11-01

    A 'plasma afterburner' just 30 centimetres long accelerates electrons hundreds of times faster than giant conventional accelerators. The result may ultimately open up a low-cost technology for particle colliders. See Letter p.92

  14. Accurate molecular dynamics and nuclear quantum effects at low cost by multiple steps in real and imaginary time: Using density functional theory to accelerate wavefunction methods

    NASA Astrophysics Data System (ADS)

    Kapil, V.; VandeVondele, J.; Ceriotti, M.

    2016-02-01

    The development and implementation of increasingly accurate methods for electronic structure calculations mean that, for many atomistic simulation problems, treating light nuclei as classical particles is now one of the most serious approximations. Even though recent developments have significantly reduced the overhead for modeling the quantum nature of the nuclei, the cost is still prohibitive when combined with advanced electronic structure methods. Here we present how multiple time step integrators can be combined with ring-polymer contraction techniques (effectively, multiple time stepping in imaginary time) to reduce virtually to zero the overhead of modelling nuclear quantum effects, while describing inter-atomic forces at high levels of electronic structure theory. This is demonstrated for a combination of MP2 and semi-local DFT applied to the Zundel cation. The approach can be seamlessly combined with other methods to reduce the computational cost of path integral calculations, such as high-order factorizations of the Boltzmann operator or generalized Langevin equation thermostats.

  15. 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.

  16. 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.

  17. Testing of biomaterials, accelerated ageing.

    PubMed

    Prodinger, A; Krausler, S; Schima, H; Thoma, H; Wolner, E; Schneider, W

    1985-01-01

    The residual elongation is a critical property of materials used for manufacturing diaphragms of artificial hearts. It is therefore important to check goods received or to control manufactured diaphragms, whether their creep properties are within the required limits. Ordinary creep tests take at least several months, while the release of goods received or diaphragms manufactured should be possible within a few days. Acceleration of the creep test by increasing the test temperature permits an estimation whether the creep properties of a material are within the required limits within a week. PMID:3870605

  18. 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.

  19. Cincinnati Big Area Additive Manufacturing (BAAM)

    SciTech Connect

    Duty, Chad E.; Love, Lonnie J.

    2015-03-04

    Oak Ridge National Laboratory (ORNL) worked with Cincinnati Incorporated (CI) to demonstrate Big Area Additive Manufacturing which increases the speed of the additive manufacturing (AM) process by over 1000X, increases the size of parts by over 10X and shows a cost reduction of over 100X. ORNL worked with CI to transition the Big Area Additive Manufacturing (BAAM) technology from a proof-of-principle (TRL 2-3) demonstration to a prototype product stage (TRL 7-8).

  20. Accurate molecular dynamics and nuclear quantum effects at low cost by multiple steps in real and imaginary time: Using density functional theory to accelerate wavefunction methods.

    PubMed

    Kapil, V; VandeVondele, J; Ceriotti, M

    2016-02-01

    The development and implementation of increasingly accurate methods for electronic structure calculations mean that, for many atomistic simulation problems, treating light nuclei as classical particles is now one of the most serious approximations. Even though recent developments have significantly reduced the overhead for modeling the quantum nature of the nuclei, the cost is still prohibitive when combined with advanced electronic structure methods. Here we present how multiple time step integrators can be combined with ring-polymer contraction techniques (effectively, multiple time stepping in imaginary time) to reduce virtually to zero the overhead of modelling nuclear quantum effects, while describing inter-atomic forces at high levels of electronic structure theory. This is demonstrated for a combination of MP2 and semi-local DFT applied to the Zundel cation. The approach can be seamlessly combined with other methods to reduce the computational cost of path integral calculations, such as high-order factorizations of the Boltzmann operator or generalized Langevin equation thermostats. PMID:26851912

  1. Accelerating advanced-materials commercialization

    NASA Astrophysics Data System (ADS)

    Maine, Elicia; Seegopaul, Purnesh

    2016-05-01

    Long commercialization times, high capital costs and sustained uncertainty deter investment in innovation for advanced materials. With appropriate strategies, technology and market uncertainties can be reduced, and the commercialization of advanced materials accelerated.

  2. Cost Benefit Studies. Final Report.

    ERIC Educational Resources Information Center

    Weiner, Arthur; Marson, Arthur A.

    This document applies Dr. Mehar Aurora's method for conducting cost benefit studies to the Food Manufacturing Technology-Dairy and the Food Manufacturing Technology-Canning and Freezing programs offered by the Moraine Park Technical Institute. Costs to individual students enrolled in the programs include tuition, fees, housing, travel, books,…

  3. Measurement of manufacturing resolution for two photon polymerization structures with different manufacturing parameters

    NASA Astrophysics Data System (ADS)

    Chung, Tien-Tung; Li, Wan-Jou; Chen, Sheng-Yuan; Hoi, Chi-Hou

    2015-02-01

    This paper studied manufacturing resolutions of micro structures made by two photon polymerization (TPP) technology with different manufacturing parameters. The light source used for the TPP manufacturing system was a low-cost 532 nm Nd:YAG green laser, and the material used was commercial resin Photomer 3015. Two objective lenses, one with magnification of 100 times (100x) and numerical aperture (NA) of 1.3 and the other with 50x and NA0.8 were used in TPP production. The manufacturing resolution, which is also named as voxel size, changed with different manufacturing parameters such as laser power and exposure time. The measurement results of TPP structures manufactured with different manufacturing parameters indicated that the minimum line width produced by the 100x-NA1.3 lens could be reduced down to 67 nanometer (nm), which was quite good for TPP systems with low-cost Nd:YAG laser.

  4. FMS: The New Wave of Manufacturing Technology.

    ERIC Educational Resources Information Center

    Industrial Education, 1986

    1986-01-01

    Flexible manufacturing systems (FMS) are described as a marriage of all of the latest technologies--robotics, numerical control, CAD/CAM (computer-assisted design/computer-assisted manufacturing), etc.--into a cost-efficient, optimized production process yielding the greatest flexibility in making various parts. A typical curriculum to teach FMS…

  5. 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.

  6. Manufacturing development of DC-10 advanced rudder

    NASA Technical Reports Server (NTRS)

    Cominsky, A.

    1979-01-01

    The design, manufacture, and ground test activities during development of production methods for an advanced composite rudder for the DC-10 transport aircraft are described. The advanced composite aft rudder is satisfactory for airline service and a cost saving in a full production manufacturing mode is anticipated.

  7. Cloud manufacturing: a new manufacturing paradigm

    NASA Astrophysics Data System (ADS)

    Zhang, Lin; Luo, Yongliang; Tao, Fei; Li, Bo Hu; Ren, Lei; Zhang, Xuesong; Guo, Hua; Cheng, Ying; Hu, Anrui; Liu, Yongkui

    2014-03-01

    Combining with the emerged technologies such as cloud computing, the Internet of things, service-oriented technologies and high performance computing, a new manufacturing paradigm - cloud manufacturing (CMfg) - for solving the bottlenecks in the informatisation development and manufacturing applications is introduced. The concept of CMfg, including its architecture, typical characteristics and the key technologies for implementing a CMfg service platform, is discussed. Three core components for constructing a CMfg system, i.e. CMfg resources, manufacturing cloud service and manufacturing cloud are studied, and the constructing method for manufacturing cloud is investigated. Finally, a prototype of CMfg and the existing related works conducted by the authors' group on CMfg are briefly presented.

  8. Selected Applications of Virtual Reality in Manufacturing

    NASA Astrophysics Data System (ADS)

    Novak-Marcincin, Jozef

    2011-01-01

    Virtual reality (VR) has become an important and useful tool in science and engineering. VR applications cover a wide range of industrial areas from product design to analysis, from product prototyping to manufacturing. The design and manufacturing of a product can be viewed, evaluated and improved in a virtual environment before its prototype is made, which is an enormous cost saving. Virtual Manufacturing (VM) is the use of computer models and simulations of manufacturing processes to aid in the design and production of manufactured products. VM is the use of manufacturing-based simulations to optimize the design of product and processes for a specific manufacturing goal such as: design for assembly; quality; lean operations; and/or flexibility.

  9. Controlling high-throughput manufacturing at the nano-scale

    NASA Astrophysics Data System (ADS)

    Cooper, Khershed P.

    2013-09-01

    Interest in nano-scale manufacturing research and development is growing. The reason is to accelerate the translation of discoveries and inventions of nanoscience and nanotechnology into products that would benefit industry, economy and society. Ongoing research in nanomanufacturing is focused primarily on developing novel nanofabrication techniques for a variety of applications—materials, energy, electronics, photonics, biomedical, etc. Our goal is to foster the development of high-throughput methods of fabricating nano-enabled products. Large-area parallel processing and highspeed continuous processing are high-throughput means for mass production. An example of large-area processing is step-and-repeat nanoimprinting, by which nanostructures are reproduced again and again over a large area, such as a 12 in wafer. Roll-to-roll processing is an example of continuous processing, by which it is possible to print and imprint multi-level nanostructures and nanodevices on a moving flexible substrate. The big pay-off is high-volume production and low unit cost. However, the anticipated cost benefits can only be realized if the increased production rate is accompanied by high yields of high quality products. To ensure product quality, we need to design and construct manufacturing systems such that the processes can be closely monitored and controlled. One approach is to bring cyber-physical systems (CPS) concepts to nanomanufacturing. CPS involves the control of a physical system such as manufacturing through modeling, computation, communication and control. Such a closely coupled system will involve in-situ metrology and closed-loop control of the physical processes guided by physics-based models and driven by appropriate instrumentation, sensing and actuation. This paper will discuss these ideas in the context of controlling high-throughput manufacturing at the nano-scale.

  10. Lightweighting Automotive Materials for Increased Fuel Efficiency and Delivering Advanced Modeling and Simulation Capabilities to U.S. Manufacturers

    SciTech Connect

    Hale, Steve

    2013-09-11

    Abstract The National Center for Manufacturing Sciences (NCMS) worked with the U.S. Department of Energy (DOE), National Energy Technology Laboratory (NETL), to bring together research and development (R&D) collaborations to develop and accelerate the knowledgebase and infrastructure for lightweighting materials and manufacturing processes for their use in structural and applications in the automotive sector. The purpose/importance of this DOE program: • 2016 CAFÉ standards. • Automotive industry technology that shall adopt the insertion of lightweighting material concepts towards manufacturing of production vehicles. • Development and manufacture of advanced research tools for modeling and simulation (M&S) applications to reduce manufacturing and material costs. • U.S. competitiveness that will help drive the development and manufacture of the next generation of materials. NCMS established a focused portfolio of applied R&D projects utilizing lightweighting materials for manufacture into automotive structures and components. Areas that were targeted in this program: • Functionality of new lightweighting materials to meet present safety requirements. • Manufacturability using new lightweighting materials. • Cost reduction for the development and use of new lightweighting materials. The automotive industry’s future continuously evolves through innovation, and lightweight materials are key in achieving a new era of lighter, more efficient vehicles. Lightweight materials are among the technical advances needed to achieve fuel/energy efficiency and reduce carbon dioxide (CO2) emissions: • Establish design criteria methodology to identify the best materials for lightweighting. • Employ state-of-the-art design tools for optimum material development for their specific applications. • Match new manufacturing technology to production volume. • Address new process variability with new production-ready processes.

  11. Composite fuselage crown panel manufacturing technology

    NASA Technical Reports Server (NTRS)

    Willden, Kurtis; Metschan, S.; Grant, C.; Brown, T.

    1992-01-01

    Commercial fuselage structures contain significant challenges in attempting to save manufacturing costs with advanced composite technology. Assembly issues, material costs, and fabrication of elements with complex geometry are each expected to drive the cost of composite fuselage structures. Boeing's efforts under the NASA ACT program have pursued key technologies for low-cost, large crown panel fabrication. An intricate bond panel design and manufacturing concepts were selected based on the efforts of the Design Build Team (DBT). The manufacturing processes selected for the intricate bond design include multiple large panel fabrication with the Advanced Tow Placement (ATP) process, innovative cure tooling concepts, resin transfer molding of long fuselage frames, and utilization of low-cost material forms. The process optimization for final design/manufacturing configuration included factory simulations and hardware demonstrations. These efforts and other optimization tasks were instrumental in reducing cost by 18 percent and weight by 45 percent relative to an aluminum baseline. The qualitative and quantitative results of the manufacturing demonstrations were used to assess manufacturing risks and technology readiness.

  12. Photovoltaic manufacturing: Present status, future prospects, and research needs

    SciTech Connect

    Wolden, C.A.; Fthenakis, V.; Kurtin, J.; Baxter, J.; Repins, I.; Shasheen, S.; Torvik, J.; Rocket, A.; Aydil, E.

    2011-03-29

    In May 2010 the United States National Science Foundation sponsored a two-day workshop to review the state-of-the-art and research challenges in photovoltaic (PV) manufacturing. This article summarizes the major conclusions and outcomes from this workshop, which was focused on identifying the science that needs to be done to help accelerate PV manufacturing. A significant portion of the article focuses on assessing the current status of and future opportunities in the major PV manufacturing technologies. These are solar cells based on crystalline silicon (c-Si), thin films of cadmium telluride (CdTe), thin films of copper indium gallium diselenide, and thin films of hydrogenated amorphous and nanocrystalline silicon. Current trends indicate that the cost per watt of c-Si and CdTe solar cells are being reduced to levels beyond the constraints commonly associated with these technologies. With a focus on TW/yr production capacity, the issue of material availability is discussed along with the emerging technologies of dye-sensitized solar cells and organic photovoltaics that are potentially less constrained by elemental abundance. Lastly, recommendations are made for research investment, with an emphasis on those areas that are expected to have cross-cutting impact.

  13. Desktop Manufacturing Technologies.

    ERIC Educational Resources Information Center

    Snyder, Mark

    1991-01-01

    Desktop manufacturing is the use of data from a computer-assisted design system to construct actual models of an object. Emerging processes are stereolithography, laser sintering, ballistic particle manufacturing, laminated object manufacturing, and photochemical machining. (SK)

  14. Accelerated Reader.

    ERIC Educational Resources Information Center

    Education Commission of the States, Denver, CO.

    This paper provides an overview of Accelerated Reader, a system of computerized testing and record-keeping that supplements the regular classroom reading program. Accelerated Reader's primary goal is to increase literature-based reading practice. The program offers a computer-aided reading comprehension and management program intended to motivate…

  15. Low-Cost Illumination-Grade LEDs

    SciTech Connect

    Epler, John

    2013-08-31

    Solid State Lighting is a cost-effective, energy-conserving technology serving a rapidly expand- ing multi-billion dollar market. This program was designed to accelerate this lighting revolution by reducing the manufacturing cost of Illumination-Grade LEDs. The technical strategy was to investigate growth substrate alternatives to standard planar sapphire, select the most effective and compatible option, and demonstrate a significant increase in Lumen/$ with a marketable LED. The most obvious alternate substrate, silicon, was extensively studied in the first two years of the program. The superior thermal and mechanical properties of Si were expected to improve wavelength uniformity and hence color yield in the manufacture of high-power illumination- grade LEDs. However, improvements in efficiency and epitaxy uniformity on standard c-plane sapphire diminished the advantages of switching to Si. Furthermore, the cost of sapphire decreased significantly and the cost of processing Si devices using our thin film process was higher than expected. We concluded that GaN on Si was a viable technology but not a practical option for Philips Lumileds. Therefore in 2012 and 2013, we sought and received amendments which broadened the scope to include other substrates and extended the time of execution. Proprietary engineered substrates, off-axis (non-c-plane) sapphire, and c-plane patterned sapphire substrates (PSS) were all investigated in the final 18 months of this program. Excellent epitaxy quality was achieved on all three candidates; however we eliminated engineered substrates and non-c-plane sapphire because of their higher combined cost of substrate, device fabrication and packaging. Ultimately, by fabricating a flip-chip (FC) LED based upon c-plane PSS we attained a 42% reduction in LED manufacturing cost relative to our LUXEON Rebel product (Q1-2012). Combined with a flux gain from 85 to 102 Lm, the LUXEON Q delivered a 210% increase in Lm/$ over this time period. The

  16. 24 CFR 982.623 - Manufactured home space rental: Housing assistance payment.

    Code of Federal Regulations, 2011 CFR

    2011-04-01

    ... 24 Housing and Urban Development 4 2011-04-01 2011-04-01 false Manufactured home space rental... Special Housing Types Manufactured Home Space Rental § 982.623 Manufactured home space rental: Housing...) Manufactured home space cost minus the total tenant payment. (ii) The rent to owner for the manufactured...

  17. 24 CFR 982.623 - Manufactured home space rental: Housing assistance payment.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... 24 Housing and Urban Development 4 2010-04-01 2010-04-01 false Manufactured home space rental... Special Housing Types Manufactured Home Space Rental § 982.623 Manufactured home space rental: Housing...) Manufactured home space cost minus the total tenant payment. (ii) The rent to owner for the manufactured...

  18. 24 CFR 982.623 - Manufactured home space rental: Housing assistance payment.

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... 24 Housing and Urban Development 4 2012-04-01 2012-04-01 false Manufactured home space rental... Special Housing Types Manufactured Home Space Rental § 982.623 Manufactured home space rental: Housing...) Manufactured home space cost minus the total tenant payment. (ii) The rent to owner for the manufactured...

  19. 24 CFR 982.623 - Manufactured home space rental: Housing assistance payment.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... 24 Housing and Urban Development 4 2014-04-01 2014-04-01 false Manufactured home space rental... Special Housing Types Manufactured Home Space Rental § 982.623 Manufactured home space rental: Housing...) Manufactured home space cost minus the total tenant payment. (ii) The rent to owner for the manufactured...

  20. Recent Advances in Plasma Acceleration

    SciTech Connect

    Hogan, Mark

    2007-03-19

    The costs and the time scales of colliders intended to reach the energy frontier are such that it is important to explore new methods of accelerating particles to high energies. Plasma-based accelerators are particularly attractive because they are capable of producing accelerating fields that are orders of magnitude larger than those used in conventional colliders. In these accelerators a drive beam, either laser or particle, produces a plasma wave (wakefield) that accelerates charged particles. The ultimate utility of plasma accelerators will depend on sustaining ultra-high accelerating fields over a substantial length to achieve a significant energy gain. More than 42 GeV energy gain was achieved in an 85 cm long plasma wakefield accelerator driven by a 42 GeV electron drive beam in the Final Focus Test Beam (FFTB) Facility at SLAC. Most of the beam electrons lose energy to the plasma wave, but some electrons in the back of the same beam pulse are accelerated with a field of {approx}52 GV/m. This effectively doubles their energy, producing the energy gain of the 3 km long SLAC accelerator in less than a meter for a small fraction of the electrons in the injected bunch. Prospects for a drive-witness bunch configuration and high-gradient positron acceleration experiments planned for the SABER facility will be discussed.

  1. Turbine airfoil manufacturing technology

    SciTech Connect

    Kortovich, C.

    1995-10-01

    The efficiency and effectiveness of the gas turbine engine is directly related to the turbine inlet temperatures. The ability to increase these temperatures has occurred as a result of improvements in materials, design, and processing techniques. A generic sequence indicating the relationship of these factors to temperature capability is schematically shown in Figure 1 for aircraft engine and land based engine materials. A basic contribution that is not captured by the Figure is the significant improvement in process and manufacturing capability that has accompanied each of these innovations. It is this capability that has allowed the designs and innovations to be applied on a high volume, cost effective scale in the aircraft gas turbine market.

  2. Metrology for Fuel Cell Manufacturing

    SciTech Connect

    Stocker, Michael; Stanfield, Eric

    2015-02-04

    The project was divided into three subprojects. The first subproject is Fuel Cell Manufacturing Variability and Its Impact on Performance. The objective was to determine if flow field channel dimensional variability has an impact on fuel cell performance. The second subproject is Non-contact Sensor Evaluation for Bipolar Plate Manufacturing Process Control and Smart Assembly of Fuel Cell Stacks. The objective was to enable cost reduction in the manufacture of fuel cell plates by providing a rapid non-contact measurement system for in-line process control. The third subproject is Optical Scatterfield Metrology for Online Catalyst Coating Inspection of PEM Soft Goods. The objective was to evaluate the suitability of Optical Scatterfield Microscopy as a viable measurement tool for in situ process control of catalyst coatings.

  3. LINEAR ACCELERATOR

    DOEpatents

    Colgate, S.A.

    1958-05-27

    An improvement is presented in linear accelerators for charged particles with respect to the stable focusing of the particle beam. The improvement consists of providing a radial electric field transverse to the accelerating electric fields and angularly introducing the beam of particles in the field. The results of the foregoing is to achieve a beam which spirals about the axis of the acceleration path. The combination of the electric fields and angular motion of the particles cooperate to provide a stable and focused particle beam.

  4. 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.

  5. Accelerating the culture change!

    PubMed

    Klunk, S W; Panetta, J; Wooten, J

    1996-11-01

    Exide Electronics, a major supplier of uninterruptible power system equipment, embarked on a journey of changing a culture to improve quality, enhance customer responsiveness, and reduce costs. This case study examines the evolution of change over a period of seven years, with particular emphasis on the most recent years, 1992 through 1995. The article focuses on the Raleigh plant operations and describes how each succeeding year built on the successes and fixed the shortcomings of the prior years to accelerate the culture change, including corrective action and continuous improvement processes, organizational structures, expectations, goals, achievements, and pitfalls. The real challenge to changing the culture was structuring a dynamic approach to accelerate change! The presentation also examines how the evolutionary process itself can be created and accelerated through ongoing communication, regular feedback of progress and goals, constant evaluation and direction of the process, and measuring and paying for performance. PMID:10162360

  6. Hydrogen manufacturing using plasma reformers

    SciTech Connect

    Bromberg, L.; Cohn, D.R.; Rabinovich, A.; Hochgreb, S.; O`Brien, C.

