Science.gov

Sample records for low-cost manufacturing processes

  1. 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.

  2. 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

  3. 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.

  4. 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. © 2015 Wiley Periodicals, Inc.

  5. 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

  6. 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.

  7. Low Cost Process for Manufacture of Oxide Dispersion Strengthened (ODS) Turbine Nozzle Components.

    DTIC Science & Technology

    1979-12-01

    SWTTPROCESS FORJIANUFACTURE OF9OXIDE)ISPERSIONSTRENGTHENED (ODS) O0 TURBINE !IJOZZLE COMPONENTS, -- , General Electric Company Aircraft Engine Group...machining processes for low pressure turbine (LPT) vanes , high pressure turbine (HPT) vanes , and HPT band segments for the F101 engine . The primary intent...for aircraft turbine nozzle components. These processes were shown capable of maintaining required microstructures and properties for the vane and

  8. 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.

  9. LOW-COST COMPOSITES IN VEHICLE MANUFACTURE - Low-Cost Composites in Automotive and Heavy Vehicle Manufacture

    SciTech Connect

    Grant, Glenn J.

    2006-11-01

    The automotive and heavy vehicle manufacturing markets are extremely sensitive to costs. Margins are not high in these markets and differences in fixed costs and national infrastructure between different companies and countries creates a highly competitive environment. Composites can offer tremendous competitive advantages in this industry to help differentiate between products by offering increased safety, strength, fuel efficiency, and recyclability. However, composites are by definition more complex than the largely monolithic materials they replace. This leads to a situation where the composite solution to a structural problem is often a higher-cost solution. To successfully implement a composite material into an engineering system there is a need to drive down the costs of the composite materials. This can be done through the use of low-cost raw material precursors, low-cost manufacturing methods, or by using composites of high specific stiffness so that less material is needed in the structure. In this issue we have gathered five papers describing some of the recent advances in the application of low-cost composites to automotive and heavy vehicle manufacturing. These papers cover metal-matrix composites (MMCs), carbon fiber and natural fiber polymer-based composites, and a unique reaction-processed cermet. The papers included here are by no means exhaustive of the increasing new composite applications in transportation manufacturing, but give a flavor of some of the current research directions.

  10. Low cost CIS device processing

    NASA Astrophysics Data System (ADS)

    Başol, B. M.; Kapur, V. K.; Leidholm, C. R.; Roe, R.; Halani, A.; Norsworthy, G.

    1997-02-01

    CIS films were grown on soda-lime glass/Mo substrates using a low cost, non-vacuum technique. Morphology of the resulting layers was improved and solar cells with 12.4% total area efficiency were demonstrated on these films. A submodule of about 25 cm2 area was also fabricated with a conversion efficiency of 8.17%. Work is now in progress to grow films containing Ga and/or S and to take this technology to larger scale production.

  11. 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.

  12. 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). Copyright © 2012 Elsevier Ltd. All rights reserved.

  13. Low-cost LANDSAT processing system

    NASA Technical Reports Server (NTRS)

    Faust, N. L.; Hooper, N. J.; Spann, G. W.

    1980-01-01

    LANDSAT analysis system is assembled from commercially available components at relatively low cost. Small-scale system is put together for price affordable for state agencies and universities. It processes LANDSAT data for subscene areas on repetitive basis. Amount of time required for processing decreases linearly with number of classifications desired. Computer programs written in FORTRAN IV are available for analyzing data.

  14. Additively Manufactured Low Cost Upper Stage Combustion Chamber

    NASA Technical Reports Server (NTRS)

    Protz, Christopher; Cooper, Ken; Ellis, David; Fikes, John; Jones, Zachary; Kim, Tony; Medina, Cory; Taminger, Karen; Willingham, Derek

    2016-01-01

    Over the past two years NASA's Low Cost Upper Stage Propulsion (LCUSP) project has developed Additive Manufacturing (AM) technologies and design tools aimed at reducing the costs and manufacturing time of regeneratively cooled rocket engine components. High pressure/high temperature combustion chambers and nozzles must be regeneratively cooled to survive their operating environment, causing their design fabrication to be costly and time consuming due to the number of individual steps and different processes required. Under LCUSP, AM technologies in Sintered Laser Melting (SLM) GRCop-84 and Electron Beam Freeform Fabrication (EBF3) Inconel 625 have been significantly advanced, allowing the team to successfully fabricate a 25k-class regenerative chamber. Estimates of the costs and schedule of future builds indicate cost reductions and significant schedule reductions will be enabled by this technology. Characterization of the microstructural and mechanical properties of the SLM-produced GRCop-84, EBF3 Inconel 625 and the interface layer between the two has been performed and indicates the properties will meet the design requirements. The LCUSP chamber is to be tested with a previously demonstrated SLM injector in order to advance the Technology Readiness Level (TRL) and demonstrate the capability of the application of these processes. NASA is advancing these technologies to reduce cost and schedule for future engine applications and commercial needs.

  15. Process and assembly plans for low cost commercial fuselage structure

    NASA Technical Reports Server (NTRS)

    Willden, Kurtis; Metschan, Stephen; Starkey, Val

    1991-01-01

    Cost and weight reduction for a composite structure is a result of selecting design concepts that can be built using efficient low cost manufacturing and assembly processes. Since design and manufacturing are inherently cost dependent, concurrent engineering in the form of a Design-Build Team (DBT) is essential for low cost designs. Detailed cost analysis from DBT designs and hardware verification must be performed to identify the cost drivers and relationships between design and manufacturing processes. Results from the global evaluation are used to quantitatively rank design, identify cost centers for higher ranking design concepts, define and prioritize a list of technical/economic issues and barriers, and identify parameters that control concept response. These results are then used for final design optimization.

  16. 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

  17. 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

  18. 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

  19. 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

  20. 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.

  1. 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.

  2. Low cost processes for silicon. [fabricated for solar cells

    NASA Technical Reports Server (NTRS)

    Lutwack, R.

    1979-01-01

    The paper describes the multiple process development of low cost processes for manufacture of silicon. A support program includes subtasks for the modeling of reactions and reactors, chemical engineering and solid-state physics studies, and development of impurity concentration measurement procedures. The preliminary economic analyses indicate total product costs ranging from $5.00 to $8.73/kg based on 1000 MT/yr plants. In the studies of impurity effects, a model which considers that degradations of solar cell performance by impurities are primarily due to decreases in base diffusion length was constructed from experimental data.

  3. 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.

  4. Broadcasting photonic lab on a chip concept through a low cost manufacturing approach.

    PubMed

    Rodríguez-Ruiz, Isaac; Teychené, Sébastien; Van Pham, Nhat; Radajewski, Dimitri; Lamadie, Fabrice; Llobera, Andreu; Charton, Sophie

    2017-08-01

    A low cost fabrication process for photonic lab on a chip systems is here proposed. For the implementation of the masters suitable for cast molding fabrication, an inexpensive dry film photoresist, patternable using standard laboratory equipment, is benchmarked against standardized SU-8 masters obtained using UV lithography and systems manufacture in clean room facilities. Results show adequate system fabrication and a comparable performance of the photonic structures for absorbance/extinction measurements. Copyright © 2017 Elsevier B.V. All rights reserved.

  5. Powder Injection Molding (PIM) for Low Cost Manufacturing of Intricate Parts to Net-Shape

    DTIC Science & Technology

    2006-05-01

    Molding (PIM) for Low Cost Manufacturing of Intricate Parts to Net-Shape 7 - 6 RTO-MP-AVT-139 high temperature materials find applications in...offers significant cost savings, increased design and materials flexibility, increased possibility of miniaturization, high mechanical properties, good...surface finish and high speed production. The activities and expertise in powder metallurgy as well as in process numerical modeling related to

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

    NASA Astrophysics Data System (ADS)

    Ku, Robert T.

    2004-05-01

    (LOS), its subsequent automated testing and burn/in process; and the placement of the LOS into a package body and hermetically sealing the package. The LOS and Package automated assembler robots have achieved a metrics of less than 1 um accuracy and 0.1 um resolution. The paper also discusses a method for the critical alignment of a single-mode fiber as the last step of the manufacturing process. This approach is in contrast to the conventional manual assembly where sub-micron fiber alignment and fixation steps are performed much earlier during the assembly process. Finally the paper discusses the value of this automated platform manufacturing approach as a key enabler for low cost small form factor optical components for the new XFP MSA class of transceiver modules.

  7. Producing optical (contact) lenses by a novel low cost process

    NASA Astrophysics Data System (ADS)

    Skipper, Richard S.; Spencer, Ian D.

    2005-09-01

    The rapid and impressive growth of China has been achieved on the back of highly labour intensive industries, often in manufacturing, and at the cost of companies and jobs in Europe and America. Approaches that worked well in the 1990's to reduce production costs in the developed countries are no longer effective when confronted with the low labour costs of China and India. We have looked at contact lenses as a product that has become highly available to consumers here but as an industry that has reduced costs by moving to low labour cost countries. The question to be answered was, "Do we have the skill to still make the product in the UK, and can we make it cheap enough to export to China?" if we do not, then contact lens manufacture will move to China sooner or later. The challenge to enter the markets of the BRIC (Brazil, Russia, India and China) countries is extremely exciting as here is the new money, high growth and here is a product that sells to those with disposable incomes. To succeed we knew we had to be radical in our approach; the radical step was very simple: to devise a process in which each step added value to the customer and not cost to the product. The presentation examines the processes used by the major producers and how, by applying good manufacturing practice sound scientific principles to them, the opportunity to design a new low cost patented process was identified.

  8. Modular Exhaust Design and Manufacturing Techniques for Low Cost Mid Volume Rapid Buidl to Order Systems

    DTIC Science & Technology

    2014-08-06

    technical data package will contain the following pieces of information: • Manufacturing Drawings • Code for running CNC machinery • Documentation...MODULAR EXHAUST DESIGN AND MANUFACTURING TECHNIQUES FOR LOW COST MID VOLUME RAPID BUILD TO ORDER SYSTEMS Kevin Nelson Project Engineer...customizable mufflers, as well as modular manufacturing techniques targeted at mid volume manufacturing quantities. A successful solution would reduce

  9. Low-cost exterior insulation process and structure

    DOEpatents

    Vohra, A.

    1999-03-02

    A low-cost exterior insulation process of stacking bags of insulating material against a wall and covering them with wire mesh and stucco provides a durable structure with good insulating value. 2 figs.

  10. 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.

  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. 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

  13. Low cost 3D scanning process using digital image processing

    NASA Astrophysics Data System (ADS)

    Aguilar, David; Romero, Carlos; Martínez, Fernando

    2017-02-01

    This paper shows the design and building of a low cost 3D scanner, able to digitize solid objects through contactless data acquisition, using active object reflection. 3D scanners are used in different applications such as: science, engineering, entertainment, etc; these are classified in: contact scanners and contactless ones, where the last ones are often the most used but they are expensive. This low-cost prototype is done through a vertical scanning of the object using a fixed camera and a mobile horizontal laser light, which is deformed depending on the 3-dimensional surface of the solid. Using digital image processing an analysis of the deformation detected by the camera was done; it allows determining the 3D coordinates using triangulation. The obtained information is processed by a Matlab script, which gives to the user a point cloud corresponding to each horizontal scanning done. The obtained results show an acceptable quality and significant details of digitalized objects, making this prototype (built on LEGO Mindstorms NXT kit) a versatile and cheap tool, which can be used for many applications, mainly by engineering students.

  14. 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.

  15. Process for Low Cost Domestic Production of LIB Cathode Materials

    SciTech Connect

    Thurston, Anthony

    2012-10-31

    The objective of the research was to determine the best low cost method for the large scale production of the Nickel-Cobalt-Manganese (NCM) layered cathode materials. The research and development focused on scaling up the licensed technology from Argonne National Laboratory in BASF’s battery material pilot plant in Beachwood Ohio. Since BASF did not have experience with the large scale production of the NCM cathode materials there was a significant amount of development that was needed to support BASF’s already existing research program. During the three year period BASF was able to develop and validate production processes for the NCM 111, 523 and 424 materials as well as begin development of the High Energy NCM. BASF also used this time period to provide free cathode material samples to numerous manufactures, OEM’s and research companies in order to validate the ma-terials. The success of the project can be demonstrated by the construction of the production plant in Elyria Ohio and the successful operation of that facility. The benefit of the project to the public will begin to be apparent as soon as material from the production plant is being used in electric vehicles.

  16. Low Cost Coherent Doppler Lidar Data Acquisition and Processing

    NASA Technical Reports Server (NTRS)

    Barnes, Bruce W.; Koch, Grady J.

    2003-01-01

    The work described in this paper details the development of a low-cost, short-development time data acquisition and processing system for a coherent Doppler lidar. This was done using common laboratory equipment and a small software investment. This system provides near real-time wind profile measurements. Coding flexibility created a very useful test bed for new techniques.

  17. 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

  18. Low-cost manufacturing of the point focus concentrating module and its key component, the Fresnel lens

    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.

  19. Investigation of low cost material processes for liquid rocket engines

    NASA Technical Reports Server (NTRS)

    Nguyentat, Thinh; Kawashige, Chester M.; Scala, James G.; Horn, Ronald M.

    1993-01-01

    The development of low cost material processes is essential to the achievement of economical liquid rocket propulsion systems in the next century. This paper will present the results of the evaluation of some promising material processes including powder metallurgy, vacuum plasma spray, metal spray forming, and bulge forming. The physical and mechanical test results from the samples and subscale hardware fabricated from high strength copper alloys and superalloys will be discussed.

  20. Investigation of low cost material processes for liquid rocket engines

    NASA Technical Reports Server (NTRS)

    Nguyentat, Thinh; Kawashige, Chester M.; Scala, James G.; Horn, Ronald M.

    1993-01-01

    The development of low cost material processes is essential to the achievement of economical liquid rocket propulsion systems in the next century. This paper will present the results of the evaluation of some promising material processes including powder metallurgy, vacuum plasma spray, metal spray forming, and bulge forming. The physical and mechanical test results from the samples and subscale hardware fabricated from high strength copper alloys and superalloys will be discussed.