    1996-10-01

    Manufacturing of hydrogen from hydrocarbon fuels is needed for a variety of applications. These applications include fuel cells used in stationary electric power production and in vehicular propulsion. Hydrogen can also be used for various combustion engine systems. There is a wide range of requirements on the capacity of the hydrogen manufacturing system, the purity of the hydrogen fuel, and capability for rapid response. The overall objectives of a hydrogen manufacturing facility are to operate with high availability at the lowest possible cost and to have minimal adverse environmental impact. Plasma technology has potential to significantly alleviate shortcomings of conventional means of manufacturing hydrogen. These shortcomings include cost and deterioration of catalysts; limitations on hydrogen production from heavy hydrocarbons; limitations on rapid response; and size and weight requirements. In addition, use of plasma technology could provide for a greater variety of operating modes; in particular the possibility of virtual elimination of CO{sub 2} production by pyrolytic operation. This mode of hydrogen production may be of increasing importance due to recent additional evidence of global warming.

  7. Exploring Manufacturing Technology.

    ERIC Educational Resources Information Center

    Iley, John; And Others

    These teacher's materials for an eight-unit course were developed to help students develop technological literacy, career exploration, and problem-solving skills relative to the manufacturing industries. The eight units include an overview of manufacturing, manufacturing enterprises and systems, manufacturing materials and selection, manufacturing…

  8. The Telemetry Agile Manufacturing Effort

    SciTech Connect

    Brown, K.D.

    1995-01-01

    The Telemetry Agile Manufacturing Effort (TAME) is an agile enterprising demonstration sponsored by the US Department of Energy (DOE). The project experimented with new approaches to product realization and assessed their impacts on performance, cost, flow time, and agility. The purpose of the project was to design the electrical and mechanical features of an integrated telemetry processor, establish the manufacturing processes, and produce an initial production lot of two to six units. This paper outlines the major methodologies utilized by the TAME, describes the accomplishments that can be attributed to each methodology, and finally, examines the lessons learned and explores the opportunities for improvement associated with the overall effort. The areas for improvement are discussed relative to an ideal vision of the future for agile enterprises. By the end of the experiment, the TAME reduced production flow time by approximately 50% and life cycle cost by more than 30%. Product performance was improved compared with conventional DOE production approaches.

  9. Acceleration switch

    DOEpatents

    Abbin, J.P. Jr.; Devaney, H.F.; Hake, L.W.

    1979-08-29

    The disclosure relates to an improved integrating acceleration switch of the type having a mass suspended within a fluid filled chamber, with the motion of the mass initially opposed by a spring and subsequently not so opposed.

  10. Acceleration switch

    DOEpatents

    Abbin, Jr., Joseph P.; Devaney, Howard F.; Hake, Lewis W.

    1982-08-17

    The disclosure relates to an improved integrating acceleration switch of the type having a mass suspended within a fluid filled chamber, with the motion of the mass initially opposed by a spring and subsequently not so opposed.

  11. ION ACCELERATOR

    DOEpatents

    Bell, J.S.

    1959-09-15

    An arrangement for the drift tubes in a linear accelerator is described whereby each drift tube acts to shield the particles from the influence of the accelerating field and focuses the particles passing through the tube. In one embodiment the drift tube is splii longitudinally into quadrants supported along the axis of the accelerator by webs from a yoke, the quadrants. webs, and yoke being of magnetic material. A magnetic focusing action is produced by energizing a winding on each web to set up a magnetic field between adjacent quadrants. In the other embodiment the quadrants are electrically insulated from each other and have opposite polarity voltages on adjacent quadrants to provide an electric focusing fleld for the particles, with the quadrants spaced sufficienily close enough to shield the particles within the tube from the accelerating electric field.

  12. Additive Manufacturing: From Rapid Prototyping to Flight

    NASA Technical Reports Server (NTRS)

    Prater, Tracie

    2015-01-01

    Additive manufacturing (AM) offers tremendous promise for the rocket propulsion community. Foundational work must be performed to ensure the safe performance of AM parts. Government, industry, and academia must collaborate in the characterization, design, modeling, and process control to accelerate the certification of AM parts for human-rated flight.

  13. LINEAR ACCELERATOR

    DOEpatents

    Christofilos, N.C.; Polk, I.J.

    1959-02-17

    Improvements in linear particle accelerators are described. A drift tube system for a linear ion accelerator reduces gap capacity between adjacent drift tube ends. This is accomplished by reducing the ratio of the diameter of the drift tube to the diameter of the resonant cavity. Concentration of magnetic field intensity at the longitudinal midpoint of the external sunface of each drift tube is reduced by increasing the external drift tube diameter at the longitudinal center region.

  14. Cost targets for domestic fuel cell CHP

    NASA Astrophysics Data System (ADS)

    Staffell, I.; Green, R.; Kendall, K.

    Fuel cells have the potential to reduce domestic energy bills by providing both heat and power at the point of use, generating high value electricity from a low cost fuel. However, the cost of installing the fuel cell must be sufficiently low to be recovered by the savings made over its lifetime. A computer simulation is used to estimate the savings and cost targets for fuel cell CHP systems. Two pitfalls of this kind of simulation are addressed: the selection of representative performance figures for fuel cells, and the range of houses from which energy demand data was taken. A meta-study of the current state of the art is presented, and used with 102 house-years of demand to simulate the range of economic performance expected from four fuel cell technologies within the UK domestic CHP market. Annual savings relative to a condensing boiler are estimated at €170-300 for a 1 kWe fuel cell, giving a target cost of €350-625 kW -1 for any fuel cell technology that can demonstrate a 2.5-year lifetime. Increasing lifetime and reducing fuel cell capacity are identified as routes to accelerated market entry. The importance of energy demand is seen to outweigh both economic and technical performance assumptions, while manufacture cost and system lifetime are highlighted as the only significant differences between the technologies considered. SOFC are considered to have the greatest potential, but uncertainty in the assumptions used precludes any clear-cut judgement.

  15. 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.

  16. Spraying Techniques for Large Scale Manufacturing of PEM-FC Electrodes

    NASA Astrophysics Data System (ADS)

    Hoffman, Casey J.

    Fuel cells are highly efficient energy conversion devices that represent one part of the solution to the world's current energy crisis in the midst of global climate change. When supplied with the necessary reactant gasses, fuel cells produce only electricity, heat, and water. The fuel used, namely hydrogen, is available from many sources including natural gas and the electrolysis of water. If the electricity for electrolysis is generated by renewable energy (e.g., solar and wind power), fuel cells represent a completely 'green' method of producing electricity. The thought of being able to produce electricity to power homes, vehicles, and other portable or stationary equipment with essentially zero environmentally harmful emissions has been driving academic and industrial fuel cell research and development with the goal of successfully commercializing this technology. Unfortunately, fuel cells cannot achieve any appreciable market penetration at their current costs. The author's hypothesis is that: the development of automated, non-contact deposition methods for electrode manufacturing will improve performance and process flexibility, thereby helping to accelerate the commercialization of PEMFC technology. The overarching motivation for this research was to lower the cost of manufacturing fuel cell electrodes and bring the technology one step closer to commercial viability. The author has proven this hypothesis through a detailed study of two non-contact spraying methods. These scalable deposition systems were incorporated into an automated electrode manufacturing system that was designed and built by the author for this research. The electrode manufacturing techniques developed by the author have been shown to produce electrodes that outperform a common lab-scale contact method that was studied as a baseline, as well as several commercially available electrodes. In addition, these scalable, large scale electrode manufacturing processes developed by the author are

  17. Advanced Technology Composite Fuselage - Manufacturing

    NASA Technical Reports Server (NTRS)

    Wilden, K. S.; Harris, C. G.; Flynn, B. W.; Gessel, M. G.; Scholz, D. B.; Stawski, S.; Winston, V.

    1997-01-01

    The goal of Boeing's Advanced Technology Composite Aircraft Structures (ATCAS) program is to develop the technology required for cost-and weight-efficient use of composite materials in transport fuselage structure. Carbon fiber reinforced epoxy was chosen for fuselage skins and stiffening elements, and for passenger and cargo floor structures. The automated fiber placement (AFP) process was selected for fabrication of stringer-stiffened and sandwich skin panels. Circumferential and window frames were braided and resin transfer molded (RTM'd). Pultrusion was selected for fabrication of floor beams and constant-section stiffening elements. Drape forming was chosen for stringers and other stiffening elements cocured to skin structures. Significant process development efforts included AFP, braiding, RTM, autoclave cure, and core blanket fabrication for both sandwich and stiffened-skin structure. Outer-mold-line and inner-mold-line tooling was developed for sandwich structures and stiffened-skin structure. The effect of design details, process control and tool design on repeatable, dimensionally stable, structure for low cost barrel assembly was assessed. Subcomponent panels representative of crown, keel, and side quadrant panels were fabricated to assess scale-up effects and manufacturing anomalies for full-scale structures. Manufacturing database including time studies, part quality, and manufacturing plans were generated to support the development of designs and analytical models to access cost, structural performance, and dimensional tolerance.

  18. Overview of Accelerator Applications in Energy

    NASA Astrophysics Data System (ADS)

    Garnett, Robert W.; Sheffield, Richard L.

    An overview of the application of accelerators and accelerator technology in energy is presented. Applications span a broad range of cost, size, and complexity and include large-scale systems requiring high-power or high-energy accelerators to drive subcritical reactors for energy production or waste transmutation, as well as small-scale industrial systems used to improve oil and gas exploration and production. The enabling accelerator technologies will also be reviewed and future directions discussed.

  19. Dielectric laser accelerators

    NASA Astrophysics Data System (ADS)

    England, R. Joel; Noble, Robert J.; Bane, Karl; Dowell, David H.; Ng, Cho-Kuen; Spencer, James E.; Tantawi, Sami; Wu, Ziran; Byer, Robert L.; Peralta, Edgar; Soong, Ken; Chang, Chia-Ming; Montazeri, Behnam; Wolf, Stephen J.; Cowan, Benjamin; Dawson, Jay; Gai, Wei; Hommelhoff, Peter; Huang, Yen-Chieh; Jing, Chunguang; McGuinness, Christopher; Palmer, Robert B.; Naranjo, Brian; Rosenzweig, James; Travish, Gil; Mizrahi, Amit; Schachter, Levi; Sears, Christopher; Werner, Gregory R.; Yoder, Rodney B.

    2014-10-01

    The use of infrared lasers to power optical-scale lithographically fabricated particle accelerators is a developing area of research that has garnered increasing interest in recent years. The physics and technology of this approach is reviewed, which is referred to as dielectric laser acceleration (DLA). In the DLA scheme operating at typical laser pulse lengths of 0.1 to 1 ps, the laser damage fluences for robust dielectric materials correspond to peak surface electric fields in the GV /m regime. The corresponding accelerating field enhancement represents a potential reduction in active length of the accelerator between 1 and 2 orders of magnitude. Power sources for DLA-based accelerators (lasers) are less costly than microwave sources (klystrons) for equivalent average power levels due to wider availability and private sector investment. Because of the high laser-to-particle coupling efficiency, required pulse energies are consistent with tabletop microJoule class lasers. Combined with the very high (MHz) repetition rates these lasers can provide, the DLA approach appears promising for a variety of applications, including future high-energy physics colliders, compact light sources, and portable medical scanners and radiative therapy machines.

  20. Acceleration Studies

    NASA Technical Reports Server (NTRS)

    Rogers, Melissa J. B.

    1993-01-01

    Work to support the NASA MSFC Acceleration Characterization and Analysis Project (ACAP) was performed. Four tasks (analysis development, analysis research, analysis documentation, and acceleration analysis) were addressed by parallel projects. Work concentrated on preparation for and implementation of near real-time SAMS data analysis during the USMP-1 mission. User support documents and case specific software documentation and tutorials were developed. Information and results were presented to microgravity users. ACAP computer facilities need to be fully implemented and networked, data resources must be cataloged and accessible, future microgravity missions must be coordinated, and continued Orbiter characterization is necessary.

  1. The Capital Intensity of Photovoltaics Manufacturing

    SciTech Connect

    Basore, Paul

    2015-10-19

    Factory capital expenditure (capex) for photovoltaic (PV) module manufacturing strongly influences the per-unit cost of a c-Si module. This provides a significant opportunity to address the U.S. DOE SunShot module price target through capex innovation. Innovation options to reduce the capex of PV manufacturing include incremental and disruptive process innovation with c-Si, platform innovations, and financial approaches. and financial approaches.

  2. Agile manufacturing from a statistical perspective

    SciTech Connect

    Easterling, R.G.

    1995-10-01

    The objective of agile manufacturing is to provide the ability to quickly realize high-quality, highly-customized, in-demand products at a cost commensurate with mass production. More broadly, agility in manufacturing, or any other endeavor, is defined as change-proficiency; the ability to thrive in an environment of unpredictable change. This report discusses the general direction of the agile manufacturing initiative, including research programs at the National Institute of Standards and Technology (NIST), the Department of Energy, and other government agencies, but focuses on agile manufacturing from a statistical perspective. The role of statistics can be important because agile manufacturing requires the collection and communication of process characterization and capability information, much of which will be data-based. The statistical community should initiate collaborative work in this important area.

  3. Plasma accelerator

    DOEpatents

    Wang, Zhehui; Barnes, Cris W.

    2002-01-01

    There has been invented an apparatus for acceleration of a plasma having coaxially positioned, constant diameter, cylindrical electrodes which are modified to converge (for a positive polarity inner electrode and a negatively charged outer electrode) at the plasma output end of the annulus between the electrodes to achieve improved particle flux per unit of power.

  4. Accelerated Achievement

    ERIC Educational Resources Information Center

    Ford, William J.

    2010-01-01

    This article focuses on the accelerated associate degree program at Ivy Tech Community College (Indiana) in which low-income students will receive an associate degree in one year. The three-year pilot program is funded by a $2.3 million grant from the Lumina Foundation for Education in Indianapolis and a $270,000 grant from the Indiana Commission…

  5. ACCELERATION INTEGRATOR

    DOEpatents

    Pope, K.E.

    1958-01-01

    This patent relates to an improved acceleration integrator and more particularly to apparatus of this nature which is gyrostabilized. The device may be used to sense the attainment by an airborne vehicle of a predetermined velocitv or distance along a given vector path. In its broad aspects, the acceleration integrator utilizes a magnetized element rotatable driven by a synchronous motor and having a cylin drical flux gap and a restrained eddy- current drag cap deposed to move into the gap. The angular velocity imparted to the rotatable cap shaft is transmitted in a positive manner to the magnetized element through a servo feedback loop. The resultant angular velocity of tae cap is proportional to the acceleration of the housing in this manner and means may be used to measure the velocity and operate switches at a pre-set magnitude. To make the above-described dcvice sensitive to acceleration in only one direction the magnetized element forms the spinning inertia element of a free gyroscope, and the outer housing functions as a gimbal of a gyroscope.

  6. Particle acceleration

    NASA Technical Reports Server (NTRS)

    Vlahos, L.; Machado, M. E.; Ramaty, R.; Murphy, R. J.; Alissandrakis, C.; Bai, T.; Batchelor, D.; Benz, A. O.; Chupp, E.; Ellison, D.

    1986-01-01

    Data is compiled from Solar Maximum Mission and Hinothori satellites, particle detectors in several satellites, ground based instruments, and balloon flights in order to answer fundamental questions relating to: (1) the requirements for the coronal magnetic field structure in the vicinity of the energization source; (2) the height (above the photosphere) of the energization source; (3) the time of energization; (4) transistion between coronal heating and flares; (5) evidence for purely thermal, purely nonthermal and hybrid type flares; (6) the time characteristics of the energization source; (7) whether every flare accelerates protons; (8) the location of the interaction site of the ions and relativistic electrons; (9) the energy spectra for ions and relativistic electrons; (10) the relationship between particles at the Sun and interplanetary space; (11) evidence for more than one acceleration mechanism; (12) whether there is single mechanism that will accelerate particles to all energies and also heat the plasma; and (13) how fast the existing mechanisms accelerate electrons up to several MeV and ions to 1 GeV.

  7. Energy Use in Manufacturing

    EIA Publications

    2006-01-01

    This report addresses both manufacturing energy consumption and characteristics of the manufacturing economy related to energy consumption. In addition, special sections on fuel switching capacity and energy-management activities between 1998 and 2002 are also featured in this report.

  8. Feed Formulation and Manufacture

    Technology Transfer Automated Retrieval System (TEKTRAN)

    This chapter provides information on feed formulation and manufacture. To formulate and manufacture high quality fish feeds, including tilapia feeds, one should have knowledge of nutrient requirements, nutrient composition, digestibility, and availability of feed ingredients; impacts of manufacturin...

  9. Electromagnetic modeling in accelerator designs

    SciTech Connect

    Cooper, R.K.; Chan, K.C.D.

    1990-01-01

    Through the years, electromagnetic modeling using computers has proved to be a cost-effective tool for accelerator designs. Traditionally, electromagnetic modeling of accelerators has been limited to resonator and magnet designs in two dimensions. In recent years with the availability of powerful computers, electromagnetic modeling of accelerators has advanced significantly. Through the above conferences, it is apparent that breakthroughs have been made during the last decade in two important areas: three-dimensional modeling and time-domain simulation. Success in both these areas have been made possible by the increasing size and speed of computers. In this paper, the advances in these two areas will be described.

  10. Breaking Barriers in Polymer Additive Manufacturing

    SciTech Connect

    Love, Lonnie J; Duty, Chad E; Post, Brian K; Lind, Randall F; Lloyd, Peter D; Kunc, Vlastimil; Peter, William H; Blue, Craig A

    2015-01-01

    Additive Manufacturing (AM) enables the creation of complex structures directly from a computer-aided design (CAD). There are limitations that prevent the technology from realizing its full potential. AM has been criticized for being slow and expensive with limited build size. Oak Ridge National Laboratory (ORNL) has developed a large scale AM system that improves upon each of these areas by more than an order of magnitude. The Big Area Additive Manufacturing (BAAM) system directly converts low cost pellets into a large, three-dimensional part at a rate exceeding 25 kg/h. By breaking these traditional barriers, it is possible for polymer AM to penetrate new manufacturing markets.

  11. Large volume manufacture of dymalloy

    SciTech Connect

    1998-06-22

    The purpose of this research was to test the commercial viability and feasibility of Dymalloy, a composite material to measure thermal conductivity. Dymalloy was developed as part of a CRADA with Sun Microsystems. Sun Microsystems was a potential end user of Dymalloy as a substrate for MCMS. Sun had no desire to be involved in the manufacture of this material. The goal of this small business CRADA with Spectra Mat was to establish the high volume commercial manufacturing industry source for Dymalloy required by an end-user such as Sun Microsystems. The difference between the fabrication technique developed during the CRADA and this proposed work related to the mechanical technique of coating the diamond powder. Mechanical parts for the high-volume diamond powder coating process existed; however, they needed to be installed in an existing coating system for evaluation. Sputtering systems similar to the one required for this project were available at LLNL. Once the diamond powder was coated, both LLNL and Spectra Mat could make and test the Dymalloy composites. Spectra Mat manufactured Dymalloy composites in order to evaluate and establish a reasonable cost estimate on their existing processing capabilities. This information was used by Spectra Mat to define the market and cost-competitive products that could be commercialized from this new substrate material.

  12. Acylinder and freeform optical manufacturing

    NASA Astrophysics Data System (ADS)

    Fess, Edward; Wolfs, Frank; DeFisher, Scott; Ross, James

    2015-10-01

    Aspheric cylinders have the ability to improve optical performance over standard cylindrical surfaces. Over the last several years there has also been development into the application and functionality of utilizing freeform surfaces to improve optical performance. Freeforms have the ability to not only improve image quality over a greater field of view, but can open up the design space of an optical system making it more compact. Freeform geometries, much like aspheric cylinders, may not have an axis of rotation to spin the optic about during manufacturing. This leads to costly fabrication processes and custom metrology set ups, which may inhibit their use. Over the last several years, OptiPro Systems has developed and optimized our eSX grinding, UFF and USF polishing, UltraSurf metrology, and ProSurf software programming technologies to make the processing of these complex geometries much easier and deterministic. In this paper we will discuss the challenges associated with manufacturing complex shapes like aspheric cylinders as well as freeform geometries, and how several technologies working together can overcome them. The technologies focus on metrology feedback to a grinding and polishing machine that is controlled through an iterative computer aided manufacturing software system. We will also present examples of these hard to manufacture shapes with results.

  13. Prospects for Accelerator Technology

    NASA Astrophysics Data System (ADS)

    Todd, Alan

    2011-02-01

    Accelerator technology today is a greater than US$5 billion per annum business. Development of higher-performance technology with improved reliability that delivers reduced system size and life cycle cost is expected to significantly increase the total accelerator technology market and open up new application sales. Potential future directions are identified and pitfalls in new market penetration are considered. Both of the present big market segments, medical radiation therapy units and semiconductor ion implanters, are approaching the "maturity" phase of their product cycles, where incremental development rather than paradigm shifts is the norm, but they should continue to dominate commercial sales for some time. It is anticipated that large discovery-science accelerators will continue to provide a specialty market beset by the unpredictable cycles resulting from the scale of the projects themselves, coupled with external political and economic drivers. Although fraught with differing market entry difficulties, the security and environmental markets, together with new, as yet unrealized, industrial material processing applications, are expected to provide the bulk of future commercial accelerator technology growth.

  14. The Present, Mid-Term, and Long-Term Supply Curves for Tellurium; and Updates in the Results from NREL's CdTe PV Module Manufacturing Cost Model (Presentation)

    SciTech Connect

    Woodhouse, M.; Goodrich, A.; Redlinger, M.; Lokanc, M.; Eggert, R.

    2013-09-01

    For those PV technologies that rely upon Te, In, and Ga, first-order observations and calculations hint that there may be resource constraints that could inhibit their successful deployment at a SunShot level. These are only first-order approximations, however, and the possibility for an expansion in global Te, In, and Ga supplies needs to be considered in the event that there are upward revisions in their demand and prices.In this study, we examine the current, mid-term, and long-term prospects of Tellurium (Te) for use in PV. We find that the current global supply base of Te would support <10 GW of annual traditional CdTe PV manufacturing production. But as for the possibility that the supply base for Te might be expanded, after compiling several preliminary cumulative availability curves we find that there may be significant upside potential in the supply base for this element - principally vis a vis increasing demand and higher prices. Primarily by reducing the Tellurium intensity in manufacturing and by increasing the recovery efficiency of Te in Cu refining processes, we calculate that it may prove affordable to PV manufacturers to expand the supply base for Te such that 100 GW, or greater, of annual CdTe PV production is possible in the 2030 - 2050 timeframe.

  15. Next Generation Print-based Manufacturing for Photovoltaics and Solid State Lighting

    SciTech Connect

    Sue A. Carter

    2012-09-07

    For the grand challenge of reducing our energy and carbon footprint, the development of renewable energy and energy efficient technologies offer a potential solution. Energy technologies can reduce our dependence on foreign oil as well as the energy consumed by the petroleum industry, the leading consumer of energy by a U.S. industry sector. Nonetheless, the manufacturing processes utilized to manufacture equipment for alternative energy technologies often involve energy-intensive processes. This undermines some of the advantages to moving to 'green' technologies in the first place. Our answer to the Industrial Technology Program's (ITP) Grand Challenge FOA was to develop a transformational low cost manufacturing process for plastic-based photovoltaics that will lower by over 50% both energy consumption and greenhouse emissions and offer a return-of-investment of over 20%. We demonstrated a Luminescent Solar Concentrator fabricated on a plastic acrylic substrate (i.e. no glass) that increases the power output of the PV cell by 2.2x with a 2% power efficiency as well as an LSC with a 7% power efficiency that increased the power output from the PV cells by 35%. S large area 20-inch x 60-inch building-integrated photovoltaic window was fabricated using contract manufacturing with a 4% power efficiency which improved the power output of the PV cell by over 50%. In addition, accelerated lifetimes of the luminescent material demonstrate lifetimes of 20-years.

  16. Heliostat cost-analysis tool

    NASA Astrophysics Data System (ADS)

    Brandt, L. D.; Chang, R. E.

    1981-10-01

    A heliostat cost analysis tool (HELCAT) that processes manufacturing transportation, and installation cost data was developed which provides a consistent structure for cost analyses. The HELCAT calculates a representation product price based on direct input data and various economic, financial, and accounting assumptions. The characteristics of this tool and its initial application in the evaluation of second generation heliostat cost estimates are discussed. A set of nominal economic and financial parameters is also suggested.

  17. Compact accelerator

    DOEpatents

    Caporaso, George J.; Sampayan, Stephen E.; Kirbie, Hugh C.

    2007-02-06

    A compact linear accelerator having at least one strip-shaped Blumlein module which guides a propagating wavefront between first and second ends and controls the output pulse at the second end. Each Blumlein module has first, second, and third planar conductor strips, with a first dielectric strip between the first and second conductor strips, and a second dielectric strip between the second and third conductor strips. Additionally, the compact linear accelerator includes a high voltage power supply connected to charge the second conductor strip to a high potential, and a switch for switching the high potential in the second conductor strip to at least one of the first and third conductor strips so as to initiate a propagating reverse polarity wavefront(s) in the corresponding dielectric strip(s).

  18. Photovoltaic manufacturing technology, Phase 1

    SciTech Connect

    Izu, M. )

    1992-03-01

    This report examines manufacturing multiple-band-gap, multiple- junction solar cells and photovoltaic modules. Amorphous silicon alloy material is deposited (using microwave plasma-assisted chemical vapor deposition) on a stainless-steel substrate using a roll-to-roll process that is continuous and automated. Rapid thermal equilibration of the metal substrate allows rapid throughput of large-area devices in smaller production machines. Potential improvements in the design, deposition, and module fabrication process are described. Problems are also discussed that could impede using these potential improvements. Energy Conversion Devices, Inc. (ECD) proposes cost and time estimates for investigating and solving these problems. Manufacturing modules for less than $1.00 per peak watt and stable module efficiencies of greater than 10% are near-term goals proposed by ECD. 18 refs.

  19. Manufacturing considerations for cockpit AMLCDs

    NASA Astrophysics Data System (ADS)

    Cannella, Vincent; Lambie, Michael G.

    1994-06-01

    Most important decisions in planning the manufacturing of AMLCDs are interrelated. Plant layout depends upon machine design and process flow, which depend upon process design, material choices and handling techniques, which in turn depend upon available machine technology as well as product design. All of these must be subordinate to specifications of product performance and cost. Since many production processes and issues are interdependent, overlapping, or even conflicting, most planning decisions do not have a simple linear path. We assume a decision sequence for manufacturing planning as follows: product specification, product design, process specification and design, production machine specification and design, facility specification and design, operational design. We will examine options, interrelations and conflicts in several of these areas and discuss the problems and challenges which provide directions for future improvements.

  20. Additive Manufacturing of Hybrid Circuits

    NASA Astrophysics Data System (ADS)

    Sarobol, Pylin; Cook, Adam; Clem, Paul G.; Keicher, David; Hirschfeld, Deidre; Hall, Aaron C.; Bell, Nelson S.

    2016-07-01

    There is a rising interest in developing functional electronics using additively manufactured components. Considerations in materials selection and pathways to forming hybrid circuits and devices must demonstrate useful electronic function; must enable integration; and must complement the complex shape, low cost, high volume, and high functionality of structural but generally electronically passive additively manufactured components. This article reviews several emerging technologies being used in industry and research/development to provide integration advantages of fabricating multilayer hybrid circuits or devices. First, we review a maskless, noncontact, direct write (DW) technology that excels in the deposition of metallic colloid inks for electrical interconnects. Second, we review a complementary technology, aerosol deposition (AD), which excels in the deposition of metallic and ceramic powder as consolidated, thick conformal coatings and is additionally patternable through masking. Finally, we show examples of hybrid circuits/devices integrated beyond 2-D planes, using combinations of DW or AD processes and conventional, established processes.

  1. Cost Effective Prototyping

    NASA Technical Reports Server (NTRS)

    Wickman, Jerry L.; Kundu, Nikhil K.

    1996-01-01

    This laboratory exercise seeks to develop a cost effective prototype development. The exercise has the potential of linking part design, CAD, mold development, quality control, metrology, mold flow, materials testing, fixture design, automation, limited parts production and other issues as related to plastics manufacturing.

  2. BICEP's acceleration

    SciTech Connect

    Contaldi, Carlo R.

    2014-10-01

    The recent Bicep2 [1] detection of, what is claimed to be primordial B-modes, opens up the possibility of constraining not only the energy scale of inflation but also the detailed acceleration history that occurred during inflation. In turn this can be used to determine the shape of the inflaton potential V(φ) for the first time — if a single, scalar inflaton is assumed to be driving the acceleration. We carry out a Monte Carlo exploration of inflationary trajectories given the current data. Using this method we obtain a posterior distribution of possible acceleration profiles ε(N) as a function of e-fold N and derived posterior distributions of the primordial power spectrum P(k) and potential V(φ). We find that the Bicep2 result, in combination with Planck measurements of total intensity Cosmic Microwave Background (CMB) anisotropies, induces a significant feature in the scalar primordial spectrum at scales k∼ 10{sup -3} Mpc {sup -1}. This is in agreement with a previous detection of a suppression in the scalar power [2].

  3. Accelerators in Research and Industry

    NASA Astrophysics Data System (ADS)

    Norton, G. A.

    1997-10-01

    Over the last sixty years the applications of ion beam accelerators has grown from basic nuclear structure research to the manufacture, preservation, and development of a large number of products which directly affect every day life. In addition, ion beam accelerators continue to provide a unique contribution in both basic and applied research in fields from art history to zoology. Applications fit into two main groups, materials analysis and materials modification. Most materials analysis include routine use of Rutherford Backscattering (RBS) and particle induced x-ray emission (PIXE) with new developments in analysis techniques being developed for remote elemental detection of plastic explosives and drugs. Existing accelerator systems and new accelerator systems are being developed for use in the area of accelerator based mass spectrometry (AMS) which is having a profound affect on a wide variety of fields which rely on counting extremely rare isotopes in very small samples. Accelerators used for materials modification continue to have a significant economic impact in the field of semiconductors and the development of new semiconductor and other high technology products.

  4. EM Structure Based and Vacuum Acceleration

    SciTech Connect

    Colby, E.R.; /SLAC

    2005-09-27

    The importance of particle acceleration may be judged from the number of applications which require some sort of accelerated beam. In addition to accelerator-based high energy physics research, non-academic applications include medical imaging and treatment, structural biology by x-ray diffraction, pulse radiography, cargo inspection, material processing, food and medical instrument sterilization, and so on. Many of these applications are already well served by existing technologies and will profit only marginally from developments in accelerator technology. Other applications are poorly served, such as structural biology, which is conducted at synchrotron radiation facilities, and medical treatment using proton accelerators, the machines for which are rare because they are complex and costly. Developments in very compact, high brightness and high gradient accelerators will change how accelerators are used for such applications, and potentially enable new ones. Physical and technical issues governing structure-based and vacuum acceleration of charged particles are reviewed, with emphasis on practical aspects.

  5. Advanced concepts for acceleration

    SciTech Connect

    Keefe, D.

    1986-07-01

    Selected examples of advanced accelerator concepts are reviewed. Such plasma accelerators as plasma beat wave accelerator, plasma wake field accelerator, and plasma grating accelerator are discussed particularly as examples of concepts for accelerating relativistic electrons or positrons. Also covered are the pulsed electron-beam, pulsed laser accelerator, inverse Cherenkov accelerator, inverse free-electron laser, switched radial-line accelerators, and two-beam accelerator. Advanced concepts for ion acceleration discussed include the electron ring accelerator, excitation of waves on intense electron beams, and two-wave combinations. (LEW)

  6. Accelerators and the Accelerator Community

    SciTech Connect

    Malamud, Ernest; Sessler, Andrew

    2008-06-01

    In this paper, standing back--looking from afar--and adopting a historical perspective, the field of accelerator science is examined. How it grew, what are the forces that made it what it is, where it is now, and what it is likely to be in the future are the subjects explored. Clearly, a great deal of personal opinion is invoked in this process.

  7. Accelerating Commercial Remote Sensing

    NASA Technical Reports Server (NTRS)

    1995-01-01

    Through the Visiting Investigator Program (VIP) at Stennis Space Center, Community Coffee was able to use satellites to forecast coffee crops in Guatemala. Using satellite imagery, the company can produce detailed maps that separate coffee cropland from wild vegetation and show information on the health of specific crops. The data can control coffee prices and eventually may be used to optimize application of fertilizers, pesticides and irrigation. This would result in maximal crop yields, minimal pollution and lower production costs. VIP is a mechanism involving NASA funding designed to accelerate the growth of commercial remote sensing by promoting general awareness and basic training in the technology.

  8. Factory Cost Model

    1996-12-17

    The Factory Cost Model (FCM) is an economic analysis tool intended to provide flat panel display (FPD) and other similar discrete component manufacturers with the ability to make first-order estimates of the cost of unit production. This software has several intended uses. Primary among these is the ability to provide first-order economic analysis for future factories. Consequently, the model requires a minimal level of input detail, and accomodates situations where actual production data are notmore » available. This software is designed to be activity based such that most of the calculated direct costs are associated with the steps of a manufacturibg process. The FCM architecture has the ability to accomodate the analysis of existing manufacturing facilities. The FCM can provide assistance with strategic economic decisions surrounding production related matters. For instance, the program can project the effect on costs and resources of a new product''s introduction, or it can assess the potential cost reduction produced by step yield improvements in the manufacturing process.« less

  9. Economics of Future Growth in Photovoltaics Manufacturing

    SciTech Connect

    Basore, Paul A.; Chung, Donald; Buonassisi, Tonio

    2015-06-14

    The past decade's record of growth in the photovoltaics manufacturing industry indicates that global investment in manufacturing capacity for photovoltaic modules tends to increase in proportion to the size of the industry. The slope of this proportionality determines how fast the industry will grow in the future. Two key parameters determine this slope. One is the annual global investment in manufacturing capacity normalized to the manufacturing capacity for the previous year (capacity-normalized capital investment rate, CapIR, units $/W). The other is how much capital investment is required for each watt of annual manufacturing capacity, normalized to the service life of the assets (capacity-normalized capital demand rate, CapDR, units $/W). If these two parameters remain unchanged from the values they have held for the past few years, global manufacturing capacity will peak in the next few years and then decline. However, it only takes a small improvement in CapIR to ensure future growth in photovoltaics. Any accompanying improvement in CapDR will accelerate that growth.

  10. Industrialization of Superconducting RF Accelerator Technology

    NASA Astrophysics Data System (ADS)

    Peiniger, Michael; Pekeler, Michael; Vogel, Hanspeter

    2012-01-01

    Superconducting RF (SRF) accelerator technology has basically existed for 50 years. It took about 20 years to conduct basic R&D and prototyping at universities and international institutes before the first superconducting accelerators were built, with industry supplying complete accelerator cavities. In parallel, the design of large scale accelerators using SRF was done worldwide. In order to build those accelerators, industry has been involved for 30 years in building the required cavities and/or accelerator modules in time and budget. To enable industry to supply these high tech components, technology transfer was made from the laboratories in the following three regions: the Americas, Asia and Europe. As will be shown, the manufacture of the SRF cavities is normally accomplished in industry whereas the cavity testing and module assembly are not performed in industry in most cases, yet. The story of industrialization is so far a story of customized projects. Therefore a real SRF accelerator product is not yet available in this market. License agreements and technology transfer between leading SRF laboratories and industry is a powerful tool for enabling industry to manufacture SRF components or turnkey superconducting accelerator modules for other laboratories and users with few or no capabilities in SRF technology. Despite all this, the SRF accelerator market today is still a small market. The manufacture and preparation of the components require a range of specialized knowledge, as well as complex and expensive manufacturing installations like for high precision machining, electron beam welding, chemical surface preparation and class ISO4 clean room assembly. Today, the involved industry in the US and Europe comprises medium-sized companies. In Japan, some big enterprises are involved. So far, roughly 2500 SRF cavities have been built by or ordered from industry worldwide. Another substantial step might come from the International Linear Collider (ILC) project

  11. Manufacturing with the Sun

    NASA Technical Reports Server (NTRS)

    Murphy, Lawrence M.; Hauser, Steven G.; Clyne, Richard J.

    1991-01-01

    Concentrated solar radiation is now a viable alternative source for many advanced manufacturing processes. Researchers at the National Renewable Energy Laboratory (NREL) have demonstrated the feasibility of processes such as solar induced surface transformation of materials (SISTM), solar based manufacturing, and solar pumped lasers. Researchers are also using sunlight to decontaminate water and soils polluted with organic compounds; these techniques could provide manufacturers with innovative alternatives to traditional methods of waste management. The solar technology that is now being integrated into today's manufacturing processes offer greater potential for tomorrow, especially as applied to the radiation abundant environment available in space and on the lunar surface.

  12. Manufacturing with the Sun

    NASA Astrophysics Data System (ADS)

    Murphy, L. M.; Hauser, S. G.; Clyne, R. J.

    1992-05-01

    Concentrated solar radiation is now a viable alternative energy source for many advanced manufacturing processes. Researchers at the National Renewable Energy Laboratory (NREL) have demonstrated the feasibility of processes such as solar-induced surface transformation of materials (SISTM), solar-based manufacturing, and solar-pumped lasers. Researchers are also using sunlight to decontaminate water and soils polluted with organic compounds; these techniques could provide manufacturers with innovative alternatives to traditional methods of waste management. The solar technology that is now being integrated into today's manufacturing processes offers even greater potential for tomorrow, especially as applied to the radiation-abundant environment available in space and on the lunar surface.

  13. Photovoltaic manufacturing technology, Phase 1

    SciTech Connect

    Somberg, H. )

    1991-11-01

    This report describes existing integrated processes for solar cell manufacturing and lists as the primary opportunity for improvement the following areas: low-cost silicon sheets with improved characteristics; improved large-scale and automated solar cell processes that can lead to cell efficiencies in the range of 14% (encapsulated) for direct-cast wafers; improved handling and lamination of large-area modules for the emerging utility market. The proposed solutions can lead to finished module costs on the order of $1.55 per square meter or a selling price of less than $2.00/Watt. The problems that may be considered generic to the industry and that have been addressed in this work are as follows: gettering and passivation of silicon wafers; spray-on passivation layers; dual antireflection coatings; ink-jet printing of metallizations; and automated handling of large-area modules and associated vertical lamination. 14 refs.

  14. Quality cell therapy manufacturing by design.

    PubMed

    Lipsitz, Yonatan Y; Timmins, Nicholas E; Zandstra, Peter W

    2016-04-01

    Transplantation of live cells as therapeutic agents is poised to offer new treatment options for a wide range of acute and chronic diseases. However, the biological complexity of cells has hampered the translation of laboratory-scale experiments into industrial processes for reliable, cost-effective manufacturing of cell-based therapies. We argue here that a solution to this challenge is to design cell manufacturing processes according to quality-by-design (QbD) principles. QbD integrates scientific knowledge and risk analysis into manufacturing process development and is already being adopted by the biopharmaceutical industry. Many opportunities to incorporate QbD into cell therapy manufacturing exist, although further technology development is required for full implementation. Linking measurable molecular and cellular characteristics of a cell population to final product quality through QbD is a crucial step in realizing the potential for cell therapies to transform healthcare. PMID:27054995

  15. Software for integrated manufacturing systems, part 1

    NASA Technical Reports Server (NTRS)

    Naylor, A. W.; Volz, R. A.

    1987-01-01

    For several years, a broad, unified approach to programming manufacturing cells, factory floors, and other manufacturing systems has been developed. It is based on a blending of distributed Ada, software components, generics and formal models. Among other things the machines and devices which make up the components, and the entire manufacturing cell is viewed as an assembly of software components. The purpose of this project is to reduce cost, increase the reliability and increase the flexibility of manufacturing software. An overview is given of the approach and an experimental generic factory floor controller that was developed using the approach is described. The controller is generic in the sense that it can control any one of a large class of factory floors making an arbitrary mix of parts.

  16. Software for integrated manufacturing systems, part 2

    NASA Technical Reports Server (NTRS)

    Volz, R. A.; Naylor, A. W.

    1987-01-01

    Part 1 presented an overview of the unified approach to manufacturing software. The specific characteristics of the approach that allow it to realize the goals of reduced cost, increased reliability and increased flexibility are considered. Why the blending of a components view, distributed languages, generics and formal models is important, why each individual part of this approach is essential, and why each component will typically have each of these parts are examined. An example of a specification for a real material handling system is presented using the approach and compared with the standard interface specification given by the manufacturer. Use of the component in a distributed manufacturing system is then compared with use of the traditional specification with a more traditional approach to designing the system. An overview is also provided of the underlying mechanisms used for implementing distributed manufacturing systems using the unified software/hardware component approach.

  17. Advances in solid dosage form manufacturing technology.

    PubMed

    Andrews, Gavin P

    2007-12-15

    Currently, the pharmaceutical and healthcare industries are moving through a period of unparalleled change. Major multinational pharmaceutical companies are restructuring, consolidating, merging and more importantly critically assessing their competitiveness to ensure constant growth in an ever-more demanding market where the cost of developing novel products is continuously increasing. The pharmaceutical manufacturing processes currently in existence for the production of solid oral dosage forms are associated with significant disadvantages and in many instances provide many processing problems. Therefore, it is well accepted that there is an increasing need for alternative processes to dramatically improve powder processing, and more importantly to ensure that acceptable, reproducible solid dosage forms can be manufactured. Consequently, pharmaceutical companies are beginning to invest in innovative processes capable of producing solid dosage forms that better meet the needs of the patient while providing efficient manufacturing operations. This article discusses two emerging solid dosage form manufacturing technologies, namely hot-melt extrusion and fluidized hot-melt granulation. PMID:17855217

  18. Forest products: Fiber loading for paper manufacturing

    SciTech Connect

    1999-09-29

    Fact sheet on manufacturing filler during paper manufacturing written for the NICE3 Program. With its new fiber loading process, Voith Sulzer, Inc., is greatly improving the efficiency of paper production and recycling. Fiber loading produces precipitated calcium carbonate (PCC) filler in the pulp recycling process at costs below conventional means. Fiber loading allows papermakers to use as much filler, like PCC, as possible because it costs 80% less than fiber. In addition, increased filler and fines retention due to fiber loading reduces the quantity of greenhouse gas emissions, deinking sludge, and other waste while substantially lowering energy costs. Currently, the most efficient way to produce PCC as filler is to make it in a satellite plant adjacent to a paper mill. Satellite plants exist near large scale paper mills (producing 700 tons per day) because the demand at large mills justifies building a costly ($15 million, average) satellite plant. This new fiber loading process combines the PCC manufacturing technology used in a satellite plant with the pulp processing operations of a paper mill. It is 33% less expensive to augment an existing paper mill with fiber loading technology than to build a satellite plant for the same purpose. This technology is applicable to the manufacturing of all printing and writing paper, regardless of the size or capacity of the paper mill.

  19. Advanced manufacturing technologies on color plasma displays

    NASA Astrophysics Data System (ADS)

    Betsui, Keiichi

    2000-06-01

    The mass production of the color plasma display started from 1996. However, since the price of the panel is still expensive, PDPs are not in widespread use at home. It is necessary to develop the new and low-cost manufacturing technologies to reduce the price of the panel. This paper describes some of the features of new fabrication technologies of PDPs.