  1. Low cost processes for fabricating silicon solar cells

    NASA Technical Reports Server (NTRS)

    Goldman, H.; Wolf, M.

    1980-01-01

    Solar cell fabrication processes, in particular junction formation and metallization, are evaluated in terms of cell efficiencies, process yields, module packing factors, and energy cost effectiveness. It is shown that for junction formation, the diffusion processes provide a relatively low-cost approach. The costs per unit cell area can be further reduced by increased wafer area and mechanized wafer handling. The costs for a large number of metallization processes, excluding the costs of the metal, are roughly comparable. However, their varying influence on cell performance leads to a significant spread in the allowable process costs.

  2. Silicon web process development. [for low cost solar cells

    NASA Technical Reports Server (NTRS)

    Duncan, C. S.; Hopkins, R. H.; Seidensticker, R. G.; Mchugh, J. P.; Hill, F. E.; Heimlich, M. E.; Driggers, J. M.

    1979-01-01

    Silicon dendritic web, a single crystal ribbon shaped during growth by crystallographic forces and surface tension (rather than dies), is a highly promising base material for efficient low cost solar cells. The form of the product smooth, flexible strips 100 to 200 microns thick, conserves expensive silicon and facilitates automation of crystal growth and the subsequent manufacturing of solar cells. These characteristics, coupled with the highest demonstrated ribbon solar cell efficiency-15.5%-make silicon web a leading candidate to achieve, or better, the 1986 Low Cost Solar Array (LSA) Project cost objective of 50 cents per peak watt of photovoltaic output power. The main objective of the Web Program, technology development to significantly increase web output rate, and to show the feasibility for simultaneous melt replenishment and growth, have largely been accomplished. Recently, web output rates of 23.6 sq cm/min, nearly three times the 8 sq cm/min maximum rate of a year ago, were achieved. Webs 4 cm wide or greater were grown on a number of occassions.

  3. High resolution image processing on low-cost microcomputers

    NASA Technical Reports Server (NTRS)

    Miller, R. L.

    1993-01-01

    Recent advances in microcomputer technology have resulted in systems that rival the speed, storage, and display capabilities of traditionally larger machines. Low-cost microcomputers can provide a powerful environment for image processing. A new software program which offers sophisticated image display and analysis on IBM-based systems is presented. Designed specifically for a microcomputer, this program provides a wide-range of functions normally found only on dedicated graphics systems, and therefore can provide most students, universities and research groups with an affordable computer platform for processing digital images. The processing of AVHRR images within this environment is presented as an example.

  4. 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.

  5. High Temperature Thermoplastic Additive Manufacturing Using Low-Cost, Open-Source Hardware

    NASA Technical Reports Server (NTRS)

    Gardner, John M.; Stelter, Christopher J.; Yashin, Edward A.; Siochi, Emilie J.

    2016-01-01

    Additive manufacturing (or 3D printing) via Fused Filament Fabrication (FFF), also known as Fused Deposition Modeling (FDM), is a process where material is placed in specific locations layer-by-layer to create a complete part. Printers designed for FFF build parts by extruding a thermoplastic filament from a nozzle in a predetermined path. Originally developed for commercial printers, 3D printing via FFF has become accessible to a much larger community of users since the introduction of Reprap printers. These low-cost, desktop machines are typically used to print prototype parts or novelty items. As the adoption of desktop sized 3D printers broadens, there is increased demand for these machines to produce functional parts that can withstand harsher conditions such as high temperature and mechanical loads. Materials meeting these requirements tend to possess better mechanical properties and higher glass transition temperatures (Tg), thus requiring printers with high temperature printing capability. This report outlines the problems and solutions, and includes a detailed description of the machine design, printing parameters, and processes specific to high temperature thermoplastic 3D printing.

  6. Combining advanced imaging processing and low cost remote imaging capabilities

    NASA Astrophysics Data System (ADS)

    Rohrer, Matthew J.; McQuiddy, Brian

    2008-04-01

    Target images are very important for evaluating the situation when Unattended Ground Sensors (UGS) are deployed. These images add a significant amount of information to determine the difference between hostile and non-hostile activities, the number of targets in an area, the difference between animals and people, the movement dynamics of targets, and when specific activities of interest are taking place. The imaging capabilities of UGS systems need to provide only target activity and not images without targets in the field of view. The current UGS remote imaging systems are not optimized for target processing and are not low cost. McQ describes in this paper an architectural and technologic approach for significantly improving the processing of images to provide target information while reducing the cost of the intelligent remote imaging capability.

  7. 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

  8. Low-cost silicon process development. Phase 4: Process improvement

    NASA Astrophysics Data System (ADS)

    Moore, E.; Newman, C.

    1981-01-01

    Three project tasks include process improvement studies, kinetic studies, and process economic studies. Process improvement studies in a miniplant focused on the correlation of current miniplant yield results with prior laboratory scale work. The silicon product reactor was operated in the thermal disproportionation mode and successfully processed 35 kilograms of tribromosilane. The yield during the test ranged from 75 to 85% of theoretical. The experimental apparatus for use in the determination of the decomposition rate of tribromosilane was assembled, tested and placed into service. The computer code, REPORT, for plant daily operations data keeping is given.

  9. Low-cost exterior insulation process and structure

    SciTech Connect

    Vohra, Arun

    1997-12-01

    The invention relates to a low-cost process for insulating walls comprising: (a) stacking bags filled with insulating material next to the exterior surface of a wall until the wall is covered, the stack of bags thus formed having fasteners to attach to a wire mesh (e.g., straps looped between the bags and fastened to the wall); (b) stretching a wire mesh (e.g., chicken wire or stucco netting) over the stack of bags, covering the side of the bags which is not adjacent to the wall; (c) fastening the wire mesh to stationary objects; (d) attaching the wire mesh to said fasteners on said stack of bags; and (e) applying a cemetitious material (e.g., stucco) to the wire mesh and allowing it to harden. Stacking the bags against the wall is preferably preceded by laying a base on the ground at the foot of the wall using a material such as cement or crushed stone wrapped in a non-woven fabric (e.g., geosynthetic felt). It is also preferred to erect stationary corner posts at the ends of the wall to be insulated, the top ends of the posts being tied to each other and/or tied or otherwise anchored to the wall. The invention also includes the structure made by this process. The structure comprises a stack of bags of insulating material next to the exterior wall of a building, said stack of bags of insulating material being attached to said wall and having a covering of cementitious material on the side not adjacent to said wall.

  10. Solvent-free dry powder coating process for low-cost manufacturing of LiNi1/3Mn1/3Co1/3O2 cathodes in lithium-ion batteries

    NASA Astrophysics Data System (ADS)

    Al-Shroofy, Mohanad; Zhang, Qinglin; Xu, Jiagang; Chen, Tao; Kaur, Aman Preet; Cheng, Yang-Tse

    2017-06-01

    We report a solvent-free dry powder coating process for making LiNi1/3Mn1/3Co1/3O2 (NMC) positive electrodes in lithium-ion batteries. This process eliminates volatile organic compound emission and reduces thermal curing time from hours to minutes. A mixture of NMC, carbon black, and poly(vinylidene difluoride) was electrostatically sprayed onto an aluminum current collector, forming a uniformly distributed electrode with controllable thickness and porosity. Charge/discharge cycling of the dry-powder-coated electrodes in lithium-ion half cells yielded a discharge specific capacity of 155 mAh g-1 and capacity retention of 80% for more than 300 cycles when the electrodes were tested between 3.0 and 4.3 V at a rate of C/5. The long-term cycling performance and durability of dry-powder coated electrodes are similar to those made by the conventional wet slurry-based method. This solvent-free dry powder coating process is a potentially lower-cost, higher-throughput, and more environmentally friendly manufacturing process compared with the conventional wet slurry-based electrode manufacturing method.

  11. Low-Cost Opportunity for Small-Scale Manufacture of Hardwood Blanks

    Treesearch

    Bruce G. Hansen; Philip A. Araman

    1985-01-01

    We analyzed the manufacture of standard-size hardwood blanks from lumber on a relatively small scale by conventional processing. Requiring an investment of just over $200,000, the conventional mill can process 500 M bf (thousand board feet) of kiln-dried lumber annually. The study focused on the economics associated with manufacture of blanks from four species -...

  12. 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.

  13. Simulation Based Low-Cost Composite Process Development at the US Air Force Research Laboratory

    NASA Technical Reports Server (NTRS)

    Rice, Brian P.; Lee, C. William; Curliss, David B.

    2003-01-01

    Low-cost composite research in the US Air Force Research Laboratory, Materials and Manufacturing Directorate, Organic Matrix Composites Branch has focused on the theme of affordable performance. Practically, this means that we use a very broad view when considering the affordability of composites. Factors such as material costs, labor costs, recurring and nonrecurring manufacturing costs are balanced against performance to arrive at the relative affordability vs. performance measure of merit. The research efforts discussed here are two projects focused on affordable processing of composites. The first topic is the use of a neural network scheme to model cure reaction kinetics, then utilize the kinetics coupled with simple heat transport models to predict, in real-time, future exotherms and control them. The neural network scheme is demonstrated to be very robust and a much more efficient method that mechanistic cure modeling approach. This enables very practical low-cost processing of thick composite parts. The second project is liquid composite molding (LCM) process simulation. LCM processing of large 3D integrated composite parts has been demonstrated to be a very cost effective way to produce large integrated aerospace components specific examples of LCM processes are resin transfer molding (RTM), vacuum assisted resin transfer molding (VARTM), and other similar approaches. LCM process simulation is a critical part of developing an LCM process approach. Flow simulation enables the development of the most robust approach to introducing resin into complex preforms. Furthermore, LCM simulation can be used in conjunction with flow front sensors to control the LCM process in real-time to account for preform or resin variability.

  14. 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.

  15. 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.

  16. 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.

  17. 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

    2009-10-07

    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.

  18. 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

  19. Development of processes for the production of low cost silicon dendritic web for solar cells

    NASA Technical Reports Server (NTRS)

    Duncan, C. S.; Seidensticker, R. G.; Mchugh, J. P.; Hopkins, R. H.; Skutch, M. E.; Driggers, J. M.; Hill, F. E.

    1980-01-01

    High area output rates and continuous, automated growth are two key technical requirements for the growth of low-cost silicon ribbons for solar cells. By means of computer-aided furnace design, silicon dendritic web output rates as high as 27 sq cm/min have been achieved, a value in excess of that projected to meet a $0.50 per peak watt solar array manufacturing cost. The feasibility of simultaneous web growth while the melt is replenished with pelletized silicon has also been demonstrated. This step is an important precursor to the development of an automated growth system. Solar cells made on the replenished material were just as efficient as devices fabricated on typical webs grown without replenishment. Moreover, web cells made on a less-refined, pelletized polycrystalline silicon synthesized by the Battelle process yielded efficiencies up to 13% (AM1).

  20. Low-Cost Manufacturing of Bioresorbable Conductors by Evaporation-Condensation-Mediated Laser Printing and Sintering of Zn Nanoparticles.

    PubMed

    Shou, Wan; Mahajan, Bikram K; Ludwig, Brandon; Yu, Xiaowei; Staggs, Joshua; Huang, Xian; Pan, Heng

    2017-07-01

    Currently, bioresorbable electronic devices are predominantly fabricated by complex and expensive vacuum-based integrated circuit (IC) processes. Here, a low-cost manufacturing approach for bioresorbable conductors on bioresorbable polymer substrates by evaporation-condensation-mediated laser printing and sintering of Zn nanoparticle is reported. Laser sintering of Zn nanoparticles has been technically difficult due to the surface oxide on nanoparticles. To circumvent the surface oxide, a novel approach is discovered to print and sinter Zn nanoparticle facilitated by evaporation-condensation in confined domains. The printing process can be performed on low-temperature substrates in ambient environment allowing easy integration on a roll-to-roll platform for economical manufacturing of bioresorbable electronics. The fabricated Zn conductors show excellent electrical conductivity (≈1.124 × 10(6) S m(-1) ), mechanical durability, and water dissolvability. Successful demonstration of strain gauges confirms the potential application in various environmentally friendly sensors and circuits. © 2017 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

  1. Processes for producing low cost, high efficiency silicon solar cells

    DOEpatents

    Rohatgi, Ajeet; Doshi, Parag; Tate, John Keith; Mejia, Jose; Chen, Zhizhang

    1998-06-16

    Processes which utilize rapid thermal processing (RTP) are provided for inexpensively producing high efficiency silicon solar cells. The RTP processes preserve minority carrier bulk lifetime .tau. and permit selective adjustment of the depth of the diffused regions, including emitter and back surface field (bsf), within the silicon substrate. In a first RTP process, an RTP step is utilized to simultaneously diffuse phosphorus and aluminum into the front and back surfaces, respectively, of a silicon substrate. Moreover, an in situ controlled cooling procedure preserves the carrier bulk lifetime .tau. and permits selective adjustment of the depth of the diffused regions. In a second RTP process, both simultaneous diffusion of the phosphorus and aluminum as well as annealing of the front and back contacts are accomplished during the RTP step. In a third RTP process, the RTP step accomplishes simultaneous diffusion of the phosphorus and aluminum, annealing of the contacts, and annealing of a double-layer antireflection/passivation coating SiN/SiO.sub.x. In a fourth RTP process, the process of applying front and back contacts is broken up into two separate respective steps, which enhances the efficiency of the cells, at a slight time expense. In a fifth RTP process, a second RTP step is utilized to fire and adhere the screen printed or evaporated contacts to the structure.

  2. Processes for producing low cost, high efficiency silicon solar cells

    DOEpatents

    Rohatgi, A.; Doshi, P.; Tate, J.K.; Mejia, J.; Chen, Z.