  20. Flow Battery System Design for Manufacturability.

    SciTech Connect

    Montoya, Tracy Louise; Meacham, Paul Gregory; Perry, David; Broyles, Robin S.; Hickey, Steven; Hernandez, Jacquelynne

    2014-10-01

    Flow battery energy storage systems can support renewable energy generation and increase energy efficiency. But, presently, the costs of flow battery energy storage systems can be a significant barrier for large-scale market penetration. For cost- effective systems to be produced, it is critical to optimize the selection of materials and components simultaneously with the adherence to requirements and manufacturing processes to allow these batteries and their manufacturers to succeed in the market by reducing costs to consumers. This report analyzes performance, safety, and testing requirements derived from applicable regulations as well as commercial and military standards that would apply to a flow battery energy storage system. System components of a zinc-bromine flow battery energy storage system, including the batteries, inverters, and control and monitoring system, are discussed relative to manufacturing. The issues addressed include costs and component availability and lead times. A service and support model including setup, maintenance and transportation is outlined, along with a description of the safety-related features of the example flow battery energy storage system to promote regulatory and environmental, safety, and health compliance in anticipation of scale manufacturing.

  1. A Survey of Hadron Therapy Accelerator Technologies.

    SciTech Connect

    PEGGS,S.; SATOGATA, T.; FLANZ, J.

    2007-06-25

    Hadron therapy has entered a new age [1]. The number of facilities grows steadily, and 'consumer' interest is high. Some groups are working on new accelerator technology, while others optimize existing designs by reducing capital and operating costs, and improving performance. This paper surveys the current requirements and directions in accelerator technology for hadron therapy.

  2. Lean Manufacturing Auto Cluster at Chennai

    NASA Astrophysics Data System (ADS)

    Bhaskaran, E.

    2012-10-01

    Due the presence of lot of automotive Industry, Chennai is known as Detroit of India, that producing over 40 % of the Indian vehicle and components. Lean manufacturing concepts have been widely recognized as an important tool in improving the competitiveness of industries. This is a continuous process involving everyone, starting from management to the shop floor. Automotive Component Industries (ACIs) in Ambattur Industrial Estate, Chennai has formed special purpose vehicle (SPV) society namely Ambattur Industrial Estate Manufacturers Association (AIEMA) Technology Centre (ATC) lean manufacturing cluster (ATC-LMC) during July 2010 under lean manufacturing competitiveness scheme, that comes under National Manufacturing Competitiveness Programme of Government of India. The Tripartite Agreement is taken place between National Productivity Council, consultants and cluster (ATC-LMC). The objective is to conduct diagnostic study, study on training and application of various lean manufacturing techniques and auditing in ten ACIs. The methodology adopted is collection of primary data/details from ten ACIs. In the first phase, diagnostic study is done and the areas for improvement in each of the cluster member companies are identified. In the second phase, training programs and implementation is done on 5S and other areas. In the third phase auditing is done and found that the lean manufacturing techniques implementation in ATC-LMC is sustainable and successful in every cluster companies, which will not only enhance competitiveness but also decrease cost, time and increase productivity. The technical efficiency of LMC companies also increases significantly.

  3. Ferroelectric ceramics in a pyroelectric accelerator

    SciTech Connect

    Shchagin, A. V.; Miroshnik, V. S.; Volkov, V. I.; Oleinik, A. N.

    2015-12-07

    The applicability of polarized ferroelectric ceramics as a pyroelectric in a pyroelectric accelerator is shown by experiments. The spectra of X-ray radiation of energy up to tens of keV, generated by accelerated electrons, have been measured on heating and cooling of the ceramics in vacuum. It is suggested that curved layers of polarized ferroelectric ceramics be used as elements of ceramic pyroelectric accelerators. Besides, nanotubes and nanowires manufactured from ferroelectric ceramics are proposed for the use in nanometer-scale ceramic pyroelectric nanoaccelerators for future applications in nanotechnologies.

  4. Accelerator system and method of accelerating particles

    NASA Technical Reports Server (NTRS)

    Wirz, Richard E. (Inventor)

    2010-01-01

    An accelerator system and method that utilize dust as the primary mass flux for generating thrust are provided. The accelerator system can include an accelerator capable of operating in a self-neutralizing mode and having a discharge chamber and at least one ionizer capable of charging dust particles. The system can also include a dust particle feeder that is capable of introducing the dust particles into the accelerator. By applying a pulsed positive and negative charge voltage to the accelerator, the charged dust particles can be accelerated thereby generating thrust and neutralizing the accelerator system.

  5. Attention's Accelerator.

    PubMed

    Reinhart, Robert M G; McClenahan, Laura J; Woodman, Geoffrey F

    2016-06-01

    How do people get attention to operate at peak efficiency in high-pressure situations? We tested the hypothesis that the general mechanism that allows this is the maintenance of multiple target representations in working and long-term memory. We recorded subjects' event-related potentials (ERPs) indexing the working memory and long-term memory representations used to control attention while performing visual search. We found that subjects used both types of memories to control attention when they performed the visual search task with a large reward at stake, or when they were cued to respond as fast as possible. However, under normal circumstances, one type of target memory was sufficient for slower task performance. The use of multiple types of memory representations appears to provide converging top-down control of attention, allowing people to step on the attentional accelerator in a variety of high-pressure situations. PMID:27056975

  6. Clean Energy Manufacturing Initiative

    SciTech Connect

    2013-04-01

    The initiative will strategically focus and rally EERE’s clean energy technology offices and Advanced Manufacturing Office around the urgent competitive opportunity for the United States to be the leader in the clean energy manufacturing industries and jobs of today and tomorrow.

  7. Manufacturing Education Curriculum Project.

    ERIC Educational Resources Information Center

    Umstattd, William D.

    The Manufacturing Education Curriculum Project's feasibility study concerned with industrial arts curriculum development in manufacturing for the senior high school level is described. The need for an industrial arts curriculum which meets and reflects present and future trends is discussed in the introduction, followed by a review of the…

  8. Developments in Agile Manufacturing

    SciTech Connect

    Clinesmith, M.G.

    1993-09-01

    As part of a project design initiative, Sandia National Laboratories and AlliedSignal Inc. Kansas City Division have joined efforts to develop a concurrent engineering capability for the manufacturing of complex precision components. The primary effort of this project, called Agile Manufacturing, is directed toward: (1) Understand the error associated with manufacturing and inspection. (2) Develop methods for correcting error. (3) Integrate diverse software technologies into a compatible process. The Agile Manufacturing System (AMS) is a system that integrates product design, manufacturing, and inspection into a closed loop, concurrent engineering process. The goal of developing the Agile Manufacturing System is to: (1) Optimize accuracy in manufacturing and inspection. (A) Use of softgage software for product evaluation. This will ensure ANSI Y14.5 compliance. (B) Establish and monitor bias between CMM and machine center. (C) Map probe deflection error and apply correction to inspection results. This applies to both on machine probing and CMM inspections. (D) Inspection process. (2) Compress the cycle time from product concept to production level manufacturing and verification. (3) Create a self-correcting process that feeds inspection results back into the machining process. (4) Link subordinate processes (cutting/probing path, softgage model, etc.) to the solid model definition.

  9. Manufacturing research strategic plan

    SciTech Connect

    1995-11-01

    This plan provides an overall strategic roadmap for the DOE-defense programs advanced manufacturing research program which supports the national science based stockpile stewardship program. This plan represents a vision required to develop the knowledge base needed to ensure an enduring national capability to rapidly and effectively manufacture nuclear weapons.

  10. Computer Aided Manufacturing.

    ERIC Educational Resources Information Center

    Insolia, Gerard

    This document contains course outlines in computer-aided manufacturing developed for a business-industry technology resource center for firms in eastern Pennsylvania by Northampton Community College. The four units of the course cover the following: (1) introduction to computer-assisted design (CAD)/computer-assisted manufacturing (CAM); (2) CAM…

  11. Mechanical Prototyping and Manufacturing Internship

    NASA Technical Reports Server (NTRS)

    Grenfell, Peter

    2016-01-01

    significantly reduced cost. I acquired and improved manufacturing and prototyping skills during my tour including learning about a CAD (Computer-Aided Design) program called Creo (Creo Parametric; design software), gaining valuable conventional machining experience with lathes, CNC (Computer Numerical Control) milling machines and various other tools, and improving my engineering project communication and collaboration skills. The internship also allowed me to better understand operations at NASA. I plan to work in the aerospace industry or do academic research benefitting space science and exploration, and this internship experience will enable me to have insight into manufacturing processes for research and development.

  12. Laser assisted direct manufacturing

    NASA Astrophysics Data System (ADS)

    Bertrand, Ph.; Smurov, I.

    2007-06-01

    Direct Laser Manufacturing (DLM) with coaxial powder injection (TRUMPF DMD 505 installation) was applied for fabrication of 3D objects from metallic and ceramic powder. One of the advantages of DLM is the possibility to build functionally graded objects in one-step manufacturing cycle by application of a 2-channel powder feeder. Several models with different types of material gradients (smooth, sharp, periodic) and multi-layered structures were manufactured from SS, stellite (Cobalt alloy), Cu and W alloys. Technology of Selective Laser Melting (SLM) was applied for manufacturing of net shaped objects from different powders (PHENIX PM-100 machine) : Inox 904L, Ni625, Cu/Sn, W and Zr02-Y2O3. Performance and limitations of SLM technology for fabrication of elements for chemical and mechanical industries are analysed. Two-component objects (Stainless steel /Cu - H13/CuNi) were fabricated in a two-step manufacturing cycle.

  13. SATCOM simulator speeds MSS deployment and lowers costs

    NASA Technical Reports Server (NTRS)

    Carey, Tim; Hassun, Roland; Koberstein, Dave

    1993-01-01

    Mobile satellite systems (MSS) are being proposed and licensed at an accelerating rate. How can the design, manufacture, and performance of these systems be optimized at costs that allow a reasonable return on investment? The answer is the use of system simulation techniques beginning early in the system design and continuing through integration, pre- and post-launch monitoring, and in-orbit monitoring. This paper focuses on using commercially available, validated simulation instruments to deliver accurate, repeatable, and cost effective measurements throughout the life of a typical mobile satellite system. A satellite communications test set is discussed that provides complete parametric test capability with a significant improvement in measurement speed for manufacturing, integration, and pre-launch and in-orbit testing. The test set can simulate actual up and down link traffic conditions to evaluate the effects of system impairments, propagation and multipath on bit error rate (BER), channel capacity and transponder and system load balancing. Using a standard set of commercial instruments to deliver accurate, verifiable measurements anywhere in the world speeds deployment, generates measurement confidence, and lowers total system cost.

  14. Terahertz-driven linear electron acceleration.

    PubMed

    Nanni, Emilio A; Huang, Wenqian R; Hong, Kyung-Han; Ravi, Koustuban; Fallahi, Arya; Moriena, Gustavo; Miller, R J Dwayne; Kärtner, Franz X

    2015-01-01

    The cost, size and availability of electron accelerators are dominated by the achievable accelerating gradient. Conventional high-brightness radio-frequency accelerating structures operate with 30-50 MeV m(-1) gradients. Electron accelerators driven with optical or infrared sources have demonstrated accelerating gradients orders of magnitude above that achievable with conventional radio-frequency structures. However, laser-driven wakefield accelerators require intense femtosecond sources and direct laser-driven accelerators suffer from low bunch charge, sub-micron tolerances and sub-femtosecond timing requirements due to the short wavelength of operation. Here we demonstrate linear acceleration of electrons with keV energy gain using optically generated terahertz pulses. Terahertz-driven accelerating structures enable high-gradient electron/proton accelerators with simple accelerating structures, high repetition rates and significant charge per bunch. These ultra-compact terahertz accelerators with extremely short electron bunches hold great potential to have a transformative impact for free electron lasers, linear colliders, ultrafast electron diffraction, X-ray science and medical therapy with X-rays and electron beams. PMID:26439410

  15. Terahertz-driven linear electron acceleration

    SciTech Connect

    Nanni, Emilio A.; Huang, Wenqian R.; Hong, Kyung-Han; Ravi, Koustuban; Fallahi, Arya; Moriena, Gustavo; Dwayne Miller, R. J.; Kärtner, Franz X.

    2015-10-06

    The cost, size and availability of electron accelerators are dominated by the achievable accelerating gradient. Conventional high-brightness radio-frequency accelerating structures operate with 30–50 MeVm-1 gradients. Electron accelerators driven with optical or infrared sources have demonstrated accelerating gradients orders of magnitude above that achievable with conventional radio-frequency structures. However, laser-driven wakefield accelerators require intense femtosecond sources and direct laser-driven accelerators suffer from low bunch charge, sub-micron tolerances and sub-femtosecond timing requirements due to the short wavelength of operation. Here we demonstrate linear acceleration of electrons with keV energy gain using optically generated terahertz pulses. Terahertz-driven accelerating structures enable high-gradient electron/proton accelerators with simple accelerating structures, high repetition rates and significant charge per bunch. As a result, these ultra-compact terahertz accelerators with extremely short electron bunches hold great potential to have a transformative impact for free electron lasers, linear colliders, ultrafast electron diffraction, X-ray science and medical therapy with X-rays and electron beams.

  16. Terahertz-driven linear electron acceleration

    PubMed Central

    Nanni, Emilio A.; Huang, Wenqian R.; Hong, Kyung-Han; Ravi, Koustuban; Fallahi, Arya; Moriena, Gustavo; Dwayne Miller, R. J.; Kärtner, Franz X.

    2015-01-01

    The cost, size and availability of electron accelerators are dominated by the achievable accelerating gradient. Conventional high-brightness radio-frequency accelerating structures operate with 30–50 MeV m−1 gradients. Electron accelerators driven with optical or infrared sources have demonstrated accelerating gradients orders of magnitude above that achievable with conventional radio-frequency structures. However, laser-driven wakefield accelerators require intense femtosecond sources and direct laser-driven accelerators suffer from low bunch charge, sub-micron tolerances and sub-femtosecond timing requirements due to the short wavelength of operation. Here we demonstrate linear acceleration of electrons with keV energy gain using optically generated terahertz pulses. Terahertz-driven accelerating structures enable high-gradient electron/proton accelerators with simple accelerating structures, high repetition rates and significant charge per bunch. These ultra-compact terahertz accelerators with extremely short electron bunches hold great potential to have a transformative impact for free electron lasers, linear colliders, ultrafast electron diffraction, X-ray science and medical therapy with X-rays and electron beams. PMID:26439410

  17. Terahertz-driven linear electron acceleration

    NASA Astrophysics Data System (ADS)

    Nanni, Emilio A.; Huang, Wenqian R.; Hong, Kyung-Han; Ravi, Koustuban; Fallahi, Arya; Moriena, Gustavo; Dwayne Miller, R. J.; Kärtner, Franz X.

    2015-10-01

    The cost, size and availability of electron accelerators are dominated by the achievable accelerating gradient. Conventional high-brightness radio-frequency accelerating structures operate with 30-50 MeV m-1 gradients. Electron accelerators driven with optical or infrared sources have demonstrated accelerating gradients orders of magnitude above that achievable with conventional radio-frequency structures. However, laser-driven wakefield accelerators require intense femtosecond sources and direct laser-driven accelerators suffer from low bunch charge, sub-micron tolerances and sub-femtosecond timing requirements due to the short wavelength of operation. Here we demonstrate linear acceleration of electrons with keV energy gain using optically generated terahertz pulses. Terahertz-driven accelerating structures enable high-gradient electron/proton accelerators with simple accelerating structures, high repetition rates and significant charge per bunch. These ultra-compact terahertz accelerators with extremely short electron bunches hold great potential to have a transformative impact for free electron lasers, linear colliders, ultrafast electron diffraction, X-ray science and medical therapy with X-rays and electron beams.

  18. CRADA final report: Technical assessment of roll-to-roll operation of lamination process, thermal treatment, and alternative carbon fiber precursors for low-cost, high-efficiency manufacturing of flow battery stacks and other energy devices

    SciTech Connect

    Daniel, Claus; Madden, Thomas; Wood, III, David L; Muth, Thomas R.; Warrington, Curtis; Ozcan, Soydan; Manson, Hunter; Tekinalp, Halil L.; Smith, Mark A.; Lu, Yuan; Loretz, Jeremy

    2015-09-23

    Among the various stationary-storage technologies under development, redox flow batteries (RFBs) offer the greatest potential to deliver inexpensive, scalable, and efficient grid-scale electrical-energy storage. Unlike traditional sealed batteries, in a flow battery power and energy are decoupled. Cell area and cell count in the stack determine the device power, and the chemical storage volume determines the total energy. Grid-scale energy-storage applications require megawatt-scale devices, which require the assembly of hundreds of large-area, bipolar cells per power plant. The cell-stack is the single system component with the largest impact on capital cost (due to the large number of highly engineered components) and operating costs (determined by overall round-trip efficiency).

  19. Optimization of space manufacturing systems

    NASA Technical Reports Server (NTRS)

    Akin, D. L.

    1979-01-01

    Four separate analyses are detailed: transportation to low earth orbit, orbit-to-orbit optimization, parametric analysis of SPS logistics based on earth and lunar source locations, and an overall program option optimization implemented with linear programming. It is found that smaller vehicles are favored for earth launch, with the current Space Shuttle being right at optimum payload size. Fully reusable launch vehicles represent a savings of 50% over the Space Shuttle; increased reliability with less maintenance could further double the savings. An optimization of orbit-to-orbit propulsion systems using lunar oxygen for propellants shows that ion propulsion is preferable by a 3:1 cost margin over a mass driver reaction engine at optimum values; however, ion engines cannot yet operate in the lower exhaust velocity range where the optimum lies, and total program costs between the two systems are ambiguous. Heavier payloads favor the use of a MDRE. A parametric model of a space manufacturing facility is proposed, and used to analyze recurring costs, total costs, and net present value discounted cash flows. Parameters studied include productivity, effects of discounting, materials source tradeoffs, economic viability of closed-cycle habitats, and effects of varying degrees of nonterrestrial SPS materials needed from earth. Finally, candidate optimal scenarios are chosen, and implemented in a linear program with external constraints in order to arrive at an optimum blend of SPS production strategies in order to maximize returns.

  20. Clean Energy Manufacturing Initiative Industrial Efficiency and Energy Productivity

    ScienceCinema

    Selldorff, John; Atwell, Monte

    2014-12-03

    Industrial efficiency and low-cost energy resources are key components to increasing U.S. energy productivity and makes the U.S. manufacturing sector more competitive. Companies find a competitive advantage in implementing efficiency technologies and practices, and technologies developed and manufactured in the U.S. enable greater competitiveness economy-wide.

  1. Clean Energy Manufacturing Initiative Industrial Efficiency and Energy Productivity

    SciTech Connect

    Selldorff, John; Atwell, Monte

    2014-09-23

    Industrial efficiency and low-cost energy resources are key components to increasing U.S. energy productivity and makes the U.S. manufacturing sector more competitive. Companies find a competitive advantage in implementing efficiency technologies and practices, and technologies developed and manufactured in the U.S. enable greater competitiveness economy-wide.

  2. 26 CFR 1.471-11 - Inventories of manufacturers.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... 26 Internal Revenue 6 2010-04-01 2010-04-01 false Inventories of manufacturers. 1.471-11 Section 1... (CONTINUED) INCOME TAXES Inventories § 1.471-11 Inventories of manufacturers. (a) Use of full absorption method of inventory costing. In order to conform as nearly as may be possible to the best...

  3. WASTE REDUCTION TECHNOLOGY EVALUATIONS AT THREE PRINTED WIRE BOARD MANUFACTURERS

    EPA Science Inventory

    Technologies at three printed wire board (PWB) manufacturers were evaluated for waste reduction, and costs were compared to existing operations. rom 1989 to 1993, these evaluations were conducted under US EPA's Waste Reduction Innovative Technology Evaluation (WRITE) Program, in ...

  4. Battery-level material cost model facilitates high-power li-ion battery cost reductions.

    SciTech Connect

    Henriksen, G.; Chemical Engineering

    2003-01-01

    Under the FreedomCAR Partnership, Argonne National Laboratory (ANL) is working to identify and develop advanced anode, cathode, and electrolyte components that can significantly reduce the cost of the cell chemistry, while simultaneously enhancing the calendar life and inherent safety of high-power Li-Ion batteries. Material cost savings are quantified and tracked via the use of a cell and battery design model that establishes the quantity of each material needed in batteries designed to meet the requirements of hybrid electric vehicles (HEVs). In order to quantify the material costs, relative to the FreedomCAR battery cost goals, ANL uses (1) laboratory cell performance data, (2) its battery design model and (3) battery manufacturing process yields to create battery-level material cost models. Using these models and industry-supplied material cost information, ANL assigns battery-level material costs for different cell chemistries. These costs can then be compared to the battery cost goals to determine the probability of meeting the goals with these cell chemistries. The most recent freedomCAR cost goals for 25-kW and 40-kW power-assist HEV batteries are $500 and $800, respectively, which is $20/kW in both cases. In 2001, ANL developed a high-power cell chemistry that was incorporated into high-power 18650 cells for use in extensive accelerated aging and thermal abuse characterization studies. This cell chemistry serves as a baseline for this material cost study. It incorporates a LiNi0.8Co0.15Al0.05O2 cathode, a synthetic graphite anode, and a LiPF6 in EC:EMC electrolyte. Based on volume production cost estimates for these materials-as well as those for binders/solvents, cathode conductive additives, separator, and current collectors--the total cell winding material cost for a 25-kW power-assist HEV battery is estimated to be $399 (based on a 48- cell battery design, each cell having a capacity of 15.4 Ah). This corresponds to {approx}$16/kW. Our goal is to

  5. SAMIS - A simulation of the solar array manufacturing industry

    NASA Technical Reports Server (NTRS)

    Chamberlain, R. G.

    1976-01-01

    SAMIS is a continuing activity of the Project Analysis and Integration Task of the Low-cost Silicon Solar Array Project (LSSA). It provides a standardized procedure for producing reliable estimates of the cost of manufacturing solar arrays or their components. These estimates are based on descriptions of the manufacturing processes which are being studied and developed by LSSA subcontractors and will be used to assess the commercial viability of those processes and to set research priorities.

  6. Acceleration modules in linear induction accelerators

    NASA Astrophysics Data System (ADS)

    Wang, Shao-Heng; Deng, Jian-Jun

    2014-05-01

    The Linear Induction Accelerator (LIA) is a unique type of accelerator that is capable of accelerating kilo-Ampere charged particle current to tens of MeV energy. The present development of LIA in MHz bursting mode and the successful application into a synchrotron have broadened LIA's usage scope. Although the transformer model is widely used to explain the acceleration mechanism of LIAs, it is not appropriate to consider the induction electric field as the field which accelerates charged particles for many modern LIAs. We have examined the transition of the magnetic cores' functions during the LIA acceleration modules' evolution, distinguished transformer type and transmission line type LIA acceleration modules, and re-considered several related issues based on transmission line type LIA acceleration module. This clarified understanding should help in the further development and design of LIA acceleration modules.

  7. Computed Tomography Inspection and Analysis for Additive Manufacturing Components

    NASA Technical Reports Server (NTRS)

    Beshears, Ronald D.

    2016-01-01

    Computed tomography (CT) inspection was performed on test articles additively manufactured from metallic materials. Metallic AM and machined wrought alloy test articles with programmed flaws were inspected using a 2MeV linear accelerator based CT system. Performance of CT inspection on identically configured wrought and AM components and programmed flaws was assessed using standard image analysis techniques to determine the impact of additive manufacturing on inspectability of objects with complex geometries.

  8. Electronic manufacturing and packaging in Japan

    NASA Technical Reports Server (NTRS)

    Kelly, Michael J.; Boulton, William R. (Editor); Kukowski, John A.; Meieran, Eugene S.; Pecht, Michael; Peeples, John W.; Tummala, Rao R.

    1995-01-01

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

  9. 75 FR 104 - Manufacturing & Services' Sustainable Manufacturing Initiative; Update

    Federal Register 2010, 2011, 2012, 2013, 2014

    2010-01-04

    ... of Trade Policy Analysis, 202-482-2831. SUPPLEMENTARY INFORMATION: ITA's Manufacturing and Services... 18, 2009. Matthew Howard, Office of Trade Policy Analysis. BILLING CODE 3510-DR-P ... International Trade Administration Manufacturing & Services' Sustainable Manufacturing Initiative; Update...

  10. Flexible Manufacturing Systems: What's in It for the Manufacturer.

    ERIC Educational Resources Information Center

    Chowdhury, A. R.; Peckman, Donald C.

    1987-01-01

    The authors define the Flexible Manufacturing System and outline its history. They describe what the processing time includes and provide advantages and disadvantages of Flexible Manufacturing Systems compared to conventional manufacturing. (CH)

  11. NASA Game Changing Development Program Manufacturing Innovation Project

    NASA Technical Reports Server (NTRS)

    Tolbert, Carol; Vickers, John

    2011-01-01

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

  12. Rapid small lot manufacturing

    SciTech Connect

    Harrigan, R.W.

    1998-05-09

    The direct connection of information, captured in forms such as CAD databases, to the factory floor is enabling a revolution in manufacturing. Rapid response to very dynamic market conditions is becoming the norm rather than the exception. In order to provide economical rapid fabrication of small numbers of variable products, one must design with manufacturing constraints in mind. In addition, flexible manufacturing systems must be programmed automatically to reduce the time for product change over in the factory and eliminate human errors. Sensor based machine control is needed to adapt idealized, model based machine programs to uncontrolled variables such as the condition of raw materials and fabrication tolerances.

  13. Advanced Engineering Environments: Implications for Aerospace Manufacturing

    NASA Technical Reports Server (NTRS)

    Thomas, D.

    2001-01-01

    There are significant challenges facing today's aerospace industry. Global competition, more complex products, geographically-distributed design teams, demands for lower cost, higher reliability and safer vehicles, and the need to incorporate the latest technologies quicker all face the developer of aerospace systems. New information technologies offer promising opportunities to develop advanced engineering environments (AEEs) to meet these challenges. Significant advances in the state-of-the-art of aerospace engineering practice are envisioned in the areas of engineering design and analytical tools, cost and risk tools, collaborative engineering, and high-fidelity simulations early in the development cycle. These advances will enable modeling and simulation of manufacturing methods, which will in turn allow manufacturing considerations to be included much earlier in the system development cycle. Significant cost savings, increased quality, and decreased manufacturing cycle time are expected to result. This paper will give an overview of the NASA's Intelligent Synthesis Environment, the agency initiative to develop an AEE, with a focus on the anticipated benefits in aerospace manufacturing.

  14. New coal breaker said to cost less, separate out more sulfur and ash than rotary types

    SciTech Connect

    Not Available

    1984-02-01

    A second-generation coal breaker that can reduce coal top size to 1/4 inch will cost less and do a better job of separating ash and sulfur from coal, according to the manufacturer Harrison Handling, Inc. The new equipment could make conventional coal breaking and crushing equipment obsolete. Citing test results, a company spokesman describes a 1% reduction in sulfur and 2.5% reduction in ash content and a higher Btu recovery rate. One utility expressed interest in whether the accelerator would handle tramp iron vetter. 3 figures.

  15. CVD Diamond Dielectric Accelerating Structures

    SciTech Connect

    Schoessow, P.; Kanareykin, A.; Gat, R.

    2009-01-22

    The electrical and mechanical properties of diamond make it an ideal candidate material for use in dielectric accelerating structures: high RF breakdown field, extremely low dielectric losses and the highest available thermoconductive coefficient. Using chemical vapor deposition (CVD) cylindrical diamond structures have been manufactured with dimensions corresponding to fundamental TM{sub 01} mode frequencies in the GHz to THz range. Surface treatments are being developed to reduce the secondary electron emission (SEE) coefficient below unity to reduce the possibility of multipactor. The diamond CVD cylindrical waveguide technology developed here can be applied to a variety of other high frequency, large-signal applications.

  16. Environmentally benign silicon solar cell manufacturing

    SciTech Connect

    Tsuo, Y.S.; Gee, J.M.; Menna, P.; Strebkov, D.S.; Pinov, A.; Zadde, V.

    1998-09-01

    The manufacturing of silicon devices--from polysilicon production, crystal growth, ingot slicing, wafer cleaning, device processing, to encapsulation--requires many steps that are energy intensive and use large amounts of water and toxic chemicals. In the past two years, the silicon integrated-circuit (IC) industry has initiated several programs to promote environmentally benign manufacturing, i.e., manufacturing practices that recover, recycle, and reuse materials resources with a minimal consumption of energy. Crystalline-silicon solar photovoltaic (PV) modules, which accounted for 87% of the worldwide module shipments in 1997, are large-area devices with many manufacturing steps similar to those used in the IC industry. Obviously, there are significant opportunities for the PV industry to implement more environmentally benign manufacturing approaches. Such approaches often have the potential for significant cost reduction by reducing energy use and/or the purchase volume of new chemicals and by cutting the amount of used chemicals that must be discarded. This paper will review recent accomplishments of the IC industry initiatives and discuss new processes for environmentally benign silicon solar-cell manufacturing.

  17. MCM-C Multichip Module Manufacturing Guide

    SciTech Connect

    Blazek, R.J.; Kautz, D.R.; Galichia, J.V.

    2000-11-20

    Honeywell Federal Manufacturing & Technologies (FM&T) provides complete microcircuit capabilities from design layout through manufacturing and final electrical testing. Manufacturing and testing capabilities include design layout, electrical and mechanical computer simulation and modeling, circuit analysis, component analysis, network fabrication, microelectronic assembly, electrical tester design, electrical testing, materials analysis, and environmental evaluation. This document provides manufacturing guidelines for multichip module-ceramic (MCM-C) microcircuits. Figure 1 illustrates an example MCM-C configuration with the parts and processes that are available. The MCM-C technology is used to manufacture microcircuits for electronic systems that require increased performance, reduced volume, and higher density that cannot be achieved by the standard hybrid microcircuit or printed wiring board technologies. The guidelines focus on the manufacturability issues that must be considered for low-temperature cofired ceramic (LTCC) network fabrication and MCM assembly and the impact that process capabilities have on the overall MCM design layout and product yield. Prerequisites that are necessary to initiate the MCM design layout include electrical, mechanical, and environmental requirements. Customer design data can be accepted in many standard electronic file formats. Other requirements include schedule, quantity, cost, classification, and quality level. Design considerations include electrical, network, packaging, and producibility; and deliverables include finished product, drawings, documentation, and electronic files.

  18. Progress on plasma accelerators

    SciTech Connect

    Chen, P.

    1986-05-01

    Several plasma accelerator concepts are reviewed, with emphasis on the Plasma Beat Wave Accelerator (PBWA) and the Plasma Wake Field Accelerator (PWFA). Various accelerator physics issues regarding these schemes are discussed, and numerical examples on laboratory scale experiments are given. The efficiency of plasma accelerators is then revealed with suggestions on improvements. Sources that cause emittance growth are discussed briefly.

  19. Flat conductor cable design, manufacture, and installation

    NASA Technical Reports Server (NTRS)

    Angele, W.; Hankins, J. D.

    1973-01-01

    Pertinent information for hardware selection, design, manufacture, and quality control necessary for flat conductor cable interconnecting harness application is presented. Comparisons are made between round wire cable and flat conductor cable. The flat conductor cable interconnecting harness systems show major cost, weight, and space savings, plus increased system performance and reliability. The design application section includes electrical characteristics, harness design and development, and a full treatise on EMC considerations. Manufacturing and quality control sections pertain primarily to the developed conductor-contact connector system and special flat conductor cable to round wire cable transitions.

  20. Terahertz-driven linear electron acceleration

    DOE PAGESBeta

    Nanni, Emilio A.; Huang, Wenqian R.; Hong, Kyung-Han; Ravi, Koustuban; Fallahi, Arya; Moriena, Gustavo; Dwayne Miller, R. J.; Kärtner, Franz X.

    2015-10-06

    The cost, size and availability of electron accelerators are dominated by the achievable accelerating gradient. Conventional high-brightness radio-frequency accelerating structures operate with 30–50 MeVm-1 gradients. Electron accelerators driven with optical or infrared sources have demonstrated accelerating gradients orders of magnitude above that achievable with conventional radio-frequency structures. However, laser-driven wakefield accelerators require intense femtosecond sources and direct laser-driven accelerators suffer from low bunch charge, sub-micron tolerances and sub-femtosecond timing requirements due to the short wavelength of operation. Here we demonstrate linear acceleration of electrons with keV energy gain using optically generated terahertz pulses. Terahertz-driven accelerating structures enable high-gradient electron/proton acceleratorsmore » with simple accelerating structures, high repetition rates and significant charge per bunch. As a result, these ultra-compact terahertz accelerators with extremely short electron bunches hold great potential to have a transformative impact for free electron lasers, linear colliders, ultrafast electron diffraction, X-ray science and medical therapy with X-rays and electron beams.« less

  1. Development of Advanced Ceramic Manufacturing Technology

    SciTech Connect

    Pujari, V.K.

    2001-04-05

    Advanced structural ceramics are enabling materials for new transportation engine systems that have the potential for significantly reducing energy consumption and pollution in automobiles and heavy vehicles. Ceramic component reliability and performance have been demonstrated in previous U.S. DOE initiatives, but high manufacturing cost was recognized as a major barrier to commercialization. Norton Advanced Ceramics (NAC), a division of Saint-Gobain Industrial Ceramics, Inc. (SGIC), was selected to perform a major Advanced Ceramics Manufacturing Technology (ACMT) Program. The overall objectives of NAC's program were to design, develop, and demonstrate advanced manufacturing technology for the production of ceramic exhaust valves for diesel engines. The specific objectives were (1) to reduce the manufacturing cost by an order of magnitude, (2) to develop and demonstrate process capability and reproducibility, and (3) to validate ceramic valve performance, durability, and reliability. The program was divided into four major tasks: Component Design and Specification, Component Manufacturing Technology Development, Inspection and Testing, and Process Demonstration. A high-power diesel engine valve for the DDC Series 149 engine was chosen as the demonstration part for this program. This was determined to be an ideal component type to demonstrate cost-effective process enhancements, the beneficial impact of advanced ceramics on transportation systems, and near-term commercialization potential. The baseline valve material was NAC's NT451 SiAION. It was replaced, later in the program, by an alternate silicon nitride composition (NT551), which utilized a lower cost raw material and a simplified powder-processing approach. The material specifications were defined based on DDC's engine requirements, and the initial and final component design tasks were completed.

  2. Accelerating deactivation

    SciTech Connect

    FISHBACK, K.M.

    1999-02-01

    In recent years, the focus of the U.S. Department of Energy (DOE) complex has shifted from defense production to facility stabilization, decommissioning, and environmental restoration. This shift from production to cleanup requires a parallel shift from operations-focused management to project-focused management for an efficient facility deactivation. In the operation-focused management organization, activities are planned and executed based on production goals and are typically repetitive and cyclic. In the project-focused management environment, activities are based on a defined scope/end objective, start date, and completion date. Since the workforce used to perform production operations is also usually relied onto perform facility deactivation, it is important to shift from an operations management approach to a project management approach. It is best if the transition is accomplished quickly so the project can move forward and workers don't spend a lot of energy anticipating change. Therefore, it is essential that managers, planners, and other workers understand the key elements associated with planning a deactivation project. This paper describes a planning approach that has been used successfully to plan deactivation projects consistent with the requirements provided in DOE Order 430.1A Life Cycle Asset Management and the companion Deactivation Implementation Guide, G430. 1A-3, while exceeding schedule expectations and reducing costs. Although the planning of a deactivation project closely mirrors the classic project planning for construction projects, there are unique variations associated with facility deactivation. The key elements of planning a deactivation project are discussed relative to scope, schedule, and cost. Management tools such as project metrics and histograms are discussed as desired outputs from the planning process. In addition, lessons learned from planning deactivation projects across the DOE complex are discussed relative to making the

  3. The Manufacturing Game

    ERIC Educational Resources Information Center

    Fenn, Margaret

    1972-01-01

    Article describes management training through playing a game which involves the creation and operation of a business organization devoted to manufacturing and sales. Precise details on setting up the game are given. (Author/PD)

  4. Computers in Manufacturing.

    ERIC Educational Resources Information Center

    Hudson, C. A.

    1982-01-01

    Advances in factory computerization (computer-aided design and computer-aided manufacturing) are reviewed, including discussions of robotics, human factors engineering, and the sociological impact of automation. (JN)

  5. Agile manufacturing concept

    NASA Astrophysics Data System (ADS)

    Goldman, Steven L.

    1994-03-01

    The initial conceptualization of agile manufacturing was the result of a 1991 study -- chaired by Lehigh Professor Roger N. Nagel and California-based entrepreneur Rick Dove, President of Paradigm Shifts, International -- of what it would take for U.S. industry to regain global manufacturing competitiveness by the early twenty-first century. This industry-led study, reviewed by senior management at over 100 companies before its release, concluded that incremental improvement of the current system of manufacturing would not be enough to be competitive in today's global marketplace. Computer-based information and production technologies that were becoming available to industry opened up the possibility of an altogether new system of manufacturing, one that would be characterized by a distinctive integration of people and technologies; of management and labor; of customers, producers, suppliers, and society.

  6. Acceleration schedules for a recirculating heavy-ion accelerator

    SciTech Connect

    Sharp, W.M.; Grote, D.P.

    2002-05-01

    Recent advances in solid-state switches have made it feasible to design programmable, high-repetition-rate pulsers for induction accelerators. These switches could lower the cost of recirculating induction accelerators, such as the ''small recirculator'' at Lawrence Livermore National Laboratory (LLNL), by substantially reducing the number of induction modules. Numerical work is reported here to determine what effects the use of fewer pulsers at higher voltage would have on the beam quality of the LLNL small recirculator. Lattices with different numbers of pulsers are examined using the fluid/envelope code CIRCE, and several schedules for acceleration and compression are compared for each configuration. For selected schedules, the phase-space dynamics is also studied using the particle-in-cell code WARP3d.

  7. Plasma-aided manufacturing

    NASA Astrophysics Data System (ADS)

    Shohet, J. L.

    1993-12-01

    Plasma-aided manufacturing is used for producing new materials with unusual and superior properties, for developing new chemical compounds and processes, for machining, and for altering and refining materials and surfaces. Plasma-aided manufacturing has direct applications to semiconductor fabrication, materials synthesis, welding, lighting, polymers, anti-corrosion coatings, machine tools, metallurgy, electrical and electronics devices, hazardous waste removal, high performance ceramics, and many other items in both the high-technology and the more traditional industries in the United States.

  8. Holonic Manufacturing Paint Shop

    NASA Astrophysics Data System (ADS)

    Lind, Morten; Roulet-Dubonnet, Olivier; Nyen, Per Åge; Gellein, Lars Tore; Lien, Terje; Skavhaug, Amund

    In pursuit of flexibility and agility within discrete manufacturing, the surrounding logistics and handling processes of a paint shop is under construction as a laboratory prototype application. Holonic Manufacturing seems to be a promising strategic paradigm and architecture to use for a system characterised by production logistics and control. This paper describes the physical devices to be used; the desired functionality; and the basic logic control designed. Additionally, the ideas for holonification based on the already designed logic control is presented.

  9. KEKB accelerator control system

    NASA Astrophysics Data System (ADS)

    Akasaka, Nobumasa; Akiyama, Atsuyoshi; Araki, Sakae; Furukawa, Kazuro; Katoh, Tadahiko; Kawamoto, Takashi; Komada, Ichitaka; Kudo, Kikuo; Naito, Takashi; Nakamura, Tatsuro; Odagiri, Jun-ichi; Ohnishi, Yukiyoshi; Sato, Masayuki; Suetake, Masaaki; Takeda, Shigeru; Takeuchi, Yasunori; Yamamoto, Noboru; Yoshioka, Masakazu; Kikutani, Eji

    2003-02-01

    The KEKB accelerator control system including a control computer system, a timing distribution system, and a safety control system are described. KEKB accelerators were installed in the same tunnel where the TRISTAN accelerator was. There were some constraints due to the reused equipment. The control system is based on Experimental Physics and Industrial Control System (EPICS). In order to reduce the cost and labor for constructing the KEKB control system, as many CAMAC modules as possible are used again. The guiding principles of the KEKB control computer system are as follows: use EPICS as the controls environment, provide a two-language system for developing application programs, use VMEbus as frontend computers as a consequence of EPICS, use standard buses, such as CAMAC, GPIB, VXIbus, ARCNET, RS-232 as field buses and use ergonomic equipment for operators and scientists. On the software side, interpretive Python and SAD languages are used for coding application programs. The purpose of the radiation safety system is to protect personnel from radiation hazards. It consists of an access control system and a beam interlock system. The access control system protects people from strong radiation inside the accelerator tunnel due to an intense beam, by controlling access to the beamline area. On the other hand, the beam interlock system prevents people from radiation exposure by interlocking the beam operation. For the convenience of accelerator operation and access control, the region covered by the safety system is divided into three major access control areas: the KEKB area, the PF-AR area, and the beam-transport (BT) area. The KEKB control system required a new timing system to match a low longitudinal acceptance due to a low-alpha machine. This timing system is based on a frequency divider/multiply technique and a digital delay technique. The RF frequency of the KEKB rings and that of the injector Linac are locked with a common divisor frequency. The common

  10. Community Petascale Project for Accelerator Science and Simulation: Advancing Computational Science for Future Accelerators and Accelerator Technologies

    SciTech Connect

    Spentzouris, P.; Cary, J.; McInnes, L.C.; Mori, W.; Ng, C.; Ng, E.; Ryne, R.; /LBL, Berkeley

    2011-11-14

    for software development and applications accounts for the natural domain areas (beam dynamics, electromagnetics, and advanced acceleration), and all areas depend on the enabling technologies activities, such as solvers and component technology, to deliver the desired performance and integrated simulation environment. The ComPASS applications focus on computationally challenging problems important for design or performance optimization to all major HEP, NP, and BES accelerator facilities. With the cost and complexity of particle accelerators rising, the use of computation to optimize their designs and find improved operating regimes becomes essential, potentially leading to significant cost savings with modest investment.

  11. Report on Toyota/Prius Motor Design and Manufacturing Assessment

    SciTech Connect

    Hsu, J.S.

    2004-07-28

    In today's hybrid vehicle market the Toyota Prius drive system is currently considered the leader in electrical, mechanical, and manufacturing innovations. It is significant that in today's marketplace Toyota is able to manufacture and sell the vehicle for a profit. This project's objective is to analyze and study the Prius drive system to understand the design and manufacturing mechanisms Toyota utilized to achieved their performance and cost goals. During the course of this research effort ORNL has dissected both the 2003 and 2004 Toyota/Prius drive motors. This study is focused primarily on motor design considerations and an assessment of manufacturing issues.

  12. A Statistical Perspective on Highly Accelerated Testing.

    SciTech Connect

    Thomas, Edward V.