    1998-06-16

    Processes which utilize rapid thermal processing (RTP) are provided for inexpensively producing high efficiency silicon solar cells. The RTP processes preserve minority carrier bulk lifetime {tau} and permit selective adjustment of the depth of the diffused regions, including emitter and back surface field (bsf), within the silicon substrate. In a first RTP process, an RTP step is utilized to simultaneously diffuse phosphorus and aluminum into the front and back surfaces, respectively, of a silicon substrate. Moreover, an in situ controlled cooling procedure preserves the carrier bulk lifetime {tau} and permits selective adjustment of the depth of the diffused regions. In a second RTP process, both simultaneous diffusion of the phosphorus and aluminum as well as annealing of the front and back contacts are accomplished during the RTP step. In a third RTP process, the RTP step accomplishes simultaneous diffusion of the phosphorus and aluminum, annealing of the contacts, and annealing of a double-layer antireflection/passivation coating SiN/SiO{sub x}. In a fourth RTP process, the process of applying front and back contacts is broken up into two separate respective steps, which enhances the efficiency of the cells, at a slight time expense. In a fifth RTP process, a second RTP step is utilized to fire and adhere the screen printed or evaporated contacts to the structure. 28 figs.

  3. Low cost processes for solar-grade silicon

    NASA Technical Reports Server (NTRS)

    Hunt, L. P.

    1975-01-01

    Upgrading metallurgical grade silicon is being pursued in four associated areas in order to improve the purity of the normally 98% material. The first two work areas involve purification of raw materials entering the process in addition to upgrading the arc furnace itself. The second two areas of process upgrading comprise improving the purity of the silicon after it leaves the arc furnace by reactive gas blowing and unidirectional freezing. The best cell produced to date was fabricated from MG-Si that had been blown with an O2-Cl2 mixture, unidirectionally solidified, and 6-float-zone passed (to determine a base boron level of 0.04 ohm/cm). The cell showed a 10.7% AMO efficiency. In the other processes category, the use of silicates as a silicon source and of electrolysis as a process were studied. The best electrolytic process uses a 1000 C fused salt of silica in cryolite.

  4. Recent advancements in low cost solar cell processing

    NASA Technical Reports Server (NTRS)

    Ralph, E. L.

    1975-01-01

    A proof-of-concept solar cell process has been developed that is adaptable to automation. This involved the development of a new contact system, a new antireflection coating system, a drift field cell design and a new contoured surface treatment. All these processes are performed without the use of vacuum chambers and expensive masking techniques, thus providing the possibility of reduced costs by automation using conventional semiconductor processing machinery. The contacts were printed on the cells by conventional silk screen machinery. The P(+) back field was formed by diffusing in aluminum from a printed aluminum back contact. The antireflection coating was formed by spinning on and baking a TiO2-SiO2 glass film. Air-mass-zero efficiencies of over 10% were achieved using this completely vacuum-free process.

  5. Recent advancements in low cost solar cell processing

    NASA Technical Reports Server (NTRS)

    Ralph, E. L.

    1975-01-01

    A proof-of-concept solar cell process has been developed that is adaptable to automation. This involved the development of a new contact system, a new antireflection coating system, a drift field cell design and a new contoured surface treatment. All these processes are performed without the use of vacuum chambers and expensive masking techniques, thus providing the possibility of reduced costs by automation using conventional semiconductor processing machinery. The contacts were printed on the cells by conventional silk screen machinery. The P(+) back field was formed by diffusing in aluminum from a printed aluminum back contact. The antireflection coating was formed by spinning on and baking a TiO2-SiO2 glass film. Air-mass-zero efficiencies of over 10% were achieved using this completely vacuum-free process.

  6. Processes for producing low cost, high efficiency silicon solar cells

    DOEpatents

    Rohatgi, Ajeet; Chen, Zhizhang; Doshi, Parag

    1996-01-01

    Processes which utilize rapid thermal processing (RTP) are provided for inexpensively producing high efficiency silicon solar cells. The RTP processes preserve minority carrier bulk lifetime .tau. and permit selective adjustment of the depth of the diffused regions, including emitter and back surface field (bsf), within the silicon substrate. Silicon solar cell efficiencies of 16.9% have been achieved. In a first RTP process, an RTP step is utilized to simultaneously diffuse phosphorus and aluminum into the front and back surfaces, respectively, of a silicon substrate. Moreover, an in situ controlled cooling procedure preserves the carrier bulk lifetime .tau. and permits selective adjustment of the depth of the diffused regions. In a second RTP process, both simultaneous diffusion of the phosphorus and aluminum as well as annealing of the front and back contacts are accomplished during the RTP step. In a third RTP process, the RTP step accomplishes simultaneous diffusion of the phosphorus and aluminum, annealing of the contacts, and annealing of a double-layer antireflection/passivation coating SiN/SiO.sub.x.

  7. Low-Cost Nanocellulose-Reinforced High-Temperature Polymer Composites for Additive Manufacturing

    SciTech Connect

    Ozcan, Soydan; Tekinalp, Halil L.; Love, Lonnie J.; Kunc, Vlastimil; Nelson, Kim

    2016-07-13

    ORNL worked with American Process Inc. to demonstrate the potential use of bio-based BioPlus® lignin-coated cellulose nanofibrils (L-CNF) as a reinforcing agent in the development of polymer feedstock suitable for additive manufacturing. L-CNF-reinforced polylactic acid (PLA) testing coupons were prepared and up to 69% increase in tensile strength and 133% increase in elastic modulus were demonstrated.

  8. A process for low cost wire grid polarizers

    NASA Astrophysics Data System (ADS)

    Watts, M. P. C.; Little, M.; Egan, E.; Hochbaum, A.; Johns, C.; Stephansen, S.

    2013-03-01

    Oblique angle metal deposition has been combined with high aspect ratio imprinted structures to create wire grid polarizers (WGP's) for use as polarization recyclers in liquid crystal displays. The process of oblique deposition was simulated to determine optimal feature profile and deposition geometry. The optical results for the oblique deposition WGP show contrast comparable to a conventionally etched WGP. The next steps to the fabrication of meter sized WGP are proposed.

  9. Low cost materials of construction for biological processes: Proceedings

    SciTech Connect

    Not Available

    1993-05-13

    The workshop was held, May 1993 in conjunction with the 15th Symposium on Biotechnology for Fuels and Chemicals. The purpose of this workshop was to present information on the biomass to ethanol process in the context of materials selection and through presentation and discussion, identify promising avenues for future research. Six technical presentations were grouped into two sessions: process assessment and technology assessment. In the process assessment session, the group felt that the pretreatment area would require the most extensive materials research due the complex chemical, physical and thermal environment. Discussion centered around the possibility of metals being leached into the process stream and their effect on the fermentation mechanics. Linings were a strong option for pretreatment assuming the economics were favorable. Fermentation was considered an important area for research also, due to the unique complex of compounds and dual phases present. Erosion in feedstock handling equipment was identified as a minor concern. In the technology assessment session, methodologies in corrosion analysis were presented in addition to an overview of current coatings/linings technology. Widely practiced testing strategies, including ASTM methods, as well as novel procedures for micro-analysis of corrosion were discussed. Various coatings and linings, including polymers and ceramics, were introduced. The prevailing recommendations for testing included keeping the testing simple until the problem warranted a more detailed approach and developing standardized testing procedures to ensure the data was reproducible and applicable. The need to evaluate currently available materials such as coatings/linings, carbon/stainless steels, or fiberglass reinforced plastic was emphasized. It was agreed that economic evaluation of each material candidate must be an integral part of any research plan.

  10. 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.

  11. Robust Low Cost Aerospike/RLV Combustion Chamber by Advanced Vacuum Plasma Process

    NASA Technical Reports Server (NTRS)

    Holmes, Richard; Ellis, David; McKechnie

    1999-01-01

    Next-generation, regeneratively cooled rocket engines will require materials that can withstand high temperatures while retaining high thermal conductivity. At the same time, fabrication techniques must be cost efficient so that engine components can be manufactured within the constraints of a shrinking NASA budget. In recent years, combustion chambers of equivalent size to the Aerospike chamber have been fabricated at NASA-Marshall Space Flight Center (MSFC) using innovative, relatively low-cost, vacuum-plasma-spray (VPS) techniques. Typically, such combustion chambers are made of the copper alloy NARloy-Z. However, current research and development conducted by NASA-Lewis Research Center (LeRC) has identified a Cu-8Cr-4Nb alloy which possesses excellent high-temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability. In fact, researchers at NASA-LeRC have demonstrated that powder metallurgy (P/M) Cu-8Cr-4Nb exhibits better mechanical properties at 1,200 F than NARloy-Z does at 1,000 F. The objective of this program was to develop and demonstrate the technology to fabricate high-performance, robust, inexpensive combustion chambers for advanced propulsion systems (such as Lockheed-Martin's VentureStar and NASA's Reusable Launch Vehicle, RLV) using the low-cost, VPS process to deposit Cu-8Cr-4Nb with mechanical properties that match or exceed those of P/M Cu-8Cr-4Nb. In addition, oxidation resistant and thermal barrier coatings can be incorporated as an integral part of the hot wall of the liner during the VPS process. Tensile properties of Cu-8Cr-4Nb material produced by VPS are reviewed and compared to material produced previously by extrusion. VPS formed combustion chamber liners have also been prepared and will be reported on following scheduled hot firing tests at NASA-Lewis.

  12. Robust Low Cost Liquid Rocket Combustion Chamber by Advanced Vacuum Plasma Process

    NASA Technical Reports Server (NTRS)

    Holmes, Richard; Elam, Sandra; Ellis, David L.; McKechnie, Timothy; Hickman, Robert; Rose, M. Franklin (Technical Monitor)

    2001-01-01

    Next-generation, regeneratively cooled rocket engines will require materials that can withstand high temperatures while retaining high thermal conductivity. Fabrication techniques must be cost efficient so that engine components can be manufactured within the constraints of shrinking budgets. Three technologies have been combined to produce an advanced liquid rocket engine combustion chamber at NASA-Marshall Space Flight Center (MSFC) using relatively low-cost, vacuum-plasma-spray (VPS) techniques. Copper alloy NARloy-Z was replaced with a new high performance Cu-8Cr-4Nb alloy developed by NASA-Glenn Research Center (GRC), which possesses excellent high-temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability. Functional gradient technology, developed building composite cartridges for space furnaces was incorporated to add oxidation resistant and thermal barrier coatings as an integral part of the hot wall of the liner during the VPS process. NiCrAlY, utilized to produce durable protective coating for the space shuttle high pressure fuel turbopump (BPFTP) turbine blades, was used as the functional gradient material coating (FGM). The FGM not only serves as a protection from oxidation or blanching, the main cause of engine failure, but also serves as a thermal barrier because of its lower thermal conductivity, reducing the temperature of the combustion liner 200 F, from 1000 F to 800 F producing longer life. The objective of this program was to develop and demonstrate the technology to fabricate high-performance, robust, inexpensive combustion chambers for advanced propulsion systems (such as Lockheed-Martin's VentureStar and NASA's Reusable Launch Vehicle, RLV) using the low-cost VPS process. VPS formed combustion chamber test articles have been formed with the FGM hot wall built in and hot fire tested, demonstrating for the first time a coating that will remain intact through the hot firing test, and with

  13. Robust Low Cost Liquid Rocket Combustion Chamber by Advanced Vacuum Plasma Process

    NASA Technical Reports Server (NTRS)

    Holmes, Richard; Elam, Sandra; Ellis, David L.; McKechnie, Timothy; Hickman, Robert; Rose, M. Franklin (Technical Monitor)

    2001-01-01

    Next-generation, regeneratively cooled rocket engines will require materials that can withstand high temperatures while retaining high thermal conductivity. Fabrication techniques must be cost efficient so that engine components can be manufactured within the constraints of shrinking budgets. Three technologies have been combined to produce an advanced liquid rocket engine combustion chamber at NASA-Marshall Space Flight Center (MSFC) using relatively low-cost, vacuum-plasma-spray (VPS) techniques. Copper alloy NARloy-Z was replaced with a new high performance Cu-8Cr-4Nb alloy developed by NASA-Glenn Research Center (GRC), which possesses excellent high-temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability. Functional gradient technology, developed building composite cartridges for space furnaces was incorporated to add oxidation resistant and thermal barrier coatings as an integral part of the hot wall of the liner during the VPS process. NiCrAlY, utilized to produce durable protective coating for the space shuttle high pressure fuel turbopump (BPFTP) turbine blades, was used as the functional gradient material coating (FGM). The FGM not only serves as a protection from oxidation or blanching, the main cause of engine failure, but also serves as a thermal barrier because of its lower thermal conductivity, reducing the temperature of the combustion liner 200 F, from 1000 F to 800 F producing longer life. The objective of this program was to develop and demonstrate the technology to fabricate high-performance, robust, inexpensive combustion chambers for advanced propulsion systems (such as Lockheed-Martin's VentureStar and NASA's Reusable Launch Vehicle, RLV) using the low-cost VPS process. VPS formed combustion chamber test articles have been formed with the FGM hot wall built in and hot fire tested, demonstrating for the first time a coating that will remain intact through the hot firing test, and with

  14. Robust Low Cost Aerospike/RLV Combustion Chamber by Advanced Vacuum Plasma Process

    NASA Technical Reports Server (NTRS)

    Holmes, Richard; Ellis, David; McKechnie

    1999-01-01

    Next-generation, regeneratively cooled rocket engines will require materials that can withstand high temperatures while retaining high thermal conductivity. At the same time, fabrication techniques must be cost efficient so that engine components can be manufactured within the constraints of a shrinking NASA budget. In recent years, combustion chambers of equivalent size to the Aerospike chamber have been fabricated at NASA-Marshall Space Flight Center (MSFC) using innovative, relatively low-cost, vacuum-plasma-spray (VPS) techniques. Typically, such combustion chambers are made of the copper alloy NARloy-Z. However, current research and development conducted by NASA-Lewis Research Center (LeRC) has identified a Cu-8Cr-4Nb alloy which possesses excellent high-temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability. In fact, researchers at NASA-LeRC have demonstrated that powder metallurgy (P/M) Cu-8Cr-4Nb exhibits better mechanical properties at 1,200 F than NARloy-Z does at 1,000 F. The objective of this program was to develop and demonstrate the technology to fabricate high-performance, robust, inexpensive combustion chambers for advanced propulsion systems (such as Lockheed-Martin's VentureStar and NASA's Reusable Launch Vehicle, RLV) using the low-cost, VPS process to deposit Cu-8Cr-4Nb with mechanical properties that match or exceed those of P/M Cu-8Cr-4Nb. In addition, oxidation resistant and thermal barrier coatings can be incorporated as an integral part of the hot wall of the liner during the VPS process. Tensile properties of Cu-8Cr-4Nb material produced by VPS are reviewed and compared to material produced previously by extrusion. VPS formed combustion chamber liners have also been prepared and will be reported on following scheduled hot firing tests at NASA-Lewis.