    2015-02-01

    Highly accelerated life testing has been heavily promoted at Sandia (and elsewhere) as a means to rapidly identify product weaknesses caused by flaws in the product's design or manufacturing process. During product development, a small number of units are forced to fail at high stress. The failed units are then examined to determine the root causes of failure. The identification of the root causes of product failures exposed by highly accelerated life testing can instigate changes to the product's design and/or manufacturing process that result in a product with increased reliability. It is widely viewed that this qualitative use of highly accelerated life testing (often associated with the acronym HALT) can be useful. However, highly accelerated life testing has also been proposed as a quantitative means for "demonstrating" the reliability of a product where unreliability is associated with loss of margin via an identified and dominating failure mechanism. It is assumed that the dominant failure mechanism can be accelerated by changing the level of a stress factor that is assumed to be related to the dominant failure mode. In extreme cases, a minimal number of units (often from a pre-production lot) are subjected to a single highly accelerated stress relative to normal use. If no (or, sufficiently few) units fail at this high stress level, some might claim that a certain level of reliability has been demonstrated (relative to normal use conditions). Underlying this claim are assumptions regarding the level of knowledge associated with the relationship between the stress level and the probability of failure. The primary purpose of this document is to discuss (from a statistical perspective) the efficacy of using accelerated life testing protocols (and, in particular, "highly accelerated" protocols) to make quantitative inferences concerning the performance of a product (e.g., reliability) when in fact there is lack-of-knowledge and uncertainty concerning the

  13. Silicon Film[trademark] photovoltaic manufacturing technology

    SciTech Connect

    Bottenberg, W.R.; Hall, R.B.; Jackson, E.L.; Lampo, S.; Mulligan, W.E.; Barnett, A.M. )

    1993-04-01

    This report describes work on a project to develop an advanced low-cost manufacturing process for a new utility-scale flatplate module based on thin active layers of polycrystalline silicon on a low-cost substrate. This is called the Silicon-Film[trademark] process. This new power module is based on a new large solar cell that is 675 cm[sup 2] in area. Eighteen of these solar cells form a 170-W module. Twelve ofthese modules form a 2-kW array. The program has three components: (1) development of a Silicon-Film[trademark] wafer machine that can manufacture wafer 675 cm[sup 2] in size with a total product cost reductionof 70%; (2) development of an advanced solar cell manufacturing process that will turn the Silicon-Film[trademark] wafer into a 14%-efficient solar cell; and (3) development of an advanced module design based on these large-area, efficient silicon solar cells with an average power of 170 watts. The completion of these three tasks will lead to a new power module designed for utility and other power applications with asubstantially lower cost.

  14. Advanced Manufacture of Reflectors

    SciTech Connect

    Angel, Roger

    2014-12-17

    The main project objective has been to develop an advanced gravity sag method for molding large glass solar reflectors with either line or point focus, and with long or short focal length. The method involves taking standard sized squares of glass, 1.65 m x 1.65 m, and shaping them by gravity sag into precision steel molds. The method is designed for high volume manufacture when incorporated into a production line with separate pre-heating and cooling. The performance objectives for the self-supporting glass mirrors made by this project include mirror optical accuracy of 2 mrad root mean square (RMS), requiring surface slope errors <1 mrad rms, a target not met by current production of solar reflectors. Our objective also included development of new methods for rapidly shaping glass mirrors and coating them for higher reflectivity and soil resistance. Reflectivity of 95% for a glass mirror with anti-soil coating was targeted, compared to the present ~94% with no anti-soil coating. Our mirror cost objective is ~$20/m2 in 2020, a significant reduction compared to the present ~$35/m2 for solar trough mirrors produced for trough solar plants. During the first year a custom batch furnace was built to develop the method with high power radiative heating to simulate transfer of glass into a hot slumping zone in a production line. To preserve the original high polish of the float glass on both front and back surfaces, as required for a second surface mirror, the mold surface is machined to the required shape as grooves which intersect the glass at cusps, reducing the mold contact area to significantly less than 1%. The mold surface is gold-plated to reflect thermal radiation. Optical metrology of glass replicas made with the system has been carried out with a novel, custom-built test system. This test provides collimated, vertically-oriented parallel beams from a linear array of co-aligned lasers translated in a perpendicular direction across the reflector. Deviations of

  15. Control systems for Coline accelerators

    NASA Astrophysics Data System (ADS)

    Baczewski, Artur; Latała, Agata; Ceglińska, Kaja; Andrasiak, Michał

    2008-01-01

    Medical linear accelerators are the largest group of devices for therapy of cancer diseases because of their compact design, relatively low operating costs, advanced features and broad range of treatment procedures. Their reliability and ease of operation are very important but the most crucial is to ensure personnel and patient safety. For this reason the development of control and safety systems is the current "leading edge" in medical linear accelerators technology. Provided internal monitoring, machine control and steering, interlock system as well as the automatic recording of the device and patient parameters are nowadays fully controlled by the computer. This paper describes in details projects connected to advanced development of Coline accelerators. As it is crucial to assure reliable steering and monitoring of all the machine settings and actual dose delivered to the patient, advanced control systems composed of steering, control and interlock systems, communication protocol as well as data management system have been developed.

  16. Accelerating Spectrum Sharing Technologies

    SciTech Connect

    Juan D. Deaton; Lynda L. Brighton; Rangam Subramanian; Hussein Moradi; Jose Loera

    2013-09-01

    Spectrum sharing potentially holds the promise of solving the emerging spectrum crisis. However, technology innovators face the conundrum of developing spectrum sharing technologies without the ability to experiment and test with real incumbent systems. Interference with operational incumbents can prevent critical services, and the cost of deploying and operating an incumbent system can be prohibitive. Thus, the lack of incumbent systems and frequency authorization for technology incubation and demonstration has stymied spectrum sharing research. To this end, industry, academia, and regulators all require a test facility for validating hypotheses and demonstrating functionality without affecting operational incumbent systems. This article proposes a four-phase program supported by our spectrum accountability architecture. We propose that our comprehensive experimentation and testing approach for technology incubation and demonstration will accelerate the development of spectrum sharing technologies.

  17. Low cost Czochralski crystal growing technology. Near implementation of the flat plate photovoltaic cost reduction of the low cost solar array project

    NASA Technical Reports Server (NTRS)

    Roberts, E. G.

    1980-01-01

    Equipment developed for the manufacture of over 100 kg of silicon ingot from one crucible by rechanging from another crucible is described. Attempts were made to eliminate the cost of raising the furnace temperature to 250 C above the melting point of silicon by using an RF coil to melt polycrystalline silicon rod as a means of rechanging the crucible. Microprocessor control of the straight growth process was developed and domonstrated for both 4 inch and 6 inch diameter. Both meltdown and melt stabilization processes were achieved using operator prompting through the microprocessor. The use of the RF work coil in poly rod melting as a heat sink in the accelerated growth process was unsuccessful. The total design concept for fabrication and interfacing of the total cold crucible system was completed.

  18. Progress update on the US photovoltaic manufacturing technology project

    SciTech Connect

    Mitchell, R.L.; Witt, C.E.; Thomas, H.P.

    1997-10-01

    The Photovoltaic Manufacturing Technology (PVMaT) project is helping the U.S. photovoltaic (PV) industry extend its world leadership role in manufacturing and stimulate the commercial development of PV modules and systems. Initiated in 1990, PVMaT is being carried out in several directed and staggered phases to support industry`s continued progress. Thirteen subcontracts awarded in FY 1996 under Phase 4A emphasize improvement and cost reduction in the manufacture of full-system PV products. Areas of work in Phase 4A included, but were not limited to, issues such as improving module-manufacturing processes; system and system-component packaging, integration, manufacturing, and assembly; product manufacturing flexibility; and balance-of-system development with the goal of product manufacturing improvements. These Phase 4A, product-driven manufacturing research and development (R&D) activities are now completing their second phase. Progress under these Phase 4A and remaining Phase 2B subcontracts from the earlier PVMaT solicitation are summarized in this paper. Evaluations of the success of this project have been carried out in FY 1995 and late FY 1996. This paper examines the 1997 cost/capacity data that have been collected from active PVMaT manufacturers.

  19. Additive manufacturing of RF absorbers

    NASA Astrophysics Data System (ADS)

    Mills, Matthew S.

    The ability of additive manufacturing techniques to fabricate integrated electromagnetic absorbers tuned for specific radio frequency bands within structural composites allows for unique combinations of mechanical and electromagnetic properties. These composites and films can be used for RF shielding of sensitive electromagnetic components through in-plane and out-of-plane RF absorption. Structural composites are a common building block of many commercial platforms. These platforms may be placed in situations in which there is a need for embedded RF absorbing properties along with structural properties. Instead of adding radar absorbing treatments to the external surface of existing structures, which adds increased size, weight and cost; it could prove to be advantageous to integrate the microwave absorbing properties directly into the composite during the fabrication process. In this thesis, a method based on additive manufacturing techniques of composites structures with prescribed electromagnetic loss, within the frequency range 1 to 26GHz, is presented. This method utilizes screen printing and nScrypt micro dispensing to pattern a carbon based ink onto low loss substrates. The materials chosen for this study will be presented, and the fabrication technique that these materials went through to create RF absorbing structures will be described. The calibration methods used, the modeling of the RF structures, and the applications in which this technology can be utilized will also be presented.

  20. Additive manufacturing of hybrid circuits

    DOE PAGESBeta

    Bell, Nelson S.; Sarobol, Pylin; Cook, Adam; Clem, Paul G.; Keicher, David M.; Hirschfeld, Deidre; Hall, Aaron Christopher

    2016-03-26

    There is a rising interest in developing functional electronics using additively manufactured components. Considerations in materials selection and pathways to forming hybrid circuits and devices must demonstrate useful electronic function; must enable integration; and must complement the complex shape, low cost, high volume, and high functionality of structural but generally electronically passive additively manufactured components. This article reviews several emerging technologies being used in industry and research/development to provide integration advantages of fabricating multilayer hybrid circuits or devices. First, we review a maskless, noncontact, direct write (DW) technology that excels in the deposition of metallic colloid inks for electrical interconnects.more » Second, we review a complementary technology, aerosol deposition (AD), which excels in the deposition of metallic and ceramic powder as consolidated, thick conformal coatings and is additionally patternable through masking. As a result, we show examples of hybrid circuits/devices integrated beyond 2-D planes, using combinations of DW or AD processes and conventional, established processes.« less

  1. 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.

  2. Means of manufacturing annular arrays

    DOEpatents

    Day, R.A.

    1985-10-10

    A method is described for manufacturing an annular acoustic transducer array from a plate of transducer material, which enables production of precision aligned arrays at low cost. The circular plate is sawed along at least two lines that are radial to the axis of the plate. At steps along each radial cut, the plate is rotated first in one direction and then in an opposite direction by a predetermined angle such as slightly less than 90/sup 0/. The cuts result in the forming of several largely ring-shaped lands, each largely ring-shaped land being joined to the other rings of different radii by thin portions of the plate, and each ring being cut into segments. The bridges that join different rings hold the transducer together until it can be mounted on a lens.

  3. Manufacturing Demonstration Facility: Low Temperature Materials Synthesis

    SciTech Connect

    Graham, David E.; Moon, Ji-Won; Armstrong, Beth L.; Datskos, Panos G.; Duty, Chad E.; Gresback, Ryan; Ivanov, Ilia N.; Jacobs, Christopher B.; Jellison, Gerald Earle; Jang, Gyoung Gug; Joshi, Pooran C.; Jung, Hyunsung; Meyer, III, Harry M.; Phelps, Tommy

    2015-06-30

    The Manufacturing Demonstration Facility (MDF) low temperature materials synthesis project was established to demonstrate a scalable and sustainable process to produce nanoparticles (NPs) for advanced manufacturing. Previous methods to chemically synthesize NPs typically required expensive, high-purity inorganic chemical reagents, organic solvents and high temperatures. These processes were typically applied at small laboratory scales at yields sufficient for NP characterization, but insufficient to support roll-to-roll processing efforts or device fabrication. The new NanoFermentation processes described here operated at a low temperature (~60 C) in low-cost, aqueous media using bacteria that produce extracellular NPs with controlled size and elemental stoichiometry. Up-scaling activities successfully demonstrated high NP yields and quality in a 900-L pilot-scale reactor, establishing this NanoFermentation process as a competitive biomanufacturing strategy to produce NPs for advanced manufacturing of power electronics, solid-state lighting and sensors.

  4. 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.

  5. Evaluation of advanced polymers for additive manufacturing

    SciTech Connect

    Rios, Orlando; Morrison, Crystal

    2015-09-01

    The goal of this Manufacturing Demonstration Facility (MDF) technical collaboration project between Oak Ridge National Laboratory (ORNL) and PPG Industries, Inc. was to evaluate the feasibility of using conventional coatings chemistry and technology to build up material layer-by-layer. The PPG-ORNL study successfully demonstrated that polymeric coatings formulations may overcome many limitations of common thermoplastics used in additive manufacturing (AM), allow lightweight nozzle design for material deposition and increase build rate. The materials effort focused on layer-by-layer deposition of coatings with each layer fusing together. The combination of materials and deposition results in an additively manufactured build that has sufficient mechanical properties to bear the load of additional layers, yet is capable of bonding across the z-layers to improve build direction strength. The formulation properties were tuned to enable a novel, high-throughput deposition method that is highly scalable, compatible with high loading of reinforcing fillers, and is inherently low-cost.

  6. Additive Manufacturing and High-Performance Computing: a Disruptive Latent Technology

    NASA Astrophysics Data System (ADS)

    Goodwin, Bruce

    2015-03-01

    This presentation will discuss the relationship between recent advances in Additive Manufacturing (AM) technology, High-Performance Computing (HPC) simulation and design capabilities, and related advances in Uncertainty Quantification (UQ), and then examines their impacts upon national and international security. The presentation surveys how AM accelerates the fabrication process, while HPC combined with UQ provides a fast track for the engineering design cycle. The combination of AM and HPC/UQ almost eliminates the engineering design and prototype iterative cycle, thereby dramatically reducing cost of production and time-to-market. These methods thereby present significant benefits for US national interests, both civilian and military, in an age of austerity. Finally, considering cyber security issues and the advent of the ``cloud,'' these disruptive, currently latent technologies may well enable proliferation and so challenge both nuclear and non-nuclear aspects of international security.

  7. National Center for Manufacturing Sciences: Environmentally conscious manufacturing

    NASA Technical Reports Server (NTRS)

    Vinton, Clare

    1995-01-01

    The purpose of this presentation is to share the results and some of the thinking of the Environmentally Conscious Manufacturing - Strategic Initiative Group (ECM-SIG) at the National Center for Manufacturing Sciences (NCMS). NCMS is a consortium of more than 185 North American Manufacturing organizations comprised of about 75 percent for profit manufacturing companies and about 25 percent nonprofit organizations that support manufacturing activities. NCMS conducts collaborative R&D programs designed to improve global competitiveness of its members and other North American manufacturers to address common issues that are important to manufacturing industries. NCMS is an industry driven organization whose agenda is established by industry with input from appropriate government agencies.

  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. Novel Nanotube Manufacturing Streamlines Production

    NASA Technical Reports Server (NTRS)

    2007-01-01

    Nanotubes have novel qualities that make them uniquely qualified for a plethora of uses, including applications in electronics, optics, and other scientific and industrial fields. The NASA process for creating these nanostructures involves using helium arc welding to vaporize an amorphous carbon rod and then form nanotubes by depositing the vapor onto a water-cooled carbon cathode, which then yields bundles, or ropes, of single-walled nanotubes at a rate of 2 grams per hour using a single setup. This eliminates costs associated with the use of metal catalysts, including the cost of product purification, resulting in a relatively inexpensive, high-quality, very pure end product. While managing to be less expensive, safer, and simpler, the process also increases the quality of the nanotubes. Goddard's Innovative Partnerships Program (IPP) Office promoted the technology, and in 2005, Boise-based Idaho Space Materials Inc. (ISM) was formed and applied for a nonexclusive license for the single-walled carbon nanotube (SWCNT) manufacturing technology. ISM commercialized its products, and the inexpensive, robust nanotubes are now in the hands of the scientists who will create the next generation of composite polymers, metals, and ceramics that will impact the way we live. In fact, researchers are examining ways for these newfound materials to be used in the manufacture of transistors and fuel cells, large screen televisions, ultra-sensitive sensors, high-resolution atomic force microscopy probes, supercapacitors, transparent conducting films, drug carriers, catalysts, and advanced composite materials, to name just a few of the myriad technologies to benefit.

  10. Review of the thermal energy standards for manufactured housing proposed by the Manufactured Housing Institute Consensus Committee

    SciTech Connect

    Conner, C.C.

    1992-02-01

    Congress passed legislation that requires the US Department of Housing and Urban Development (HUD) to revise the energy efficiency standards for manufactured housing contained in the Manufactured Home Construction and Safety Standards (MHCSS). The Manufactured Housing Institute's Consensus Committee (MHICC) proposed revised standards to HUD based on an analysis contained in a 1989 report by E. Levy. This document is primarily a review of the Levy report, including the methods and inputs to that analysis. The approach to be used in developing the revised standard was specified by Congress as a cost-benefit analysis in which the costs of energy efficiency measures (EEM) were balanced against the benefits of energy savings. The resulting optimum specified an overall level of energy efficiency in terms of a maximum allowable building shell U-value (overall thermal transmittance) that produced the lowest life-cycle cost to the owner of a manufactured home. In his 1989 analysis, this was the general approach used by Levy.

  11. Injector Design for Advanced Accelerators

    NASA Astrophysics Data System (ADS)

    Henestroza, Enrique; Faltens, A.

    1996-11-01

    Accelerator designs intended to provide acceleration at a much lower cost per Joule than the ILSE or ELISE designs are under study. For these designs, which typically have many beams, an injector of significantly lower cost is needed. A goal, which from our design appears to be achievable, is to reduce the transverse dimension to half that of the 2 MeV, 800 mA ILSE injector(E. Henestroza, ``Injectors for Heavy Ion Fusion", Proc. of the 11th International Wkshp. on Laser Interaction and Related Plasma Phenomena, 1993.) while generating about the same current. A single channel of a lower cost injector includes an 800 kV column, accelerating a 700 mA beam extracted from a potassium source of 4 cm radius by a 120 kV electrode. The beam passes into a superconducting 7 T solenoid of 15 cm aperture and 15 cm length. This high-field solenoid provides the focusing needed for a small beam without increasing the electric field gradient. The injector and its matching section, also designed, fit within a 12 cm radius, which is small enough to allow construction of attractive multi-beam injectors. We will present solutions for the generation and transport of 700 mA potassium beams of up to 1.6 MeV within the same transverse constraint.

  12. A variable acceleration calibration system

    NASA Astrophysics Data System (ADS)

    Johnson, Thomas H.

    2011-12-01

    A variable acceleration calibration system that applies loads using gravitational and centripetal acceleration serves as an alternative, efficient and cost effective method for calibrating internal wind tunnel force balances. Two proof-of-concept variable acceleration calibration systems are designed, fabricated and tested. The NASA UT-36 force balance served as the test balance for the calibration experiments. The variable acceleration calibration systems are shown to be capable of performing three component calibration experiments with an approximate applied load error on the order of 1% of the full scale calibration loads. Sources of error are indentified using experimental design methods and a propagation of uncertainty analysis. Three types of uncertainty are indentified for the systems and are attributed to prediction error, calibration error and pure error. Angular velocity uncertainty is shown to be the largest indentified source of prediction error. The calibration uncertainties using a production variable acceleration based system are shown to be potentially equivalent to current methods. The production quality system can be realized using lighter materials and a more precise instrumentation. Further research is needed to account for balance deflection, forcing effects due to vibration, and large tare loads. A gyroscope measurement technique is shown to be capable of resolving the balance deflection angle calculation. Long term research objectives include a demonstration of a six degree of freedom calibration, and a large capacity balance calibration.

  13. Environmentally sound manufacturing

    NASA Technical Reports Server (NTRS)

    Caddy, Larry A.; Bowman, Ross; Richards, Rex A.

    1994-01-01

    The NASA/Thiokol/industry team has developed and started implementation of an environmentally sound manufacturing plan for the continued production of solid rocket motors. They have worked with other industry representatives and the U.S. Environmental Protection Agency to prepare a comprehensive plan to eliminate all ozone depleting chemicals from manufacturing processes and to reduce the use of other hazardous materials used to produce the space shuttle reusable solid rocket motors. The team used a classical approach for problem solving combined with a creative synthesis of new approaches to attack this problem. As our ability to gather data on the state of the Earth's environmental health increases, environmentally sound manufacturing must become an integral part of the business decision making process.

  14. Environmentally sound manufacturing

    NASA Astrophysics Data System (ADS)

    Caddy, Larry A.; Bowman, Ross; Richards, Rex A.

    The NASA/Thiokol/industry team has developed and started implementation of an environmentally sound manufacturing plan for the continued production of solid rocket motors. They have worked with other industry representatives and the U.S. Environmental Protection Agency to prepare a comprehensive plan to eliminate all ozone depleting chemicals from manufacturing processes and to reduce the use of other hazardous materials used to produce the space shuttle reusable solid rocket motors. The team used a classical approach for problem solving combined with a creative synthesis of new approaches to attack this problem. As our ability to gather data on the state of the Earth's environmental health increases, environmentally sound manufacturing must become an integral part of the business decision making process.

  15. Recent developments in the economic modeling of photovoltaic module manufacturing

    NASA Technical Reports Server (NTRS)

    Chamberlain, R. G.

    1979-01-01

    Recent developments in the solar array manufacturing industry costing standards (SAMICS) are described. Consideration is given to the added capability to handle arbitrary operating schedules and the revised procedure for calculation of one-time costs. The results of an extensive validation study are summarized.

  16. 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.

  17. Method and apparatus for manufacturing gas tags

    DOEpatents

    Gross, Kenny C.; Laug, Matthew T.

    1996-01-01

    For use in the manufacture of gas tags employed in a gas tagging failure detection system for a nuclear reactor, a plurality of commercial feed gases each having a respective noble gas isotopic composition are blended under computer control to provide various tag gas mixtures having selected isotopic ratios which are optimized for specified defined conditions such as cost. Using a new approach employing a discrete variable structure rather than the known continuous-variable optimization problem, the computer controlled gas tag manufacturing process employs an analytical formalism from condensed matter physics known as stochastic relaxation, which is a special case of simulated annealing, for input feed gas selection. For a tag blending process involving M tag isotopes with N distinct feed gas mixtures commercially available from an enriched gas supplier, the manufacturing process calculates the cost difference between multiple combinations and specifies gas mixtures which approach the optimum defined conditions. The manufacturing process is then used to control tag blending apparatus incorporating tag gas canisters connected by stainless-steel tubing with computer controlled valves, with the canisters automatically filled with metered quantities of the required feed gases.

  18. Method and apparatus for manufacturing gas tags

    DOEpatents

    Gross, K.C.; Laug, M.T.

    1996-12-17

    For use in the manufacture of gas tags employed in a gas tagging failure detection system for a nuclear reactor, a plurality of commercial feed gases each having a respective noble gas isotopic composition are blended under computer control to provide various tag gas mixtures having selected isotopic ratios which are optimized for specified defined conditions such as cost. Using a new approach employing a discrete variable structure rather than the known continuous-variable optimization problem, the computer controlled gas tag manufacturing process employs an analytical formalism from condensed matter physics known as stochastic relaxation, which is a special case of simulated annealing, for input feed gas selection. For a tag blending process involving M tag isotopes with N distinct feed gas mixtures commercially available from an enriched gas supplier, the manufacturing process calculates the cost difference between multiple combinations and specifies gas mixtures which approach the optimum defined conditions. The manufacturing process is then used to control tag blending apparatus incorporating tag gas canisters connected by stainless-steel tubing with computer controlled valves, with the canisters automatically filled with metered quantities of the required feed gases. 4 figs.

  19. 78 FR 67117 - Manufacturing Council

    Federal Register 2010, 2011, 2012, 2013, 2014

    2013-11-08

    ... International Trade Administration Manufacturing Council AGENCY: International Trade Administration, U.S. Department of Commerce. ACTION: Notice of an Opportunity to Apply for Membership on the Manufacturing Council.... manufacturing industry to fill five vacant positions on the Manufacturing Council (Council). The purpose of...

  20. Educational Costs.

    ERIC Educational Resources Information Center

    Arnold, Robert

    Problems in educational cost accounting and a new cost accounting approach are described in this paper. The limitations of the individualized cost (student units) approach and the comparative cost approach (in the form of fund-function-object) are illustrated. A new strategy, an activity-based system of accounting, is advocated. Borrowed from…

  1. Manufacturing Laboratory (Fact Sheet)

    SciTech Connect

    Not Available

    2011-10-01

    This fact sheet describes the purpose, lab specifications, applications scenarios, and information on how to partner with NREL's Manufacturing Laboratory at the Energy Systems Integration Facility. The Manufacturing Laboratory at NREL's Energy Systems Integration Facility (ESIF) focuses on developing methods and technologies that will assist manufacturers of hydrogen and fuel cell technologies, as well as other renewable energy technologies, to scale up their manufacturing capabilities to volumes that meet DOE and industry targets. Specifically, the manufacturing activity is currently focused on developing and validating quality control techniques to assist manufacturers of low temperature and high temperature fuel cells in the transition from low to high volume production methods for cells and stacks. Capabilities include initial proof-of-concept studies through prototype system development and in-line validation. Existing diagnostic capabilities address a wide range of materials, including polymer films, carbon and catalyst coatings, carbon fiber papers and wovens, and multi-layer assemblies of these materials, as well as ceramic-based materials in pre- or post-fired forms. Work leading to the development of non-contact, non-destructive techniques to measure critical dimensional and functional properties of fuel cell and other materials, and validation of those techniques on the continuous processing line. This work will be supported by materials provided by our partners. Looking forward, the equipment in the laboratory is set up to be modified and extended to provide processing capabilities such as coating, casting, and deposition of functional layers, as well as associated processes such as drying or curing. In addition, continuous processes are used for components of organic and thin film photovoltaics (PV) as well as battery technologies, so synergies with these important areas will be explored.

  2. ATS materials/manufacturing

    SciTech Connect

    Karnitz, M.A.; Wright, I.G.; Ferber, M.K.

    1997-11-01

    The Materials/Manufacturing Technology subelement is a part of the base technology portion of the Advanced Turbine Systems (ATS) Program. The work in this subelement is being performed predominantly by industry with assistance from national laboratories and universities. The projects in this subelement are aimed toward hastening the incorporation of new materials and components in gas turbines. Work is currently ongoing on thermal barrier coatings (TBCs), the scale-up of single crystal airfoil manufacturing technologies, materials characterization, and technology information exchange. This paper presents highlights of the activities during the past year. 12 refs., 24 figs., 4 tabs.

  3. Dusty-Plasma Particle Accelerator

    NASA Technical Reports Server (NTRS)

    Foster, John E.

    2005-01-01

    A dusty-plasma apparatus is being investigated as means of accelerating nanometer- and micrometer-sized particles. Applications for the dusty-plasma particle accelerators fall into two classes: Simulation of a variety of rapidly moving dust particles and micrometeoroids in outer-space environments that include micrometeoroid streams, comet tails, planetary rings, and nebulae and Deposition or implantation of nanoparticles on substrates for diverse industrial purposes that could include hardening, increasing thermal insulation, altering optical properties, and/or increasing permittivities of substrate materials. Relative to prior apparatuses used for similar applications, dusty-plasma particle accelerators offer such potential advantages as smaller size, lower cost, less complexity, and increased particle flux densities. A dusty-plasma particle accelerator exploits the fact that an isolated particle immersed in plasma acquires a net electric charge that depends on the relative mobilities of electrons and ions. Typically, a particle that is immersed in a low-temperature, partially ionized gas, wherein the average kinetic energy of electrons exceeds that of ions, causes the particle to become negatively charged. The particle can then be accelerated by applying an appropriate electric field. A dusty-plasma particle accelerator (see figure) includes a plasma source such as a radio-frequency induction discharge apparatus containing (1) a shallow cup with a biasable electrode to hold the particles to be accelerated and (2) a holder for the substrate on which the particles are to impinge. Depending on the specific design, a pair of electrostatic-acceleration grids between the substrate and discharge plasma can be used to both collimate and further accelerate particles exiting the particle holder. Once exposed to the discharge plasma, the particles in the cup quickly acquire a negative charge. Application of a negative voltage pulse to the biasable electrode results in the

  4. Real time PV manufacturing diagnostic system

    SciTech Connect

    Kochergin, Vladimir; Crawford, Michael A.

    2015-09-01

    The main obstacle Photovoltaic (PV) industry is facing at present is the higher cost of PV energy compared to that of fossil energy. While solar cell efficiencies continue to make incremental gains these improvements are so far insufficient to drive PV costs down to match that of fossil energy. Improved in-line diagnostics however, has the potential to significantly increase the productivity and reduce cost by improving the yield of the process. On this Phase I/Phase II SBIR project MicroXact developed and demonstrated at CIGS pilot manufacturing line a high-throughput in-line PV manufacturing diagnostic system, which was verified to provide fast and accurate data on the spatial uniformity of thickness, an composition of the thin films comprising the solar cell as the solar cell is processed reel-to-reel. In Phase II project MicroXact developed a stand-alone system prototype and demonstrated the following technical characteristics: 1) ability of real time defect/composition inconsistency detection over 60cm wide web at web speeds up to 3m/minute; 2) Better than 1mm spatial resolution on 60cm wide web; 3) an average better than 20nm spectral resolution resulting in more than sufficient sensitivity to composition imperfections (copper-rich and copper-poor regions were detected). The system was verified to be high vacuum compatible. Phase II results completely validated both technical and economic feasibility of the proposed concept. MicroXact’s solution is an enabling technique for in-line PV manufacturing diagnostics to increase the productivity of PV manufacturing lines and reduce the cost of solar energy, thus reducing the US dependency on foreign oil while simultaneously reducing emission of greenhouse gasses.

  5. A CORBA-based manufacturing environment

    SciTech Connect

    Pancerella, C.M.; Whiteside, R.A.; Klevgard, P.A.

    1996-08-01

    A CORBA-based distributed object software system was developed for Sandia`s Agile Manufacturing Testbed (SAMT). This information architecture supports the goals of agile manufacturing: rapid response to changing requirements; small lot machining; reduction in both time and cost of the product realization process; and integration within a heterogeneous, wide-area networked enterprise. Features of the resulting software-controlled manufacturing environment are: (1) Easy plug-and-play of manufacturing devices. (2) Support for both automated and manual operations. (3) Information flow both into and out of manufacturing devices. (4) Dynamic task sequencer. Each of the heterogeneous physical objects (lathe, milling machine, robot arm, etc.) has a corresponding software object that supports a common IDL interface called IDevice. This interface provides operations for material processing, material movement, status monitoring, and other administrative tasks. CORBA objects allow for the encapsulation of a machine tool, its controller, and the network interface to the controller. Both manual and automated operations are supported by the software system. If an IDevice object receives a request for a non-automated operation, it uses an associated Console object to affect the operation by communications with a human machinist. A design goal of the Console object for a machine is to provide an information-intensive environment for the machinist, rather than just the transmittal of instructions to be carried out. In addition to the flow of information into manufacturing devices (e.g., control and NC code), the software architecture supports the easy extraction of data (e.g., sensor data or inspection reports) back out of the machine and into the broader information processing environment The task sequencer object dynamically locates devices, accepts jobs, and dispatches tasks in the manufacturing cell. A job script captures setup operations, material movement, and processing.

  6. Laser driven ion accelerator

    DOEpatents

    Tajima, Toshiki

    2006-04-18

    A system and method of accelerating ions in an accelerator to optimize the energy produced by a light source. Several parameters may be controlled in constructing a target used in the accelerator system to adjust performance of the accelerator system. These parameters include the material, thickness, geometry and surface of the target.

  7. Laser driven ion accelerator

    DOEpatents

    Tajima, Toshiki

    2005-06-14

    A system and method of accelerating ions in an accelerator to optimize the energy produced by a light source. Several parameters may be controlled in constructing a target used in the accelerator system to adjust performance of the accelerator system. These parameters include the material, thickness, geometry and surface of the target.

  8. Expert Systems Application In Manufacturing

    NASA Astrophysics Data System (ADS)

    Som, Pradip; Chitturi, Ramesh; Babu, A. J. G.

    1987-05-01

    Expert system, a special branch of Artificial Intelligence finds its way in the domain of manufacturing. This paper presents the basic ideas and features of the expert systems, problems in manufacturing and application of expert systems in manufacturing. As the process planning is an important phase in manufacturing, the suitability of expert systems for process planning area has been highlighted. Several expert systems, developed to solve manufacturing problems are also discussed in the paper.

  9. The cost of waste: Coatings

    SciTech Connect

    Rice, S.

    1996-06-01

    Some of the greatest opportunities for tapping into hidden profit potential at industrial coatings manufacturing plants may be in their waste or, rather, in their ability to eliminate the root causes of waste generation. This occurs because the total cost of waste (TCOW) does not appear only in a plant`s cost to dispose or recycle its waste. TCOW has four principal components, each of which are shown in different lines in the monthly financial accounting report. An additional potential component--the production plant capacity and personnel that are utilized producing controllable waste instead of product for sale and profit--fails to show up at all. Expanding the focus of waste reduction from merely reducing an individual component`s costs to eliminating the root causes of controllable waste generation provides significant additional profits and frees plant production equipment and people to: make more product for sale and profit, and reduce per-unit manufacturing costs.

  10. 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.

  11. 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.

  12. How much domestic quick response manufacturing can a business afford?

    NASA Astrophysics Data System (ADS)

    Warburton, Roger D. H.; Warner, Steven B.

    2000-10-01

    Employment in the U.S. apparel industry has declined dramatically since the 1960s. Will it fall inexorably to zero, or is there some base level that can endure? If so, what strategic characteristics are required to survive? There is considerable interest in Quick Response Manufacturing (QRM), not only as a reason to support domestic manufacturing, but also as part of the larger goal of reducing supply chain costs. However, since Domestic Manufacturing is more expensive, why should anyone bother considering it? This paper presents an analytical model of a team approach that includes both domestic and offshore manufacturing. Despite the additional costs associated with U.S. manufacturing, our model predicts that including a domestic contractor is legitimate and cost effective. However, the alliance must be genuinely cooperative. A partnership has to be established early in the retailer's planning cycle, and the manufacturer should participate in the planning. Also, sharing data and making timely decisions imposes a strategic business approach, and the model allows us to describe the characteristic roles and capabilities required. Using this model for guidance, we anticipate that retailers will have the stock to satisfy more customers with fewer markdowns, while manufacturers will see increased margins and lower inventories.

  13. Manufacturing scale-up of composite fuselage crown panels

    NASA Technical Reports Server (NTRS)

    Willden, Kurtis; Gessel, M.; Grant, Carroll G.; Brown, T.

    1993-01-01

    The goal of the Boeing effort under the NASA ACT program is to reduce manufacturing costs of composite fuselage structure. Materials, fabrication of complex subcomponents and assembly issues are expected to drive the costs of composite fuselage structure. Several manufacturing concepts for the crown section of the fuselage were evaluated through the efforts of a Design Build Team (DBT). A skin-stringer-frame intricate bond design that required no fasteners for the panel assembly was selected for further manufacturing demonstrations. The manufacturing processes selected for the intricate bond design include Advanced Tow Placement (ATP) for multiple skin fabrication, resin transfer molding (RTM) of fuselage frames, innovative cure tooling, and utilization of low-cost material forms. Optimization of these processes for final design/manufacturing configuration was evaluated through the fabrication of several intricate bond panels. Panels up to 7 ft. by 10 ft. in size were fabricated to simulate half scale production parts. The qualitative and quantitative results of these manufacturing demonstrations were used to assess manufacturing risks and technology readiness for production.

  14. 19 CFR 10.877 - Direct costs of processing operations.

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... manufacture of the specific good, including fringe benefits, on-the-job training, and the costs of engineering..., design, engineering, and blueprint costs, to the extent that they are allocable to the specific good;...

  15. 19 CFR 10.877 - Direct costs of processing operations.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... manufacture of the specific good, including fringe benefits, on-the-job training, and the costs of engineering..., design, engineering, and blueprint costs, to the extent that they are allocable to the specific good;...

  16. 19 CFR 10.814 - Direct costs of processing operations.

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... manufacture of the specific good, including fringe benefits, on-the-job training, and the costs of engineering..., design, engineering, and blueprint costs, to the extent that they are allocable to the specific good;...

  17. 19 CFR 10.814 - Direct costs of processing operations.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... manufacture of the specific good, including fringe benefits, on-the-job training, and the costs of engineering..., design, engineering, and blueprint costs, to the extent that they are allocable to the specific good;...

  18. 19 CFR 10.877 - Direct costs of processing operations.

    Code of Federal Regulations, 2011 CFR

    2011-04-01

    ... manufacture of the specific good, including fringe benefits, on-the-job training, and the costs of engineering..., design, engineering, and blueprint costs, to the extent that they are allocable to the specific good;...

  19. 19 CFR 10.814 - Direct costs of processing operations.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ..., design, engineering, and blueprint costs, to the extent that they are allocable to the specific good; (4... manufacture of the specific good, including fringe benefits, on-the-job training, and the costs of...

  20. 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.

  1. Advanced Computing for Manufacturing.

    ERIC Educational Resources Information Center

    Erisman, Albert M.; Neves, Kenneth W.

    1987-01-01

    Discusses ways that supercomputers are being used in the manufacturing industry, including the design and production of airplanes and automobiles. Describes problems that need to be solved in the next few years for supercomputers to assume a major role in industry. (TW)

  2. Manufacturing (Industrial) Technician.

    ERIC Educational Resources Information Center

    Ohio State Univ., Columbus. Center on Education and Training for Employment.

    This document contains 35 units to consider for use in a tech prep competency profile for the occupation of manufacturing (industrial) technician. All the units listed will not necessarily apply to every situation or tech prep consortium, nor will all the competencies within each unit be appropriate. Several units appear within each specific…

  3. Turbine airfoil manufacturing technology

    SciTech Connect

    Kortovich, C.

    1995-12-31

    The specific goal of this program is to define manufacturing methods that will allow single crystal technology to be applied to complex-cored airfoils components for power generation applications. Tasks addressed include: alloy melt practice to reduce the sulfur content; improvement of casting process; core materials design; and grain orientation control.

  4. Reusing Old Manufacturing Buildings

    ERIC Educational Resources Information Center

    Roman, Harry T.

    2014-01-01

    This article presents an interesting design challenge for students, one that will certainly let them integrate subject matter and get a sense of pride for doing something useful in their own community. The author would be willing to bet that the average town or city has some old red brick manufacturing building(s) that have seen much better days.…

  5. Manufacturing and Merchandising Careers

    ERIC Educational Resources Information Center

    Ryan, Peter J.; And Others

    1977-01-01

    Anyone with a flair for business, product development, or promotion might consider a manufacturing or merchandising occupation. The music industry offers many career opportunities for administrators, salespersons, marketing specialists--the record industry offers positions from promotion manager to rack jobber. Describes instrument company…

  6. Drug development and manufacturing

    DOEpatents

    Warner, Benjamin P.; McCleskey, T. Mark; Burrell, Anthony K.

    2015-10-13

    X-ray fluorescence (XRF) spectrometry has been used for detecting binding events and measuring binding selectivities between chemicals and receptors. XRF may also be used for estimating the therapeutic index of a chemical, for estimating the binding selectivity of a chemical versus chemical analogs, for measuring post-translational modifications of proteins, and for drug manufacturing.

  7. Manufacturing Technology. Curriculum Guide.

    ERIC Educational Resources Information Center

    North Dakota State Board for Vocational Education, Bismarck.

    This guide provides the basic foundation to develop a one-semester course based on the cluster concept, manufacturing technology. One of a set of six guides for an industrial arts curriculum at the junior high school level, it suggests activities that allow students (1) to become familiar with and use some of the tools, materials, and processes…

  8. Illinois Manufacturing Technology Curriculum.

    ERIC Educational Resources Information Center

    Cliffe, Roger; And Others

    This manufacturing technology curriculum involves students in learning problem-solving, communication, team building, quality control, safety, math, science, and technical skills. The document begins with a section on implementation, which gives background information on the purposes and development of the curriculum, explains its rationale,…

  9. 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.

  10. Photonic Crystal Laser-Driven Accelerator Structures

    SciTech Connect

    Cowan, Benjamin M.

    2007-08-22

    Laser-driven acceleration holds great promise for significantly improving accelerating gradient. However, scaling the conventional process of structure-based acceleration in vacuum down to optical wavelengths requires a substantially different kind of structure. We require an optical waveguide that (1) is constructed out of dielectric materials, (2) has transverse size on the order of a wavelength, and (3) supports a mode with speed-of-light phase velocity in vacuum. Photonic crystals---structures whose electromagnetic properties are spatially periodic---can meet these requirements. We discuss simulated photonic crystal accelerator structures and describe their properties. We begin with a class of two-dimensional structures which serves to illustrate the design considerations and trade-offs involved. We then present a three-dimensional structure, and describe its performance in terms of accelerating gradient and efficiency. We discuss particle beam dynamics in this structure, demonstrating a method for keeping a beam confined to the waveguide. We also discuss material and fabrication considerations. Since accelerating gradient is limited by optical damage to the structure, the damage threshold of the dielectric is a critical parameter. We experimentally measure the damage threshold of silicon for picosecond pulses in the infrared, and determine that our structure is capable of sustaining an accelerating gradient of 300 MV/m at 1550 nm. Finally, we discuss possibilities for manufacturing these structures using common microfabrication techniques.

  11. U.S. Wind Energy Manufacturing & Supply Chain: A Competitive Analysis

    SciTech Connect

    Fullenkamp, Patrick

    2014-06-15

    The Global Wind Network (GLWN) assessed the key factors that determine wind energy component manufacturing costs and pricing on a global basis in order to provide a better understanding of the factors that will help enhance the competitiveness of U.S. manufacturers, and reduce installed system costs.

  12. 78 FR 44095 - Request for Information on Pilots To Inform the Creation of Potential New Manufacturing...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2013-07-23

    ... NIST's planning for a FFO in FY 2014 to competitively fund a select number of new M-TACs (78 FR 37422... Potential New Manufacturing Technology Acceleration Centers (M-TACs); Extension of Comment Period AGENCY... NIST's planning for a Federal Funding Opportunity (FFO) for new manufacturing technology...

  13. Analysis of quality costs - A critical element in CIM

    NASA Technical Reports Server (NTRS)

    Unal, Resit; Dean, Edwin B.

    1990-01-01

    Computer integrated manufacturing (CIM) is a cohesive database of manufacturing information, providing an opportunity to track quality costs and measure progress toward their reduction. This paper presents the quality cost concept as an approach to identify, measure and reduce quality costs while improving quality within CIM. The effect of advanced failure prevention methodologies, such as continuous process improvement and the quality engineering methods of Taguchi, on quality and cost, is discussed.

  14. Hybrid Laser-Plasma Wakefield Acceleration

    SciTech Connect

    Hidding, B.; Koenigstein, T.; Willi, O.; Pretzler, G.; Karsch, S.; Rosenzweig, J. B.

    2010-11-04

    The concept of driving a driver/witness-type plasma wakefield accelerator (PWFA) with quasimonoenergetic double electron bunches from a laser wakefield accelerator (LWFA) is studied. In the quasimonoenergetic LWFA/SMLWFA (self-modulated LWFA) regime, it is possible to generate multiple quasimonoenergetic electron bunches with durations of only a few fs and distances of only a few tens of fs with a comparably simple experimental setup. In a subsequent high-density plasma afterburner stage the witness bunch energy can be boosted in the plasma wakefield generated by the driver. Such a hybrid system can increase the maximum energy output of a laser wakefield accelerator and is well suited to study driver/witness plasma accelerator phenomena and can be used as a cost-effective test-bed for future high-energy plasma-based accelerators.