  15. 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.

  16. 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.

  17. Development of a low-cost extrusion-embossing process for a linear Fresnel lens photovoltaic concentration

    SciTech Connect

    Not Available

    1984-09-01

    Results of efforts to fabricate linear Fresnel lens using a low-cost extrusion-embossing process indicated that the extrusion-embossing process will be difficult to adapt to the manufacture of efficient lenses. Lenses produced in pilot runs acheived only 72% optical efficiency at 25X geometric concentration ratio, compared to 87% for lenses made by casting or Lensfilm processes. A highly accurate, yet simple, outdoor focal plane flux profile test apparatus was developed that can be used to qualify new lenses and to check the quality of production lenses.

  18. Manufacture of patient-specific vascular replicas for endovascular simulation using fast, low-cost method.

    PubMed

    Kaneko, Naoki; Mashiko, Toshihiro; Ohnishi, Taihei; Ohta, Makoto; Namba, Katsunari; Watanabe, Eiju; Kawai, Kensuke

    2016-12-15

    Patient-specific vascular replicas are essential to the simulation of endovascular treatment or for vascular research. The inside of silicone replica is required to be smooth for manipulating interventional devices without resistance. In this report, we demonstrate the fabrication of patient-specific silicone vessels with a low-cost desktop 3D printer. We show that the surface of an acrylonitrile butadiene styrene (ABS) model printed by the 3D printer can be smoothed by a single dipping in ABS solvent in a time-dependent manner, where a short dip has less effect on the shape of the model. The vascular mold is coated with transparent silicone and then the ABS mold is dissolved after the silicone is cured. Interventional devices can pass through the inside of the smoothed silicone vessel with lower pushing force compared to the vessel without smoothing. The material cost and time required to fabricate the silicone vessel is about USD $2 and 24 h, which is much lower than the current fabrication methods. This fast and low-cost method offers the possibility of testing strategies before attempting particularly difficult cases, while improving the training of endovascular therapy, enabling the trialing of new devices, and broadening the scope of vascular research.

  19. Manufacture of patient-specific vascular replicas for endovascular simulation using fast, low-cost method

    NASA Astrophysics Data System (ADS)

    Kaneko, Naoki; Mashiko, Toshihiro; Ohnishi, Taihei; Ohta, Makoto; Namba, Katsunari; Watanabe, Eiju; Kawai, Kensuke

    2016-12-01

    Patient-specific vascular replicas are essential to the simulation of endovascular treatment or for vascular research. The inside of silicone replica is required to be smooth for manipulating interventional devices without resistance. In this report, we demonstrate the fabrication of patient-specific silicone vessels with a low-cost desktop 3D printer. We show that the surface of an acrylonitrile butadiene styrene (ABS) model printed by the 3D printer can be smoothed by a single dipping in ABS solvent in a time-dependent manner, where a short dip has less effect on the shape of the model. The vascular mold is coated with transparent silicone and then the ABS mold is dissolved after the silicone is cured. Interventional devices can pass through the inside of the smoothed silicone vessel with lower pushing force compared to the vessel without smoothing. The material cost and time required to fabricate the silicone vessel is about USD $2 and 24 h, which is much lower than the current fabrication methods. This fast and low-cost method offers the possibility of testing strategies before attempting particularly difficult cases, while improving the training of endovascular therapy, enabling the trialing of new devices, and broadening the scope of vascular research.

  20. Manufacture of patient-specific vascular replicas for endovascular simulation using fast, low-cost method

    PubMed Central

    Kaneko, Naoki; Mashiko, Toshihiro; Ohnishi, Taihei; Ohta, Makoto; Namba, Katsunari; Watanabe, Eiju; Kawai, Kensuke

    2016-01-01

    Patient-specific vascular replicas are essential to the simulation of endovascular treatment or for vascular research. The inside of silicone replica is required to be smooth for manipulating interventional devices without resistance. In this report, we demonstrate the fabrication of patient-specific silicone vessels with a low-cost desktop 3D printer. We show that the surface of an acrylonitrile butadiene styrene (ABS) model printed by the 3D printer can be smoothed by a single dipping in ABS solvent in a time-dependent manner, where a short dip has less effect on the shape of the model. The vascular mold is coated with transparent silicone and then the ABS mold is dissolved after the silicone is cured. Interventional devices can pass through the inside of the smoothed silicone vessel with lower pushing force compared to the vessel without smoothing. The material cost and time required to fabricate the silicone vessel is about USD $2 and 24 h, which is much lower than the current fabrication methods. This fast and low-cost method offers the possibility of testing strategies before attempting particularly difficult cases, while improving the training of endovascular therapy, enabling the trialing of new devices, and broadening the scope of vascular research. PMID:27976687

  1. A low-cost vector processor boosting compute-intensive image processing operations

    NASA Technical Reports Server (NTRS)

    Adorf, Hans-Martin

    1992-01-01

    Low-cost vector processing (VP) is within reach of everyone seriously engaged in scientific computing. The advent of affordable add-on VP-boards for standard workstations complemented by mathematical/statistical libraries is beginning to impact compute-intensive tasks such as image processing. A case in point in the restoration of distorted images from the Hubble Space Telescope. A low-cost implementation is presented of the standard Tarasko-Richardson-Lucy restoration algorithm on an Intel i860-based VP-board which is seamlessly interfaced to a commercial, interactive image processing system. First experience is reported (including some benchmarks for standalone FFT's) and some conclusions are drawn.

  2. Manufacturing processes

    NASA Technical Reports Server (NTRS)

    Bennet, Jay; Brower, David; Levine, Stan; Walker, Ray; Wooten, John

    1991-01-01

    The following issues are covered: process development frequently lags behind material development, high fabrication costs, flex joints (bellows) - a continuing program, SRM fabrication-induced defects, and in-space assembly will require simplified design.

  3. Low-cost Electromagnetic Heating Technology for Polymer Extrusion-based Additive Manufacturing

    SciTech Connect

    Carter, William G.; Rios, Orlando; Akers, Ronald R.; Morrison, William A.

    2016-01-07

    To improve the flow of materials used in in polymer additive manufacturing, ORNL and Ajax Tocco created an induction system for heating fused deposition modeling (FDM) nozzles used in polymer additive manufacturing. The system is capable of reaching a temperature of 230 C, a typical nozzle temperature for extruding ABS polymers, in 17 seconds. A prototype system was built at ORNL and sent to Ajax Tocco who analyzed the system and created a finalized power supply. The induction system was mounted to a PrintSpace Altair desktop printer and used to create several test parts similar in quality to those created using a resistive heated nozzle.

  4. 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.

  5. Low Cost Chemical Feedstocks Using an Improved and Energy Efficient Natural Gas Liquid Removal Process

    SciTech Connect

    2004-07-01

    This factsheet describes a research project whose goal is to develop a new low-cost and energy efficient NGL recovery process - through a combination of theoretical, bench-scale, and pilot-scale testing - so that it can be offered to the natural gas industry for commercialization.

  6. 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.

  7. Low-cost Landsat digital processing system for state and local information systems

    NASA Technical Reports Server (NTRS)

    Hooper, N. J.; Spann, G. W.; Faust, N. L.; Paludan, C. T. N.

    1979-01-01

    The paper details a minicomputer-based system which is well within the budget of many state, regional, and local agencies that previously could not afford digital processing capability. In order to achieve this goal a workable small-scale Landsat system is examined to provide low-cost automated processing. It is anticipated that the alternative systems will be based on a single minicomputer, but that the peripherals will vary depending on the capability emphasized in a particular system.

  8. 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.

  9. Opportunities for Low Cost Processing of Erbium 8-Quinolinolates for Active Integrated Photonic Applications.

    PubMed

    Penna, Stefano; Mattiello, Leonardo; Di Bartolo, Silvia; Pizzoleo, Angelo; Attanasio, Vincenzo; Beleffi, Giorgio Maria Tosi; Otomo, Akira

    2016-04-01

    Erbium-doped organic emitters are promising active materials for Photonic Integrated Circuits (PICs) due to their emission shown at 1550 nm combined to the potential low cost processing. In particular, Erbium Quinoline (ErQ) gained a strong interest in the last decade for the good emission efficiency. This contribution reports the results derived from the application of ErQ as active core material within a buried optical waveguide, following the development of a purposed optical process to control the refractive index of ErQ and then to define a patterned structure from a single thin film deposition step. The reported results show the potential of Er-doped organic materials for low cost processing and application to planar PICs.

  10. 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.

  11. 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.

  12. Microstructure/property studies supporting development of low cost processes for TiAl automotive valves

    SciTech Connect

    Jones, P.E.; Porter, W.J. III; Keller, M.M.; Eylon, D.

    1995-07-01

    Lightweight gamma titanium aluminide automotive valves may significantly improve engine performance and fuel economy. However, low cost mass production processes must be developed to realize these gains. Permanent mold casting processes and low cost heat treatments are being developed to enable commercial introduction of TiAl automotive valves. Microstructural development, tensile, creep, and high cycle fatigue properties of permanent mold Ti-47Al-2Nb-1.75Cr (at%) castings are compared with investment castings of similar size. A recommendation is made to use as-HIP castings for components not designed to damage tolerant criteria. This work was performed as pan of a vertically integrated team effort to transfer aerospace TiAl technology to the automotive market.

  13. Manufacturing of novel low-cost adsorbent: Co-granulation of limestone and coffee waste.

    PubMed

    Iakovleva, Evgenia; Sillanpää, Mika; Maydannik, Philipp; Liu, Jiang Tao; Allen, Stephen; Albadarin, Ahmad B; Mangwandi, Chirangano

    2017-12-01

    Limestone and coffee waste were used during the wet co-granulation process for the production of efficient adsorbents to be used in the removal of anionic and cationic dyes. The adsorbents were characterized using different analytical techniques such as XRD, SEM, FTIR, organic elemental analysis, the nitrogen adsorption method, with wettability, strength and adsorption tests. The adsorption capacity of granules was determined by removal of methylene blue (MB) and orange II (OR) from single and mixed solutions. In the mixed solution, co-granules removed 100% of MB and 85% of OR. The equilibria were established after 6 and 480 h for MB and OR, respectively. Copyright © 2017 Elsevier Ltd. All rights reserved.

  14. Development of a low cost permanent mold casting process for TiAl automotive valves

    SciTech Connect

    Jones, P.E.; Porter, W.J. III; Eylon, D.; Colvin, G.

    1995-12-31

    This paper reviews progress made in the development of a low cost permanent mold casting process for TiAl automotive valves. The issues studied include mold life, mold/metal reaction, shrinkage void control, dimensional control, and post casting processes. More than 800 Ti-47Al-2Nb-1.75 Cr (at%) valves were produced by gravity, centrifugal, and pressure assisted casting methods on a laboratory scale. Microstructures, tensile, creep, and fatigue properties of as-HIP and as-heat treated valves are described. Process scale up challenges identified in this work are also discussed.

  15. A low-cost photovoltaic cell process based on thick film techniques

    NASA Technical Reports Server (NTRS)

    Mardesich, N.; Pepe, A.; Bunyan, S.; Edwards, B.; Olson, C.

    1980-01-01

    The low-cost, easily automated processing for solar cell fabrication being developed at Spectrolab for the DOE LSA program is described. These processes include plasma-etching, spray-on diffusion sources and antireflective coating, thick film metallization, aluminum back contacts, laser scribing and ultrasonic soldering. The process sequence has been shown to produce solar cells having 15% conversion efficiency at AM1 which meet the cell fabrication budget required for the DOE 1986 cost goal of $0.70 per peak watt in 1980.

  16. Low-cost high-manufacturability and thermal stability optical front-end for 10-Gb ethernet applications

    NASA Astrophysics Data System (ADS)

    Lee, Shin-Ge; Lee, Chun-Hsing; Liao, Li-Chun; Tsai, Cheng-Hung; Chen, Chih-Li; Huang, Min-Fa; Hsu, Chih-Hao; Cheng, Fu-Yi; Kao, Min-Sheng; Wang, Chiung-Hung

    2004-05-01

    With the drastic expansion of internet usage, the demand of 10Gb/s transmission optoelectronic devices for local-area-network (LAN) and storage-area-network (SAN) are increasing. The key issues of these applications are to improve cost, manufacturability and reliability of optoelectronic devices in high speed transmission. The authors have demonstrated extremely low cost, high manufacturability and thermal stability optical fron-end for 10Gb/s Ethernet applications in this paper. High performance and high sensitivity of 10Gb/s transmitter optical sub-assembly (TOSA) and receiver optical sub-assembly (ROSA) with TO-Can packages are discussed and demonstrated to overcome the critical points in high speed applications, respectively. Moreover, 10km interconnection of 10Gb/s optical front-end without isolated elements inside are also proved to be error free at 10.3125Gb/s. In order to improve the signal integrity and manufacturability of 10Gb/s OSA in small form factor transceiver modules assembly, the authors also integrate high speed flex board and OSA package to extend the signal path, and to minimize the effect of crosstalk in modules. Furthermore, the integration of flex board and OSA package more release the difficulties in conjuunction OSA and electrical sub-assembly (ESA) in module to fulfill the request of 10Gb/s transeivers' Multi-Source Agreement (MSA). The performance of temperature stabilized TOSA over wide case temperature range is also experimented. The optical eye diagram of 10Gb/s TOSA developed in this study showing excellent eye quality passing 10Gb/s Ethernet mask test between 0°C to 85°C.

  17. Full-solution processed flexible organic solar cells using low-cost printable copper electrodes.

    PubMed

    Li, Kan; Zhen, Hongyu; Niu, Liyong; Fang, Xu; Zhang, Yaokang; Guo, Ruisheng; Yu, You; Yan, Feng; Li, Haifeng; Zheng, Zijian

    2014-11-12

    Full-solution-processed flexible organic solar cells (OSCs) are fabricated using low-cost and high-quality printable Cu electrodes, which achieve a power conversion efficiency as high as 2.77% and show remarkable stability upon 1000 bending cycles. This device performance is thought to be the best among all full-solution-processed OSCs reported in the literature using the same active materials. This printed Cu electrode is promising for application in roll-to-roll fabrication of flexible OSCs.

  18. Low-cost digital image processing at the University of Oklahoma

    NASA Technical Reports Server (NTRS)

    Harrington, J. A., Jr.

    1981-01-01

    Computer assisted instruction in remote sensing at the University of Oklahoma involves two separate approaches and is dependent upon initial preprocessing of a LANDSAT computer compatible tape using software developed for an IBM 370/158 computer. In-house generated preprocessing algorithms permits students or researchers to select a subset of a LANDSAT scene for subsequent analysis using either general purpose statistical packages or color graphic image processing software developed for Apple II microcomputers. Procedures for preprocessing the data and image analysis using either of the two approaches for low-cost LANDSAT data processing are described.

  19. Development of the silane process for the production of low-cost polysilicon

    NASA Technical Reports Server (NTRS)

    Iya, S. K.

    1986-01-01

    It was recognized that the traditional hot rod type deposition process for decomposing silane is energy intensive, and a different approach for converting silane to silicon was chosen. A 1200 metric tons/year capacity commercial plant was constructed in Moses Lake, Washington. A fluidized bed processor was chosen as the most promising technology and several encouraging test runs were conducted. This technology continues to be very promising in producing low cost polysilicon. The Union Carbide silane process and the research development on the fluidized bed silane decomposition are discussed.

  20. Processing Requirements For Multi-Sensor, Low-Cost Brilliant Munitions

    NASA Astrophysics Data System (ADS)

    Klein, Lawrence A.; Kassis, Suhail Y.

    1989-09-01

    A generic mission for an autonomous fire-and-forget brilliant munition is presented and used to identify the functions that an embedded signal processor must perform. Based on these functions and other operational factors (such as weather, larger search areas, lower false alarm rates, and munition maneuverability), the processing loads in bits/second, messages/second, operations/second, and instructions/second are derived. The paper concludes with an evaluation of general implementation issues, such as the requirements for data fusion, distributed and parallel processing architectures, trusted software, and low-cost hardware.

  1. Experiments to evaluate high-temperature rolling as a low-cost process for silicon solar cells

    NASA Technical Reports Server (NTRS)

    Noel, G. T.; Kulkarni, S.; Wolf, M.; Pope, D. P.; Graham, C. D., Jr.

    1976-01-01

    Mechanical rolling (a process used in industry for producing large quantities of metallic sheet and strip) has been suggested for the rapid low-cost manufacture of silicon sheet to be used for photovoltaic power generation equipment, such as solar arrays. The advantages of rolling include: high rates of production, wide sheets as products, good control of dimension, and (in the case of solar grade silicon) minimal development of impurities. Experiments have been performed using high-temperature, high-speed compression of polycrystalline silicon cylinders. Metallography and X-ray diffraction techniques have been used to examine the samples both before and after compression, and a model process has been designed to evaluate the technical practicality and economic feasibility of the method.

  2. Experiments to evaluate high-temperature rolling as a low-cost process for silicon solar cells

    NASA Technical Reports Server (NTRS)

    Noel, G. T.; Kulkarni, S.; Wolf, M.; Pope, D. P.; Graham, C. D., Jr.

    1976-01-01

    Mechanical rolling (a process used in industry for producing large quantities of metallic sheet and strip) has been suggested for the rapid low-cost manufacture of silicon sheet to be used for photovoltaic power generation equipment, such as solar arrays. The advantages of rolling include: high rates of production, wide sheets as products, good control of dimension, and (in the case of solar grade silicon) minimal development of impurities. Experiments have been performed using high-temperature, high-speed compression of polycrystalline silicon cylinders. Metallography and X-ray diffraction techniques have been used to examine the samples both before and after compression, and a model process has been designed to evaluate the technical practicality and economic feasibility of the method.

  3. Large area low cost processing for CIS photovoltaics. Final technical report

    SciTech Connect

    B. Basol; G. Norsworthy; C. Leidholm; A. Halani; R. Roe; V. Kapur

    1999-07-22

    An ink coating method was developed for CIS absorber deposition. The technique involves four processing steps: (1) preparation of a Cu-In alloy powder, (2) preparation of an ink using this powder, (3) deposition of the ink on a substrate in the form of a precursor layer, and (4) selenization to convert the Cu-In precursor into a fused CIS film. Absorbers grown by this low-cost, large-area method were used in the fabrication of 10.5% efficient solar cells.

  4. NON-MELT PROCESSING OF "LOW-COST", ARMSTRONG TITANIUM AND TITANIUM ALLOY POWDERS

    SciTech Connect

    Peter, William H; Blue, Craig A; Clive, Scorey; Ernst, Bill; McKernan, John; Kiggans, Jim; Rivard, John D; Yu, Dr. Charlie

    2007-01-01

    In the last decade, a considerable effort has been made to develop new methods for producing low cost titanium and titanium powders. The Armstrong process is a new method of producing titanium powder via reducing TiCl4 vapor in molten sodium. The process is scalable, and can be used to produce pre-alloyed powders. Non-melt processing and powder metallurgy approaches are economically viable with the commercially pure powders. In this investigation, several non-melt processing technologies, including vacuum hot pressing, extrusion, roll compaction, and forging techniques, will be evaluated using the Armstrong titanium powders. The metallurgical, chemical, and mechanical properties of the processed titanium samples will be discussed.

  5. Selective sorption of PCBs by low-cost polymers and application to soil washing processes

    SciTech Connect

    Sivavec, T.M.; Webb, J.L.; Gascoyne, D.G.

    1996-10-01

    Surfactant-assisted soil washing and soil flushing processes have shown to be a promising soil decontamination method. In these and other remediation technologies that employ surfactants to mobilize organic contaminants, large volumes of contaminated aqueous solutions are generated. An efficient process to selectively concentrate the organic contaminant from the aqueous surfactant solution, thereby allowing the recycle of the surfactant, is considered essential for cost-effective application of these remediation methods. To this end, a process was developed wherein commercial, low-cost polymers are used to selectively sorb PCBs and petroleum oils from aqueous surfactant solutions. Sorption isotherms and sorption rates were determined for a large number of polymer sorbents and several significant structure-property relationships were observed. Two classes of polymers, polyester elastomers and carbon-filled elastomer rubbers (e.g., recycled rubber tire), were found to perform superiorly in this application and a successful pilot-scale demonstration of the process was conducted.

  6. MEMS transducers low-cost fabrication using SU-8 in a sacrificial layer-free process

    NASA Astrophysics Data System (ADS)

    Ge, Chang; Cretu, Edmond

    2017-04-01

    We report novel low-cost and rapid fabrication technologies for the fabrication of movable polymer-based MEMS structures, electrically actuated. Using SU-8 photoresist as structural material, both ordinary and functionalized by conductive fillers (nano-Ag particles and carbon nanotubes), the novel fabrication methods provide simple processes, without the use of any sacrificial layer, for achieving suspended structures (beams and membranes) through either binary or gray-scale photolithography. Experimental validation has demonstrated high yields (over 99% for one of the process flows) in achieving electrostatically actuated microstructures with resonant frequencies in the 0.5–0.8 MHz range, with a stable dynamic behavior tested for a period longer than three months. The technology also confirms that ‘doping’ SU-8 with conductive fillers can preserve its photo-patterning capabilities, while modifying other physical properties (electrical conductivity). As the patterning of SU-8 films can take place on either rigid or flexible substrates, this low-cost technology promises a wide range of applications.

  7. Low-cost data analysis systems for processing multispectral scanner data

    NASA Technical Reports Server (NTRS)

    Whitley, S. L.

    1975-01-01

    A research-oriented data analysis system was developed which is used for evaluating complex remote sensor systems and for development of techniques for application of remotely sensed data. Some modular hardware components were developed which may be added to one's existing facilities to establish a low-cost data analysis system for processing multispectral scanner data. Software modules which are compatible with small general purpose digital computers process and analyze remote sensor data, and convert it to information needed by users. The software modules are written in FORTRAN IV language for ease of transfer to other computer systems. The basic hardware and software system requirements are defined for some low-cost data analysis systems consisting of an image display system, a small general purpose digital computer, and an output recording device. The hardware modules consist of: a LANDSAT MSS data reformatting program; a series of spectral pattern recognition programs required to generate surface classification maps and tabular information; programs to convert computer generated maps from image space to a geographically referenced base; programs to extract data and irregularly shaped areas and to produce thematic maps of the designated areas; and programs to tabulate acreages of selected classification categories. Some off-the-shelf, inexpensive digital image display systems are described.

  8. A candidate low-cost processing sequence for terrestrial silicon solar cell panel

    NASA Technical Reports Server (NTRS)

    Bickler, D. B.; Gallagher, B. D.; Sanchez, L. E.

    1978-01-01

    Manufacturing sequence for silicon solar cells using Czochralsky crystal growing techniques in order to produce at a rate of 20 MW per year on a 24-hour per day basis is discussed. Cost analysis of the manufacturing is presented and consideration is given to the following processing decision categories of the manufacturing of an unencapsulated solar cell from a silicon wafer: (1) treatment of the optical surface; (2) formation of the junction(s); and (3) metallization of electrical collectors. The manufacturing of encapsulated solar modules from solar cells, using two glass plates, a low iron front surface, and a standard float glass back plate, is described. Totaling the three major activities of wafer making, cell manufacturing, and module fabrication, the resulting contribution to module price will be 1.945 $/watt.

  9. Toward high solids loading process for lignocellulosic biofuel production at a low cost.

    PubMed

    Jin, Mingjie; Sarks, Cory; Bals, Bryan D; Posawatz, Nick; Gunawan, Christa; Dale, Bruce E; Balan, Venkatesh

    2017-05-01

    High solids loadings (>18 wt%) in enzymatic hydrolysis and fermentation are desired for lignocellulosic biofuel production at a high titer and low cost. However, sugar conversion and ethanol yield decrease with increasing solids loading. The factor(s) limiting sugar conversion at high solids loading is not clearly understood. In the present study, we investigated the effect of solids loading on simultaneous saccharification and co-fermentation (SSCF) of AFEX™ (ammonia fiber expansion) pretreated corn stover for ethanol production using a xylose fermenting strain Saccharomyces cerevisiae 424A(LNH-ST). Decreased sugar conversion and ethanol yield with increasing solids loading were also observed. End-product (ethanol) was proven to be the major cause of this issue and increased degradation products with increasing solids loading was also a cause. For the first time, we show that with in situ removal of end-product by performing SSCF aerobically, sugar conversion stopped decreasing with increasing solids loading and monomeric sugar conversion reached as high as 93% at a high solids loading of 24.9 wt%. Techno-economic analysis was employed to explore the economic possibilities of cellulosic ethanol production at high solids loadings. The results suggest that low-cost in situ removal of ethanol during SSCF would significantly improve the economics of high solids loading processes. Biotechnol. Bioeng. 2017;114: 980-989. © 2016 Wiley Periodicals, Inc. © 2016 Wiley Periodicals, Inc.

  10. Low-cost, solution processable carbon nanotube supercapacitors and their characterization

    NASA Astrophysics Data System (ADS)

    Lehtimäki, Suvi; Tuukkanen, Sampo; Pörhönen, Juho; Moilanen, Pasi; Virtanen, Jorma; Honkanen, Mari; Lupo, Donald

    2014-06-01

    We report ecological and low-cost carbon nanotube (CNT) supercapacitors fabricated using a simple, scalable solution processing method, where the use of a highly porous and electrically conductive active material eliminates the need for a current collector. Electrodes were fabricated on a poly(ethylene terephthalate) substrate from a printable multi-wall CNT ink, where the CNTs are solubilized in water using xylan as a dispersion agent. The dispersion method facilitates a very high concentration of CNTs in the ink. Supercapacitors were assembled using a paper separator and an aqueous NaCl electrolyte and the devices were characterized with a galvanostatic discharge method defined by an industrial standard. The capacitance of the 2 cm^2 devices was 6 mF/cm^2 (2.3 F/g) and equivalent series resistance 80 Ω . Low-cost supercapacitors fabricated from safe and environmentally friendly materials have potential applications as energy storage devices in ubiquitous and autonomous intelligence as well as in disposable low-end products.

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

    SciTech Connect

    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, 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

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

    DOE PAGES

    Mo, Jingke; Zhang, Feng -Yuan; Dehoff, Ryan R.; ...

    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

  13. Mussel processing wastewater: a low-cost substrate for the production of astaxanthin by Xanthophyllomyces dendrorhous.