  15. Hybrid Laser-Plasma Wakefield Acceleration

    NASA Astrophysics Data System (ADS)

    Hidding, B.; Königstein, T.; Karsch, S.; Willi, O.; Pretzler, G.; Rosenzweig, J. B.

    2010-11-01

    The concept of driving a driver/witness-type plasma wakefield accelerator (PWFA) with quasimonoenergetic double electron bunches from a laser wakefield accelerator (LWFA) is studied. In the quasimonoenergetic LWFA/SMLWFA (self-modulated LWFA) regime, it is possible to generate multiple quasimonoenergetic electron bunches with durations of only a few fs and distances of only a few tens of fs with a comparably simple experimental setup. In a subsequent high-density plasma afterburner stage the witness bunch energy can be boosted in the plasma wakefield generated by the driver. Such a hybrid system can increase the maximum energy output of a laser wakefield accelerator and is well suited to study driver/witness plasma accelerator phenomena and can be used as a cost-effective test-bed for future high-energy plasma-based accelerators.

  16. Demystifying the Cost Estimation Process

    ERIC Educational Resources Information Center

    Obi, Samuel C.

    2010-01-01

    In manufacturing today, nothing is more important than giving a customer a clear and straight-forward accounting of what their money has purchased. Many potentially promising return business orders are lost because of unclear, ambiguous, or improper billing. One of the best ways of resolving cost bargaining conflicts is by providing a…

  17. The Energy Cost of Automobiles

    ERIC Educational Resources Information Center

    Berry, R. Stephen; Fels, Margaret F.

    1973-01-01

    Presents two respective comparisons between ideal and real energy cost for the manufacture of a new automobile and between free energy savings from processing the old automobile into low and high grade scraps. Suggests the wasted thermodynamic potential should be considered in making decisions about energy savings. (CC)

  18. Accelerator-induced transients in Accelerator Driven Subcritical Reactors

    NASA Astrophysics Data System (ADS)

    Ahmad, Ali; Lindley, Benjamin A.; Parks, Geoffrey T.

    2012-12-01

    Achieving higher particles energies and beam powers have long been the main focus of research in accelerator technology. Since Accelerator Driven Subcritical Reactors (ADSRs) have become the subject of increasing interest, accelerator reliability and modes of operation have become important matters that require further research and development in order to accommodate the engineering and economic needs of ADSRs. This paper focuses on neutronic and thermo-mechanical analyses of accelerator-induced transients in an ADSR. Such transients fall into three main categories: beam interruptions (trips), pulsed-beam operation, and beam overpower. The concept of a multiple-target ADSR is shown to increase system reliability and to mitigate the negative effects of beam interruptions, such as thermal cyclic fatigue in the fuel cladding and the huge financial cost of total power loss. This work also demonstrates the effectiveness of the temperature-to-reactivity feedback mechanisms in ADSRs. A comparison of shutdown mechanisms using control rods and beam cut-off highlights the intrinsic safety features of ADSRs. It is evident that the presence of control rods is crucial in an industrial-scale ADSR. This paper also proposes a method to monitor core reactivity online using the repetitive pattern of beam current fluctuations in a pulsed-beam operation mode. Results were produced using PTS-ADS, a computer code developed specifically to study the dynamic neutronic and thermal responses to beam transients in subcritical reactor systems.

  19. Miniature accelerator-driven gamma source concept.

    SciTech Connect

    Garnett, R. W.; Chan, K. D.; Wangler, Thomas P.,; Wood R. L.; Carlsten, B. E.; Kirbie, H. C.

    2003-01-01

    Recent developments in W-band (-100 GHz) traveling wave tube technology at Los Alarnos may lead to a compact high-power W-band RE source. A conceptual design of a compact 8-MeV electron linac that codd be powered by this source is presented, including electromagnetic structure calculations, proposed rnicrojbbrication and manufacturing methods, supporting calculations to estimate accelerator performance, and gumma production rates based on preliminary target geometries and expected output beam current.

  20. Scintillator manufacture at Fermilab

    SciTech Connect

    Mellott, K.; Bross, A.; Pla-Dalmau, A.

    1998-08-01

    A decade of research into plastic scintillation materials at Fermilab is reviewed. Early work with plastic optical fiber fabrication is revisited and recent experiments with large-scale commercial methods for production of bulk scintillator are discussed. Costs for various forms of scintillator are examined and new development goals including cost reduction methods and quality improvement techniques are suggested.

  1. Cost goals

    NASA Technical Reports Server (NTRS)

    Hoag, J.

    1981-01-01

    Cost goal activities for the point focusing parabolic dish program are reported. Cost goals involve three tasks: (1) determination of the value of the dish systems to potential users; (2) the cost targets of the dish system are set out; (3) the value side and cost side are integrated to provide information concerning the potential size of the market for parabolic dishes. The latter two activities are emphasized.

  2. Tracking Costs

    ERIC Educational Resources Information Center

    Erickson, Paul W.

    2010-01-01

    Even though there's been a slight reprieve in energy costs, the reality is that the cost of non-renewable energy is increasing, and state education budgets are shrinking. One way to keep energy and operations costs from overshadowing education budgets is to develop a 10-year energy audit plan to eliminate waste. First, facility managers should…

  3. The direction of acceleration

    NASA Astrophysics Data System (ADS)

    Wilhelm, Thomas; Burde, Jan-Philipp; Lück, Stephan

    2015-11-01

    Acceleration is a physical quantity that is difficult to understand and hence its complexity is often erroneously simplified. Many students think of acceleration as equivalent to velocity, a ˜ v. For others, acceleration is a scalar quantity, which describes the change in speed Δ|v| or Δ|v|/Δt (as opposed to the change in velocity). The main difficulty with the concept of acceleration therefore lies in developing a correct understanding of its direction. The free iOS app AccelVisu supports students in acquiring a correct conception of acceleration by showing acceleration arrows directly at moving objects.

  4. TURBULENT SHEAR ACCELERATION

    SciTech Connect

    Ohira, Yutaka

    2013-04-10

    We consider particle acceleration by large-scale incompressible turbulence with a length scale larger than the particle mean free path. We derive an ensemble-averaged transport equation of energetic charged particles from an extended transport equation that contains the shear acceleration. The ensemble-averaged transport equation describes particle acceleration by incompressible turbulence (turbulent shear acceleration). We find that for Kolmogorov turbulence, the turbulent shear acceleration becomes important on small scales. Moreover, using Monte Carlo simulations, we confirm that the ensemble-averaged transport equation describes the turbulent shear acceleration.

  5. Material Design, Selection, and Manufacturing Methods for System Sustainment

    SciTech Connect

    David Sowder, Jim Lula, Curtis Marshall

    2010-02-18

    This paper describes a material selection and validation process proven to be successful for manufacturing high-reliability long-life product. The National Secure Manufacturing Center business unit of the Kansas City Plant (herein called KCP) designs and manufactures complex electrical and mechanical components used in extreme environments. The material manufacturing heritage is founded in the systems design to manufacturing practices that support the U.S. Department of Energy’s National Nuclear Security Administration (DOE/NNSA). Material Engineers at KCP work with the systems designers to recommend materials, develop test methods, perform analytical analysis of test data, define cradle to grave needs, present final selection and fielding. The KCP material engineers typically will maintain cost control by utilizing commercial products when possible, but have the resources and to develop and produce unique formulations as necessary. This approach is currently being used to mature technologies to manufacture materials with improved characteristics using nano-composite filler materials that will enhance system design and production. For some products the engineers plan and carry out science-based life-cycle material surveillance processes. Recent examples of the approach include refurbished manufacturing of the high voltage power supplies for cockpit displays in operational aircraft; dry film lubricant application to improve bearing life for guided munitions gyroscope gimbals, ceramic substrate design for electrical circuit manufacturing, and tailored polymeric materials for various systems. The following examples show evidence of KCP concurrent design-to-manufacturing techniques used to achieve system solutions that satisfy or exceed demanding requirements.

  6. Manufactured Home Energy Audit user`s manual

    SciTech Connect

    1997-09-01

    The Manufactured Home Energy Audit (MHEA) is a software tool that predicts manufactured home energy consumption and recommends weatherization retrofit measures. It was developed to assist local weatherization agencies working with the US Department of Energy (DOE) Weatherization Assistance Program. Whether new or experienced, employed within or outside the Weatherization Assistance Program, all users can benefit from incorporating MHEA into their manufactured home weatherization programs. DOE anticipates that the state weatherization assistance programs that incorporate MHEA into their programs will find significant growth in the energy and cost savings achieved from manufactured home weatherization. The easy-to-use MHEA displays a colorful, graphical interface for entering simple inputs and provides understandable, usable results. The user enters information about the manufactured home construction, heating equipment, cooling equipment, and weather site. MHEA then calculates annual energy consumption using a simplified building energy analysis technique. MHEA stands apart from other building energy analysis tools in many ways. Calculations incorporated into the computer code specifically address manufactured home heating and cooling load trends. The retrofit measures evaluated by MHEA are all applicable to manufactured homes. Help messages describe common manufactured home weatherization practices as well as provide hints on how to install retrofit measures. These and other features help make MHEA easy to use when evaluating energy consumption and the effects of weatherization retrofit measures for manufactured homes.

  7. Diamond turning considerations in the manufacture of beam shaping optics

    NASA Astrophysics Data System (ADS)

    Davis, Gregg E.; Herrit, Gary L.; Hedges, Alan R.

    2011-10-01

    Advances in diamond turning technology have offered optical designers new degrees of freedom in beam shaping optics. While designers have these new manufacturing methods at their disposal, they may not be aware of special process limitations and cost drivers. The purpose of this paper is to present some of these critical manufacturing issues. We will discuss briefly special beam shaping optic types and applications. Then in more detail we will discuss the four key diamond turning techniques and the types of optics they can produce. These four key manufacturing techniques are: standard 2 axis diamond turning, slow tool servo, fast tool servo, micromilling. During the discussion we will present surface shapes, process limitations, as well as cost drivers for each technique. In summary will we present this data in a matrix that will aid the designer in selecting manufacturing techniques and optic types.

  8. Advanced Manufacturing for a U.S. Clean Energy Economy (Fact Sheet)

    SciTech Connect

    Not Available

    2012-03-01

    This fact sheet is an overview of the U.S. Department of Energy's Advanced Manufacturing Office. Manufacturing is central to our economy, culture, and history. The industrial sector produces 11% of U.S. gross domestic product (GDP), employs 12 million people, and generates 57% of U.S. export value. However, U.S. industry consumes about one-third of all energy produced in the United States, and significant cost-effective energy efficiency and advanced manufacturing opportunities remain unexploited. As a critical component of the National Innovation Policy for Advanced Manufacturing, the U.S. Department of Energy's (DOE's) Advanced Manufacturing Office (AMO) is focused on creating a fertile environment for advanced manufacturing innovation, enabling vigorous domestic development of transformative manufacturing technologies, promoting coordinated public and private investment in precompetitive advanced manufacturing technology infrastructure, and facilitating the rapid scale-up and market penetration of advanced manufacturing technologies.

  9. Perspectives on Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Bourell, David L.

    2016-07-01

    Additive manufacturing (AM) has skyrocketed in visibility commercially and in the public sector. This article describes the development of this field from early layered manufacturing approaches of photosculpture, topography, and material deposition. Certain precursors to modern AM processes are also briefly described. The growth of the field over the last 30 years is presented. Included is the standard delineation of AM technologies into seven broad categories. The economics of AM part generation is considered, and the impacts of the economics on application sectors are described. On the basis of current trends, the future outlook will include a convergence of AM fabricators, mass-produced AM fabricators, enabling of topology optimization designs, and specialization in the AM legal arena. Long-term developments with huge impact are organ printing and volume-based printing.

  10. 48 CFR 31.205-26 - Material costs.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... CONTRACTING REQUIREMENTS CONTRACT COST PRINCIPLES AND PROCEDURES Contracts With Commercial Organizations 31..., subassemblies, components, and manufacturing supplies, whether purchased or manufactured by the contractor, and... returned to vendors; and (2) Credit such income and other credits either directly to the cost of...

  11. PV Cz silicon manufacturing technology improvements

    NASA Astrophysics Data System (ADS)

    Jester, T.

    1995-09-01

    This describes work done in the final phase of a 3-y, 3-phase contract to demonstrate cost reductions and improvements in manufacturing technology. The work focused on near-term projects in the SSI (Siemens Solar Industries) Czochralski (Cz) manufacturing facility in Camarillo, CA; the final phase was concentrated in areas of crystal growth, wafer technology, and environmental, safety, and health issues. During this period: (1) The crystal-growing operation improved with increased growth capacity; (2) Wafer processing with wire saws continued to progress; the wire saws yielded almost 50 percent more wafers per inch in production. The wire saws needs less etching, too; (3) Cell processing improvements focused on better handling and higher mechanical yield. The cell electrical distribution improved with a smaller standard deviation in the distribution; and (4) Module designs for lower material and labor costs continued, with focus on a new junction box, larger modules with larger cells, and less costly framing techniques. Two modules demonstrating these cost reductions were delivered during this phase.

  12. Technology for Manufacturing Efficiency

    NASA Technical Reports Server (NTRS)

    1995-01-01

    The Ground Processing Scheduling System (GPSS) was developed by Ames Research Center, Kennedy Space Center and divisions of the Lockheed Company to maintain the scheduling for preparing a Space Shuttle Orbiter for a mission. Red Pepper Software Company, now part of PeopleSoft, Inc., commercialized the software as their ResponseAgent product line. The software enables users to monitor manufacturing variables, report issues and develop solutions to existing problems.

  13. Advancements in asphere manufacturing

    NASA Astrophysics Data System (ADS)

    Fess, Edward; DeFisher, Scott

    2013-09-01

    Aspheric optics can pose as a challenge to the manufacturing community due to the surface shape and level of quality required. The aspheric surface may have inflection points that limit the usable tool size during manufacturing, or there may be a stringent tolerance on the slope for mid-spatial frequencies that may be problematic for sub-aperture finishing techniques to achieve. As aspheres become more commonplace in the optics community, requests for more complex aspheres have risen. OptiPro Systems has been developing technologies to create a robust aspheric manufacturing process. Contour deterministic microgrinding is performed on a Pro80 or eSX platform. These platforms utilize software and the latest advancements in machine motion to accurately contour the aspheric shape. Then the optics are finished using UltraForm Finishing (UFF), which is a sub-aperture polishing process. This process has the capability to adjust the diameter and compliance of the polishing lap to allow for finishing over a wide range of shapes and conditions. Finally, the aspheric surfaces are qualified using an OptiTrace contact profilometer, or an UltraSurf non-contact 3D surface scanner. The OptiTrace uses a stylus to scan across the surface of the part, and the UltraSurf utilizes several different optical pens to scan the surface and generate a topographical map of the surface under test. This presentation will focus on the challenges for asphere manufacturing, how OptiPro has implemented its technologies to combat these challenges, and provide surface data for analysis.

  14. Electrohydrodynamic Printing and Manufacturing

    NASA Technical Reports Server (NTRS)

    Aksay, Ilhan A. (Inventor); Saville, Dudley A. (Inventor); Poon, Hak Fei (Inventor); Korkut, Sibel (Inventor); Chen, Chuan-hua (Inventor)

    2014-01-01

    An stable electrohydrodynamic filament is obtained by causing a straight electrohydrodynamic filament formed from a liquid to emerge from a Taylor cone, the filament having a diameter of from 10 nm to 100.mu.m. Such filaments are useful in electrohydrodynamic printing and manufacturing techniques and their application in liquid drop/particle and fiber production, colloidal deployment and assembly, and composite materials processing.

  15. Precision manufacturing of compact disc master stampers

    SciTech Connect

    Bifano, T.; Caggiano, H.; Bierden, P.

    1996-12-31

    The authors have developed a new manufacturing process for compact disc master stamper production. Stamper is an industry term for the mold used to replicate polymer CDs in an injection molding device. The stamper surface contains a negative image of the CD`s >1 billion features, each measuring 0.5 {mu}m wide, 1-3{mu}m long, and 150 nm tall. These features are embossed in a spiral pattern on the 138 mm diameter stamper substrate. In conventional mastering, nickel sub-master stampers are generated by electroforming from a glass master with a masked photoresist layer. In the new process, called Precision Stamper Manufacturing (PSM), sub-master stampers are not required - the ceramic master is used directly as a stamper for injection molding. The technology uses precision manufacturing to improve productivity, reduce hazardous waste, and reduce costs in production of master stampers. All critical process steps have been proven feasible in the research reported here. More than 120 minutes of conventional manufacturing processes are replaced by about 20 minutes of precision machining processes, with improved precision in the final component. Another benefit of PSM is that it eliminates most process steps that produce hazardous wastes. Objectives of the experimental research have been to verify feasibility of the method, and to manufacture a prototype CD stamper. Over the past year, we have demonstrated feasibility of all process steps in the new method, and results will be presented. Also, we uncovered and quantified several important limitations for each process step, and combined the individual steps into a manufacturing cycle through which a full-scale working stamper prototype was made. These experiments made use of available facilities at two major equipment suppliers for the CD, an ion machining equipment, and a national research facility, in addition to facilities at Boston University and Prism Corporation.

  16. When your contract manufacturer becomes your competitor.

    PubMed

    Arruñda, Benito; Vázquez, Xosé H

    2006-09-01

    PC maker Lenovo started out as a distributor of equipment made by IBM and other companies; now it has formed a joint venture with IBM and will eventually affix its own logo to its computers. Shanghai Automotive Industry Corporation (SAIC) started out manufacturing vehicles for Volkswagen and GM; now it's preparing to sell its own cars in China, Europe, and North America. Lenovo and SAIC represent a host of formerly anonymous makers of brand-name products that are breaking out of their defined roles and pushing the brands themselves aside. In this article, the authors explore the double-edged relationships original equipment manufacturers (OEMs) forge with their contract manufacturers (CMs). On the one hand, an OEM can reduce its labor costs, free up capital, and improve worker productivity by outsourcing all the manufacturing of a product. The company can then concentrate on value-adding activities--research and development, product design, and marketing, for instance. On the other hand, an OEM that retains a contract manufacturer may find itself immersed in a melodrama replete with promiscuity (the ambitious CM pursues liaisons with other OEMs), infidelity (the OEM's retailers and distributors shift their business to the upstart CM), and betrayal (the brazen CM transmits the OEM's intellectual property to the OEM's rivals or keeps it for itself when the contract is up). OEMs cannot simply terminate their outsourcing arrangements--they need contract manufacturers in order to keep specializing, adding value, and staying competitive. But OEMs can manage these relationships so that they don't become weak or the CMs too strong. Doing so requires modesty about revealing trade secrets; caution about whom one consorts with; and a judicious degree of intimacy, loyalty, and generosity toward partners and customers. PMID:16967627

  17. Personal computers in accelerator control

    NASA Astrophysics Data System (ADS)

    Anderssen, P. S.

    1988-07-01

    The advent of the personal computer has created a popular movement which has also made a strong impact on science and engineering. Flexible software environments combined with good computational performance and large storage capacities are becoming available at steadily decreasing costs. Of equal importance, however, is the quality of the user interface offered on many of these products. Graphics and screen interaction is available in ways that were only possible on specialized systems before. Accelerator engineers were quick to pick up the new technology. The first applications were probably for controllers and data gatherers for beam measurement equipment. Others followed, and today it is conceivable to make personal computer a standard component of an accelerator control system. This paper reviews the experience gained at CERN so far and describes the approach taken in the design of the common control center for the SPS and the future LEP accelerators. The design goal has been to be able to integrate personal computers into the accelerator control system and to build the operator's workplace around it.

  18. A portable accelerator control toolkit

    SciTech Connect

    Watson, W.A. III

    1997-06-01

    In recent years, the expense of creating good control software has led to a number of collaborative efforts among laboratories to share this cost. The EPICS collaboration is a particularly successful example of this trend. More recently another collaborative effort has addressed the need for sophisticated high level software, including model driven accelerator controls. This work builds upon the CDEV (Common DEVice) software framework, which provides a generic abstraction of a control system, and maps that abstraction onto a number of site-specific control systems including EPICS, the SLAC control system, CERN/PS and others. In principle, it is now possible to create portable accelerator control applications which have no knowledge of the underlying and site-specific control system. Applications based on CDEV now provide a growing suite of tools for accelerator operations, including general purpose displays, an on-line accelerator model, beamline steering, machine status displays incorporating both hardware and model information (such as beam positions overlaid with beta functions) and more. A survey of CDEV compatible portable applications will be presented, as well as plans for future development.

  19. Advanced manufacturing: Technology diffusion

    SciTech Connect

    Tesar, A.

    1995-12-01

    In this paper we examine how manufacturing technology diffuses rom the developers of technology across national borders to those who do not have the capability or resources to develop advanced technology on their own. None of the wide variety of technology diffusion mechanisms discussed in this paper are new, yet the opportunities to apply these mechanisms are growing. A dramatic increase in technology diffusion occurred over the last decade. The two major trends which probably drive this increase are a worldwide inclination towards ``freer`` markets and diminishing isolation. Technology is most rapidly diffusing from the US In fact, the US is supplying technology for the rest of the world. The value of the technology supplied by the US more than doubled from 1985 to 1992 (see the Introduction for details). History shows us that technology diffusion is inevitable. It is the rates at which technologies diffuse to other countries which can vary considerably. Manufacturers in these countries are increasingly able to absorb technology. Their manufacturing efficiency is expected to progress as technology becomes increasingly available and utilized.

  20. Efficiency and Innovation in U.S. Manufacturing Energy Use

    SciTech Connect

    2005-06-01

    The NAM has partnered with the Alliance to Save Energy to develop this booklet for manufacturers who want to achieve more strategic control over rising energy costs. Being better energy managers is important not only for each company, but is also an essential component in achieving a low-inflation, high-growth economy. We hope that the opportunities outlined in this booklet will encourage manufacturers to make energy efficiency a part of standard operating procedure.