    PubMed

    Amado, Isabel Rodríguez; Vázquez, José Antonio

    2015-11-09

    The use of astaxanthin in different industries such as the chemical, pharmaceutical, food, animal feed and cosmetic has been receiving increasing attention in recent years. Natural supplies of the pigment include crustacean by-products, algal, and microbial cultivation, being the yeast Xanthophyllomyces dendrorhous together with the alga Haematococcus pluvialis the most promising microorganisms for this bioproduction. Different vegetable by-products of the food industry have been explored so far as low-cost substrates for the production of astaxanthin by X. dendrorhous. This study focuses for the first time on the use of a low-cost formulated medium from a marine by-product, mussel-processing wastewater, for the production of astaxanthin by the yeast X. dendrorhous. The yeast was able to grow in non-saccharified mussel broth, revealing the ability of the microorganism to hydrolyze glycogen. However, partial glycogen saccharification with α-amylase was needed for astaxanthin biosynthesis, obtaining maximal productions of 22.5-26.0 mg/L towards the end of the culture and coinciding with yeast highest amylolytic activity. Cultivations in totally-saccharified media revealed an increase in maximal cell concentrations and a decrease in maximal growth rates and astaxanthin production with increasing glucose initial concentration. Astaxanthin production was higher in partially-saccharified mussel-processing waste than in synthetic medium (yeast peptone dextrose) containing glucose as carbon source (13 mg/L), suggesting this by-product is a promising nutritive medium for astaxanthin production. The use of this effluent also contributes towards the recycling and depuration of this highly pollutant effluent.

  14. Preparation of wafer-level glass cavities by a low-cost chemical foaming process (CFP).

    PubMed

    Shang, Jintang; Chen, Boyin; Lin, Wei; Wong, Ching-Ping; Zhang, Di; Xu, Chao; Liu, Junwen; Huang, Qing-An

    2011-04-21

    A novel foaming process-chemical foaming process (CFP)-using foaming agents to fabricate wafer-level micro glass cavities including channels and bubbles was investigated. The process consists of the following steps sequentially: (1) shallow cavities were fabricated by a wet etching on a silicon wafer; (2) powders of a proper foaming agent were placed in a silicon cavity, named 'mother cavity', on the etched silicon surface; (3) the silicon cavities were sealed with a glass wafer by anodic bonding; (4) the bonded wafers were heated to above the softening point of the glass, and baked for several minutes, when the gas released by the decomposition of the foaming agent in the 'mother cavity' went into the other sealed interconnected silicon cavities to foam the softened glass into cylindrical channels named 'daughter channels', or spherical bubbles named 'son bubbles'. Results showed that wafer-level micro glass cavities with smooth wall surfaces were achieved successfully without contamination by the CFP. A model for the CFP was proposed to predict the final shape of the glass cavity. Experimental results corresponded with model predictions. The CFP provides a low-cost avenue to preparation of micro glass cavities of high quality for applications such as micro-reactors, micro total analysis systems (μTAS), analytical and bio-analytical applications, and MEMS packaging.

  15. Low-cost laser printable photomask: One-step, photoresist-free, fully solution processed high-grade photolithography mask

    NASA Astrophysics Data System (ADS)

    Yun, Jinho; Kim, Jongsu; Yang, Minyang; Kang, Bongchul

    2017-02-01

    Owing to the short life cycle of present-day microelectronics, conventional method of photomask fabrication should be replaced in order to improve the resultant agility and productivity of photolithography. To fulfill these requirements, we suggest a fully solution-based one-step fabrication method of a high-grade photomask, without the use of a photoresist, vacuum deposition, and etching process. The photomask is fabricated via the laser-induced instantaneous thermochemical metallization of an optically catalyzed hybrid complex synthesized in-situ from a low-cost particle-free organometallic solution. This reaction yields a masking layer whose high selectivity of less than 1 μm, self-generated retroreflective structure, and excellent optical surface are comparable to those of masks fabricated by vacuum depositions. In addition, the complexity of the process is minimized owing to the solution deposition of all the constituent layers. A series of evaluations and the application of this method to an actual photolithography process confirm that this approach constitute a next-generation photomask fabrication method by satisfying both improved agility and productivity of microelectronics manufacturing.

  16. Manufacture and optimization of low-cost tubular ceramic supports for membrane filtration: application to algal solution concentration.

    PubMed

    Issaoui, Mansour; Limousy, Lionel; Lebeau, Bénédicte; Bouaziz, Jamel; Fourati, Mohieddine

    2017-01-05

    Low-cost tubular macroporous supports for ceramic membranes were elaborated using the extrusion method, followed by curing, debinding, and sintering processes, from a powder mixture containing kaolin, starch, and sand. The obtained substrates were characterized using mercury intrusion porosimetry, water absorption test, water permeability, scanning electron microscopy, and three-point bending test to evaluate the effects of the additives on the relevant characteristics. According to experimental results, adding the starch ratio to the kaolin powder shows a notable impact on the membrane porosity and consequently on the water permeability of the tubular supports, whereas their mechanical strength decreased compared to those prepared from kaolin alone. It has been shown that the addition of an appropriate amount of starch to the ceramic paste leads to obtaining membrane supports with the desired porosity. Indeed, the water permeability increased significantly from 20 to 612 L h(-1) m(-2) bar(-1) for samples without and with 20 wt% of starch, respectively, as well as the open porosity, the apparent porosity, and the pore size distribution. The bending strength decreased slightly and reached about 4 MPa for samples with the highest starch amounts. On the other hand, the incorporation of sand in a mixture of kaolin + 10 wt% starch increased the mechanical strength and the water permeability. The samples containing 3 wt% of sand exhibited a bending strength four times higher than the supports without sand; the water permeability measured was about 221 L h(-1) m(-2) bar(-1). These elaborated tubular supports for membrane are found to be suitable for solution concentration; they were applied for algal solution and are also easily cleaned by water.

  17. 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).

  18. Low-Cost Process for Silicon Purification with Bubble Adsorption in Al-Si Melt

    NASA Astrophysics Data System (ADS)

    Yu, Wenzhou; Ma, Wenhui; Lv, Guoqiang; Ren, Yongsheng; Dai, Yongnian; Morita, Kazuki

    2014-08-01

    The primary silicon and Al-Si alloy have been separated in hypereutectic Al-Si melt by the electromagnetic stirring and directional solidification processes. During the electromagnetic separation process, the behavior of a hydrogen bubble in Al-Si melt has been discussed. Furthermore, the bubble adsorption effect for the Si purification has been revealed. The results show that the bubble cavity formed in the lower part of the sample by pulling it up. The scanning electron microscope along with energy dispersive spectrometer (SEM-EDS) analysis indicated that a lot of impurities were adsorbed onto the surface of the bubble cavity that may be beneficial for the Si purification. By decreasing the pulling-up rates, the size of the bubble cavity in Al-Si alloy increased, which results in the decreasing of the impurity contents in primary silicon. In this work, the impurity content in primary silicon is 10.8 ppmw, which is obviously improved compared with the 777.57 ppmw in metallurgical silicon. It is a low-cost technology that will be a potential route for the Si purification.

  19. Defect Engineering, Cell Processing, and Modeling for High-Performance, Low-Cost Crystalline Silicon Photovoltaics

    SciTech Connect

    Buonassisi, Tonio

    2013-02-26

    The objective of this project is to close the efficiency gap between industrial multicrystalline silicon (mc-Si) and monocrystalline silicon solar cells, while preserving the economic advantage of low-cost, high-volume substrates inherent to mc-Si. Over the course of this project, we made significant progress toward this goal, as evidenced by the evolution in solar-cell efficiencies. While most of the benefits of university projects are diffuse in nature, several unique contributions can be traced to this project, including the development of novel characterization methods, defect-simulation tools, and novel solar-cell processing approaches mitigate the effects of iron impurities ("Impurities to Efficiency" simulator) and dislocations. In collaboration with our industrial partners, this project contributed to the development of cell processing recipes, specialty materials, and equipment that increased cell efficiencies overall (not just multicrystalline silicon). Additionally, several students and postdocs who were either partially or fully engaged in this project (as evidenced by the publication record) are currently in the PV industry, with others to follow.

  20. A new low-cost ultrasonic and meteorological sensor for observation of snow hydrological processes

    NASA Astrophysics Data System (ADS)

    Weiler, M.; Pohl, S.; Garvelmann, J.; Wawerla, J.

    2012-04-01

    The high spatial and temporal dynamics of snow accumulation and melt is generally difficult to capture. Instrumental methods have been developed to capture snow height in combination with meteorological variables, however, these stations are usually quite expensive and only few locations can be instrumented. In order to capture the dynamics due to different elevations, aspects, vegetation cover, and snow redistribution, a low-cost station network is needed that focuses on snow processes and can be set up in rugged environments. We developed a digital-based sensor with low power consumption that can be easily deployed and can collect data up to 6 month. Data collected by the sensors include: snow height, air temperature and humidity, surface (snow) temperature, liquid precipitation, global radiation, and wind speed. In addition, the sensor can be upgraded to take a digital picture of the environment for time-lapse photography. The bus system of the sensor is built to allow GPSR modem access in future. We successfully compared the system with standard, high-cost meteorological measurements and already deployed over 50 stations in three watersheds in the Black Forest, Germany. We also successfully use the sensor for water level measurements in streams and other applications are certainly possible.

  1. MATERIALS DEGRADATION ANALYSIS AND DEVELOPMENT TO ENABLE ULTRA LOW COST, WEB-PROCESSED WHITE P-OLED FOR SSL

    SciTech Connect

    DR. DEVIN MACKENZIE

    2011-12-13

    Progress over Phase II of DE-FG02-07ER86293 'Materials Degradation Analysis and Development to Enable Ultra Low Cost, Web-Processed White P-OLED for SSL' was initially rapid in terms of device performance improvements. We exceeded our device luminance lifetime goals for printed flexible white OLEDs as laid out in our project proposal. Our Phase II performance target was to demonstrate >1500 hours luminance lifetime at 100 Cd/m2 from a printed flexible device. We now have R&D devices well in excess of 8000 hrs lifetime at 100 Cd/m2, tested in air. We also were able to produce devices which met the voltage target of >1500 hours below 15V operation. After completing the initial performance milestones, we went on to focus on color-related degradation issues which were cited as important to commercialization of the technology by our manufacturing partners. We also put additional focus on cathode work as the active material development that occurred over the STTR time period required an adaptation of the cathode from the original cathode formulations which were developed based on previous generation active layer materials. We were able to improve compatibility of the cathode with some of the newer generation active layer materials and improve device yield and voltage behavior. An additional objective of the initial Phase II was to further develop the underlying manufacturing technology and real-life product specifications. This is a key requirement that must be met to ensure eventual commercialization of this DOE-funded technology. The link between commercial investment for full commercialization and R&D efforts in OLED solid State Lighting is often a large one. Add-Vision's lower cost, printed OLED manufacturing approach is an attraction, but close engagement with manufacturing partners and addressing customer specifications is a very important link. Manufacturing technology encompasses development of moisture reduction encapsulation technology, improved cost

  2. Nanostructured Materials for High Efficiency Low Cost Solution-Processed Photovoltaics

    SciTech Connect

    Salleo, Alberto

    2012-10-31

    The goal of the project was to develop a suite of materials coupled with processing technologies aimed at the fabrication of entirely solution-processed photovoltaic devices. Most of the emphasis in terms of innovation was placed on the transparent electrodes, widely considered a critical component of the solar cell in terms of cost and performance. The active layer technologies proposed hinged on the fabrication and deposition of semiconducting nanoparticles. The electrode development hit all the milestones proposed: by the end of the grant we were able to fabricate transparent and flexible electrodes with transmission over the solar spectrum higher than 85% and sheet resistance lower than 10 Ω/square. To the best of our knowledge, this is the highest-performance transparent electrode reported. Furthermore these electrodes were deposited by spray-coating, a large-area, low-cost deposition techniques. Hence the first main goal of the proposal, which was to find an alternative to ITO was successfully achieved. Organic photovoltaic devices were made with these electrodes having a performance indistinguishable from that of devices made on ITO (the industry standard), e.g. ~5% for P3HT:PCBM cells. We also innovated in the active-area part of the device where semiconducting inks were designed rather than nanoparticle suspensions. The process we selected, called air-stable ink rolling (AIR) allowed to deposit well-controlled films of ternary and quaternary II-VI semiconductors. Developing a new technology from scratch proved to be more challenging than anticipated and therefore we were not able to demonstrate a fully integrated device using our nanostructured high-performance transparent electrodes as well as AIR active layers. As a result, we did not achieve the second main goal of the proposal, which was to fabricate an entire cell using nanostructured materials. We were able to develop the components separately but did not integrate them in a device.

  3. ICE: A Scalable, Low-Cost FPGA-Based Telescope Signal Processing and Networking System

    NASA Astrophysics Data System (ADS)

    Bandura, K.; Bender, A. N.; Cliche, J. F.; de Haan, T.; Dobbs, M. A.; Gilbert, A. J.; Griffin, S.; Hsyu, G.; Ittah, D.; Parra, J. Mena; Montgomery, J.; Pinsonneault-Marotte, T.; Siegel, S.; Smecher, G.; Tang, Q. Y.; Vanderlinde, K.; Whitehorn, N.

    We present an overview of the ‘ICE’ hardware and software framework that implements large arrays of interconnected field-programmable gate array (FPGA)-based data acquisition, signal processing and networking nodes economically. The system was conceived for application to radio, millimeter and sub-millimeter telescope readout systems that have requirements beyond typical off-the-shelf processing systems, such as careful control of interference signals produced by the digital electronics, and clocking of all elements in the system from a single precise observatory-derived oscillator. A new generation of telescopes operating at these frequency bands and designed with a vastly increased emphasis on digital signal processing to support their detector multiplexing technology or high-bandwidth correlators — data rates exceeding a terabyte per second — are becoming common. The ICE system is built around a custom FPGA motherboard that makes use of an Xilinx Kintex-7 FPGA and ARM-based co-processor. The system is specialized for specific applications through software, firmware and custom mezzanine daughter boards that interface to the FPGA through the industry-standard FPGA mezzanine card (FMC) specifications. For high density applications, the motherboards are packaged in 16-slot crates with ICE backplanes that implement a low-cost passive full-mesh network between the motherboards in a crate, allow high bandwidth interconnection between crates and enable data offload to a computer cluster. A Python-based control software library automatically detects and operates the hardware in the array. Examples of specific telescope applications of the ICE framework are presented, namely the frequency-multiplexed bolometer readout systems used for the South Pole Telescope (SPT) and Simons Array and the digitizer, F-engine, and networking engine for the Canadian Hydrogen Intensity Mapping Experiment (CHIME) and Hydrogen Intensity and Real-time Analysis eXperiment (HIRAX

  4. Micro-Thermoelectric Generation Modules Fabricated with Low-Cost Mechanical Machining Processes

    NASA Astrophysics Data System (ADS)

    Liu, Dawei; Jin, A. J.; Peng, Wenbo; Li, Qiming; Gao, Hu; Zhu, Lianjun; Li, Fu; Zhu, Zhixiang

    2017-05-01

    Micro/small-scale thermoelectric generation modules are able to produce continuous, noise-free and reliable electricity power using low temperature differences that widely exist in nature or industry. These advantages bring them great application prospects in the fields of remote monitoring, microelectronics/micro-electromechanical systems (MEMS), medical apparatus and smart management system, which often require a power source free of maintenance and vibration. In this work, a prototypical thermoelectric module (12 mm × 12 mm × 0.8 mm) with 15 pairs of micro-scale thermoelectric legs (0.2 mm in width and 0.6 mm in height for each leg) is fabricated using a low-cost mechanical machining process. In this process, cutting and polishing are the main methods for the preparation of thermoelectric pairs from commercial polycrystalline materials and for the fabrication of electrode patterns. The as-fabricated module is tested for its power generation properties with the hot side heated by an electrical heater and the cold side by cold air. With the heater temperature of 375 K, the thermoelectric potential is about 9.1 mV, the short circuit current is about 14.5 mA, and the maximum output power is about 32.8 μW. The finite element method is applied to analyze the heat transfer of the module during our test. The temperature difference and heat flux are simulated, according to which the output powers at different temperatures are calculated, and the result is relatively consistent compared to the test results.

  5. Micro-Thermoelectric Generation Modules Fabricated with Low-Cost Mechanical Machining Processes

    NASA Astrophysics Data System (ADS)

    Liu, Dawei; Jin, A. J.; Peng, Wenbo; Li, Qiming; Gao, Hu; Zhu, Lianjun; Li, Fu; Zhu, Zhixiang

    2016-11-01

    Micro/small-scale thermoelectric generation modules are able to produce continuous, noise-free and reliable electricity power using low temperature differences that widely exist in nature or industry. These advantages bring them great application prospects in the fields of remote monitoring, microelectronics/micro-electromechanical systems (MEMS), medical apparatus and smart management system, which often require a power source free of maintenance and vibration. In this work, a prototypical thermoelectric module (12 mm × 12 mm × 0.8 mm) with 15 pairs of micro-scale thermoelectric legs (0.2 mm in width and 0.6 mm in height for each leg) is fabricated using a low-cost mechanical machining process. In this process, cutting and polishing are the main methods for the preparation of thermoelectric pairs from commercial polycrystalline materials and for the fabrication of electrode patterns. The as-fabricated module is tested for its power generation properties with the hot side heated by an electrical heater and the cold side by cold air. With the heater temperature of 375 K, the thermoelectric potential is about 9.1 mV, the short circuit current is about 14.5 mA, and the maximum output power is about 32.8 μW. The finite element method is applied to analyze the heat transfer of the module during our test. The temperature difference and heat flux are simulated, according to which the output powers at different temperatures are calculated, and the result is relatively consistent compared to the test results.

  6. 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.

  7. Low-cost copper complexes as p-dopants in solution processable hole transport layers

    SciTech Connect

    Kellermann, Renate; Taroata, Dan; Maltenberger, Anna; Hartmann, David; Schmid, Guenter; Brabec, Christoph J.

    2015-09-07

    We demonstrate the usage of the Lewis-acidic copper(II)hexafluoroacetylacetonate (Cu(hfac){sub 2}) and copper(II)trifluoroacetylacetonate (Cu(tfac){sub 2}) as low-cost p-dopants for conductivity enhancement of solution processable hole transport layers based on small molecules in organic light emitting diodes (OLEDs). The materials were clearly soluble in mixtures of environmentally friendly anisole and xylene and spin-coated under ambient atmosphere. Enhancements of two and four orders of magnitude, reaching 4.0 × 10{sup −11} S/cm with a dopant concentration of only 2 mol% Cu(hfac){sub 2} and 1.5 × 10{sup −9} S/cm with 5 mol% Cu(tfac){sub 2} in 2,2′,7,7′-tetra(N,N-ditolyl)amino-9,9-spiro-bifluorene (spiro-TTB), respectively, were achieved. Red light emitting diodes were fabricated with reduced driving voltages and enhanced current and power efficiencies (8.6 lm/W with Cu(hfac){sub 2} and 5.6 lm/W with Cu(tfac){sub 2}) compared to the OLED with undoped spiro-TTB (3.9 lm/W). The OLED with Cu(hfac){sub 2} doped spiro-TTB showed an over 8 times improved LT{sub 50} lifetime of 70 h at a starting luminance of 5000 cd/m{sup 2}. The LT{sub 50} lifetime of the reference OLED with PEDOT:PSS was only 8 h. Both non-optimized OLEDs were operated at similar driving voltage and power efficiency.

  8. Pilot-Scale Silicone Process for Low-Cost Carbon Dioxide Capture

    SciTech Connect

    Farnum, Rachel; Perry, Robert; Wood, Benjamin

    2014-12-31

    GE Global Research is developing technology to remove carbon dioxide (CO 2) from the flue gas of coal-fired powerplants. A mixture of 3-aminopropyl end-capped polydimethylsiloxane (GAP-1m) and triethylene glycol (TEG) is the preferred CO2-capture solvent. GE Global Research was contracted by the Department of Energy to test a pilot-scale continuous CO2 absorption/desorption system using a GAP-1m/TEG mixture as the solvent. As part of that effort, an Environmental, Health, and Safety (EH&S) assessment for a CO2-capture system for a 550 MW coal-fired powerplant was conducted. Five components of the solvent, CAS#2469-55-8 (GAP-0), CAS#106214-84-0 (GAP-1-4), TEG, and methanol and xylene (minor contaminants from the aminosilicone) are included in this assessment. One by-product, GAP- 1m/SOX salt, and dodecylbenzenesulfonicacid (DDBSA) were also identified foranalysis. An EH&S assessment was also completed for the manufacturing process for the GAP-1m solvent. The chemicals associated with the manufacturing process include methanol, xylene, allyl chloride, potassium cyanate, sodium hydroxide (NaOH), tetramethyldisiloxane (TMDSO), tetramethyl ammonium hydroxide, Karstedt catalyst, octamethylcyclotetrasiloxane (D4), Aliquat 336, methyl carbamate, potassium chloride, trimethylamine, and (3-aminopropyl) dimethyl silanol. The toxicological effects of each component of both the CO2 capture system and the manufacturing process were defined, and control mechanisms necessary to comply with U.S. EH&S regulations are summarized. Engineering and control systems, including environmental abatement, are described for minimizing exposure and release of the chemical components. Proper handling and storage recommendations are made for each chemical to minimize risk to workers and the surrounding community.

  9. Continuous Process for Low-Cost, High-Quality YSZ Powder

    SciTech Connect

    Scott L. Swartz; Michael Beachy; Matthew M. Seabaugh

    2006-03-31

    This report describes results obtained by NexTech Materials, Ltd. in a project funded by DOE under the auspices of the Solid-State Energy Conversion Alliance (SECA). The project focused on development of YSZ electrolyte powder synthesis technology that could be ''tailored'' to the process-specific needs of different solid oxide fuel cell (SOFC) designs being developed by SECA's industry teams. The work in the project involved bench-scale processing work aimed at establishing a homogeneous precipitation process for producing YSZ electrolyte powder, scaleup of the process to 20-kilogram batch sizes, and evaluation of the YSZ powder products produced by the process. The developed process involved the steps of: (a) preparation of an aqueous hydrous oxide slurry via coprecipitation; (b) washing of residual salts from the precipitated hydroxide slurry followed by drying; (c) calcination of the dried powder to crystallize the YSZ powder and achieve desired surface area; and (d) milling of the calcined powder to targeted particle size. YSZ powders thus prepared were subjected to a comprehensive set of characterization and performance tests, including particle size distribution and surface area analyses, sintering performance studies, and ionic conductivity measurements. A number of different YSZ powder formulations were established, all of which had desirable performance attributes relative to commercially available YSZ powders. Powder characterization and performance metrics that were established at the onset of the project were met or exceeded. A manufacturing cost analysis was performed, and a manufactured cost of $27/kg was estimated based on this analysis. The analysis also allowed an identification of process refinements that would lead to even lower cost.

  10. Low-cost-silicon-process development. Phase IV: process improvement. Second quarterly technical progress report

    SciTech Connect

    Giraudi, R. V.; Newman, C. G.

    1981-04-01

    A number of promising techniques for improving the overall yield and economics of the tribromosilane based process to produce solar cell grade silicon is investigated. The current work is aimed at the identification of an optimum process and the characterization of that process through mini-plant operation and analysis. The three project tasks include process improvement studies, kinetic studies, and process economic studies. During this second quarter reporting period process improvement studies continued in the mini-plant, focusing on the correlation of current mini-plant yield results with prior laboratory scale work. Silicon bromination in the synthesis unit and tribromosilane purification in the distillation unit proceeded efficiently and without complication during this reporting period. Tribromosilane yields in the synthesis unit were low due to unobtainable higher reaction temperatures. Initial polycrystalline silicon production studies have indicated consistent yields of 85%. The laboratory scale static bulb reactor system was calibrated by observing the decomposition of t-butyl chloride. These results compared very well to results obtained by previous investigators for the same decomposition. Upon the conclusion of the calibration tests, the tribromosilane decomposition rate study was initiated. Two decompositions were completed and it was concluded that the reaction order can not be determined at this time. A free space reactor apparatus was assembled and tribromosilane decompositions, as a function of dilution in argon, was studied.

  11. Low-cost Solar Array (LSA) project

    NASA Technical Reports Server (NTRS)

    1978-01-01

    Progress made by the Low-Cost Silicon Solar Array Project during the period January through March 1978 is reported. It includes task reports on silicon material processing, large-area silicon sheet development, encapsulation materials testing and development, project engineering and operations, and manufacturing techniques, plus the steps taken to integrate these efforts.

  12. Evaluation of selected chemical processes for production of low-cost silicon

    NASA Technical Reports Server (NTRS)

    Blocher, J. M., Jr.; Browning, M. F.; Wilson, W. J.; Carmichael, D. C.

    1976-01-01

    Plant construction costs and manufacturing costs were estimated for the production of solar-grade silicon by the reduction of silicon tetrachloride in a fluidized bed of seed particles, and several modifications of the iodide process using either thermal decomposition on heated filaments (rods) or hydrogen reduction in a fluidized bed of seed particles. Energy consumption data for the zinc reduction process and each of the iodide process options are given and all appear to be acceptable from the standpoint of energy pay back. Information is presented on the experimental zinc reduction of SiCl4 and electrolytic recovery of zinc from ZnCl2. All of the experimental work performed thus far has supported the initial assumption as to technical feasibility of producing semiconductor silicon by the zinc reduction or iodide processes proposed. The results of a more thorough thermodynamic evaluation of the iodination of silicon oxide/carbon mixtures are presented which explain apparent inconsistencies in an earlier cursory examination of the system.

  13. Low-cost data analysis systems for processing multispectral scanner data

    NASA Technical Reports Server (NTRS)

    Whitely, S. L.

    1976-01-01

    The basic hardware and software requirements are described for four low cost analysis systems for computer generated land use maps. The data analysis systems consist of an image display system, a small digital computer, and an output recording device. Software is described together with some of the display and recording devices, and typical costs are cited. Computer requirements are given, and two approaches are described for converting black-white film and electrostatic printer output to inexpensive color output products. Examples of output products are shown.

  14. Analysis and evaluation in the production process and equipment area of the low-cost solar array project

    NASA Technical Reports Server (NTRS)

    Goldman, H.; Wolf, M.

    1979-01-01

    The energy consumed in manufacturing silicon solar cell modules was calculated for the current process, as well as for 1982 and 1986 projected processes. In addition, energy payback times for the above three sequences are shown. The module manufacturing energy was partitioned two ways. In one way, the silicon reduction, silicon purification, sheet formation, cell fabrication, and encapsulation energies were found. In addition, the facility, equipment, processing material and direct material lost-in-process energies were appropriated in junction formation processes and full module manufacturing sequences. A brief methodology accounting for the energy of silicon wafers lost-in-processing during cell manufacturing is described.

  15. A low cost technique to evaluate usable product for small manufacturing companies: a case study on Garcia robot.

    PubMed

    An, Vatana; Soares, Marcelo

    2012-01-01

    A usability evaluation technique to evaluate user interfaces is introduces. The technique is effective and affordable for small manufacturing companies. By using this technique, an integration of users' feedbacks and some usability concepts, a product can be 3 times easier to use among potential users and more than 5 times easier to use among motivated users. In addition, the technique can be implemented with the company's employees as participants.

  16. Design, durability and low cost processing technology for composite fan exit guide vanes

    NASA Technical Reports Server (NTRS)

    Blecherman, S. S.

    1980-01-01

    A program was conducted to design, fabricate and test a durable, low cost, lightweight composite fan exit guide vane for high bypass ratio gas turbine engine application. Eight candidate material/design combinations were evaluated by NASTRAN finite element analysis. Four of these candidate systems were selected for composite vane fabrication by two vendors. A core and shell vane design was chosen in which the unidirectional graphite core fiber was the same for all candidates. The shell material, fiber orientation and ply configuration were varied. Material tests were performed on raw material and composite specimens to establish specification requirements. Composite vanes were nondestructively inspected and subsequently fatigue tested in both dry and 'wet' conditions. The program provided relevant data with respect to design analysis, materials properties, inspection standards, improved durability, weight benefits and part price of the composite fan exit guide vane.

  17. Design, durability and low cost processing technology for composite fan exit guide vanes

    NASA Technical Reports Server (NTRS)

    Blecherman, S. S.

    1980-01-01

    A program was conducted to design, fabricate and test a durable, low cost, lightweight composite fan exit guide vane for high bypass ratio gas turbine engine application. Eight candidate material/design combinations were evaluated by NASTRAN finite element analysis. Four of these candidate systems were selected for composite vane fabrication by two vendors. A core and shell vane design was chosen in which the unidirectional graphite core fiber was the same for all candidates. The shell material, fiber orientation and ply configuration were varied. Material tests were performed on raw material and composite specimens to establish specification requirements. Composite vanes were nondestructively inspected and subsequently fatigue tested in both dry and 'wet' conditions. The program provided relevant data with respect to design analysis, materials properties, inspection standards, improved durability, weight benefits and part price of the composite fan exit guide vane.

  18. Low cost tooling material and process for graphite and Kevlar composites

    NASA Technical Reports Server (NTRS)

    Childs, William I.

    1987-01-01

    An Extruded Sheet Tooling Compound (ESTC) was developed for use in quickly building low cost molds for fabricating composites. The ESTC is a very highly mineral-filled resin system formed into a 6 mm thick sheet. The sheet is laid on the pattern, vacuum (bag) is applied to remove air from the pattern surface, and the assembly is heat cured. The formed ESTC is then backed and/or framed and ready for use. The cured ESTC exhibits low coefficient of thermal expansion and maintains strength at temperatures of 180 to 200 C. Tools were made and used successfully for: Compression molding of high strength epoxy sheet molding compound, stamping of aluminum, resin transfer molding of polyester, and liquid resin molding of polyester. Several variations of ESTC can be made for specific requirements. Higher thermal conductivity can be achieved by using an aluminum particle filler. Room temperature gel is possible to allow use of foam patterns.

  19. Manufacturing Process of Flat Display

    NASA Astrophysics Data System (ADS)

    Ohmi, Tadahiro

    A large size display for entertainment, internet, PC and other information instruments is key tool for coming IT revolutionary era, so that the large size display must be characterized by very low electric power consumption and human friendly performance without tiring user's eyes. Thus, liquid crystal (LC) and electroluminescence (EL) displays are candidates for this target. High quality poly-silicon TFT is essentially required even for LCD displays instead current amorphous Si TFT, because very large current drivability is necessary for TFT due to the increase of LCD cell capacitor with an increase of display size up to 50 inches and beyond. The key issue for this target is a creation of very low temperature poly-Si TFT manufacturing technology without excimer laser annealing and very low cost manufacturing which is characterized by very simplified display structures and very simplified manufacturing steps based on very drastic progress of various relating materials and components such as backlights, polarizer, color filter, and etc.

  20. Low-cost manufacturing of flow channels with multi-nozzle abrasive-waterjets: a feasibility investigation

    SciTech Connect

    Liu, H. T.; Hovanski, Yuri; Caldwell, Dustin D.; Williford, Ralph E.

    2008-11-28

    Stamping and photochemical machining have been two of the common methods for manufacturing flow channels used in reformers, reactors, heat exchangers, and fuel-cell stacks. The flow channels are then bonded to form the finish products. These methods are severely constrainted by plate area and thickness, material type, and environmental concerns. Furthermore, they are too costly to meet the U. S. DoE's targeted goal - untaxed price of $2.00-3.00/gge (gasoline gallon equivalent). Abrasive-waterjets were applied for machining various flow-channel patterns such as high-espect-ratio slots/ribs on several metals and non-metals were conducted to demonstrate its merits over other machine tools.

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

    SciTech Connect

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

    2015-08-01

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

  2. A low cost fluorescence lifetime measurement system based on SPAD detectors and FPGA processing

    NASA Astrophysics Data System (ADS)

    Franch, N.; Alonso, O.; Canals, J.; Vilà, A.; Dieguez, A.

    2017-02-01

    This work presents a low cost fluorescence life time measurement system, aimed at carrying out fast diagnostic tests through label detection in a portable system so it can be used in a medical consultation, within a short time span. The system uses Time Correlated Single Photon Counting (TCSPC), measuring the arrival time of individual photons and building a histogram of those times, showing the fluorescence decay of the label which is characteristic of each fluorescent substance. The system is implemented using a Xilinx FPGA which controls the experiment and includes a Time to Digital Converter (TDC) to perform measurements with a resolution in the order of tenths of picoseconds. Also included are a laser diode and the driving electronics to generate short pulses as well as a HV-CMOS implemented Single Photon Avalanche Diode (SPAD) as a high gain sensor. The system is entirely configurable so it can easily be adapted to the target label molecule and measurement needs. The histogram is constructed within the FPGA and can then be read as convenient. Various performance parameters are also shown, as well as experimental measurements of a quantum dot fluorescence decay as a proof of concept.

  3. Development of large area, low-cost, solar cell processing sequence

    NASA Technical Reports Server (NTRS)

    Chitre, S.; Donon, J.

    1981-01-01

    A cost effective process based on state-of-the-art technology has been developed for the production of large-area (55 sq cm and larger) solar cells. The process is capable of providing silicon and polysilicon cell efficiencies in excess of 10% at an overall cost of 12 c/watt in 1980 dollars. The process provides large throughputs and is suitable for complete automation with high yields. Various stages of the process development are discussed.

  4. Beryllium Manufacturing Processes

    SciTech Connect

    Goldberg, A

    2006-06-30

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

  5. Low cost silicon solar array project. Task 1: Establishment of the feasibility of a process capable of low cost, high volume production of silane, SiH4

    NASA Technical Reports Server (NTRS)

    Breneman, W. C.; Mui, J. Y. P.

    1976-01-01

    The kinetics of the redistribution of dichlorosilane and trichlorosilane vapor over a tertiary amine ion exchange resin catalyst were investigated. The hydrogenation of SiCl4 to form HSiCl3 and the direct synthesis of H2SiCl2 from HCl gas and metallurgical silicon metal were also studied. The purification of SiH4 using activated carbon adsorbent was studied along with a process for storing SiH4 absorbed on carbon. The latter makes possible a higher volumetric efficiency than compressed gas storage. A mini-plant designed to produce ten pounds per day of SiH4 is described.

  6. High throughput transmission optical projection tomography using low cost graphics processing unit.

    PubMed

    Vinegoni, Claudio; Fexon, Lyuba; Feruglio, Paolo Fumene; Pivovarov, Misha; Figueiredo, Jose-Luiz; Nahrendorf, Matthias; Pozzo, Antonio; Sbarbati, Andrea; Weissleder, Ralph

    2009-12-07

    We implement the use of a graphics processing unit (GPU) in order to achieve real time data processing for high-throughput transmission optical projection tomography imaging. By implementing the GPU we have obtained a 300 fold performance enhancement in comparison to a CPU workstation implementation. This enables to obtain on-the-fly reconstructions enabling for high throughput imaging.

  7. Research and development of low cost processes for integrated solar arrays

    NASA Technical Reports Server (NTRS)

    Wolf, M.; Crossman, L. D.

    1975-01-01

    Si reduction, purification and sheet generation work has been concentrated on gaining information about a reduction process combined with purification (higher purity arc furnace with gas blowing and gradient freezing), transport process with purification and polycrystal sheet growth potential (SiF2), plastic deformation for sheet generation, and float zone sheet recrystallization.

  8. A Low Cost Microcomputer System for Process Dynamics and Control Simulations.

    ERIC Educational Resources Information Center

    Crowl, D. A.; Durisin, M. J.

    1983-01-01

    Discusses a video simulator microcomputer system used to provide real-time demonstrations to strengthen students' understanding of process dynamics and control. Also discusses hardware/software and simulations developed using the system. The four simulations model various configurations of a process liquid level tank system. (JN)

  9. Bench-Scale Silicone Process for Low-Cost CO{sub 2} Capture

    SciTech Connect

    Fresia, Megan; Vogt, Kirk

    2013-12-31

    GE Global Research is developing technology to remove carbon dioxide (CO{sub 2}) from the flue gas of coal-fired power plants. A mixture of 3-aminopropyl end-capped polydimethylsiloxane (GAP-1m) and triethylene glycol (TEG) is the preferred CO{sub 2} capture solvent. GE Global Research was contracted by the Department of Energy to test a bench-scale continuous CO{sub 2} absorption/desorption system using a GAP-1m/TEG mixture as the solvent. SiVance LLC was sub-contracted to provide the GAP-1m material and conduct an Environmental, Health, and Safety (EH&S) assessment for a 550 MW coal-fired power plant. Five components of the solvent, CAS#2469-55-8 (GAP-0), CAS#106214-84-0 (GAP-1-4), TEG, and methanol and xylene (minor contaminants from the aminosilicone) are included in this assessment. One by-product, GAP-1m/SOX salt, and dodecylbenzenesulfonic acid (DDBSA) were also identified for analysis. All of the solvent components and DDBSA are listed on the EPA’s TSCA Inventory allowing companies to manufacture and use the chemicals commercially. The toxicological effects of each component were defined, and control mechanisms necessary to comply with U.S. EH&S regulations are summarized. An engineering and control system, including environmental abatement, was described for minimizing exposure and release of the chemical components. Proper handling and storage recommendations are made for each chemical to minimize risk to workers and the surrounding community.

  10. Rugged low-cost display systems

    NASA Astrophysics Data System (ADS)

    Stewart, Roger; Chiang, Anne; Hermanns, Anno; Vicentini, Frederic; Jacobsen, Jeffrey; Atherton, Jim; Boling, Ed; Cuomo, Frank; Drzaic, Paul; Pearson, Sean

    2002-08-01

    Alien technology has developed a family of rugged, plastic displays for portable devices like SmartCards, electronic signs, cellular telephones and military devices. These displays are driven by ultra-miniaturized silicon integrated circuits called NanoBlcok ICs that are put together using a Fluidic Self Assembly (FSA) process. This low-cost, high- volume manufacturing technique makes possible new types of liquid crystal and OLED display products.

  11. A low-cost polysilicon process based on the synthesis and decomposition of dichlorosilane

    NASA Technical Reports Server (NTRS)

    Mccormick, J. R.; Plahutnik, F.; Sawyer, D.; Arvidson, A.; Goldfarb, S.

    1982-01-01

    Major process steps of a dichlorosilane based chemical vapor deposition (CVD) process for the production of polycrystalline silicon have been evaluated. While an economic analysis of the process indicates that it is not capable of meeting JPL/DOE price objectives ($14.00/kg in 1980 dollars), product price in the $19.00/kg to $25.00/kg range may be achieved. Product quality has been evaluated and ascertained to be comparable to semiconductor-grade polycrystalline silicon. Solar cells fabricated from the material are also equivalent to those fabricated from semiconductor-grade polycrystalline silicon.

  12. A low-cost polysilicon process based on the synthesis and decomposition of dichlorosilane

    NASA Technical Reports Server (NTRS)

    Mccormick, J. R.; Plahutnik, F.; Sawyer, D.; Arvidson, A.; Goldfarb, S.

    1982-01-01

    Major process steps of a dichlorosilane based chemical vapor deposition (CVD) process for the production of polycrystalline silicon have been evaluated. While an economic analysis of the process indicates that it is not capable of meeting JPL/DOE price objectives ($14.00/kg in 1980 dollars), product price in the $19.00/kg to $25.00/kg range may be achieved. Product quality has been evaluated and ascertained to be comparable to semiconductor-grade polycrystalline silicon. Solar cells fabricated from the material are also equivalent to those fabricated from semiconductor-grade polycrystalline silicon.

  13. Design of a Facility to Implement a Low Cost Process for Production of NHC

    DTIC Science & Technology

    1979-05-15

    consists of three 4 in. ID pipe loops staged in series to pro- vide efficient B2 conversion and B1O yield. Condensed B10 pro- duct is collected in...B INTRODUCTION 11 DESIGN BASIS 13 General 13 B10 Process 14 NHC Process 20 PROCESS DESCRIPTION 25 General 25 BlO Production 29 NHC Production 34...Maintenance Procedures 86 Repair Parts 96 APPENDIX A - Tradeoff Calculation of Optimum Number of B10 Reactors B10 Reactor Tradeoff LIST OF FIGURES

  14. A Module Experimental Process System Development Unit (MEPSDU). [development of low cost solar arrays

    NASA Technical Reports Server (NTRS)

    1981-01-01

    The technical readiness of a cost effective process sequence that has the potential for the production of flat plate photovoltaic modules which met the price goal in 1986 of $.70 or less per Watt peak was demonstrated. The proposed process sequence was reviewed and laboratory verification experiments were conducted. The preliminary process includes the following features: semicrystalline silicon (10 cm by 10 cm) as the silicon input material; spray on dopant diffusion source; Al paste BSF formation; spray on AR coating; electroless Ni plate solder dip metallization; laser scribe edges; K & S tabbing and stringing machine; and laminated EVA modules.

  15. Erosion processes by water in agricultural landscapes: a low-cost methodology for post-event analyses

    NASA Astrophysics Data System (ADS)

    Prosdocimi, Massimo; Calligaro, Simone; Sofia, Giulia; Tarolli, Paolo

    2015-04-01

    Throughout the world, agricultural landscapes assume a great importance, especially for supplying food and a livelihood. Among the land degradation phenomena, erosion processes caused by water are those that may most affect the benefits provided by agricultural lands and endanger people who work and live there. In particular, erosion processes that affect the banks of agricultural channels may cause the bank failure and represent, in this way, a severe threat to floodplain inhabitants and agricultural crops. Similarly, rills and gullies are critical soil erosion processes as well, because they bear upon the productivity of a farm and represent a cost that growers have to deal with. To estimate quantitatively soil losses due to bank erosion and rills processes, area based measurements of surface changes are necessary but, sometimes, they may be difficult to realize. In fact, surface changes due to short-term events have to be represented with fine resolution and their monitoring may entail too much money and time. The main objective of this work is to show the effectiveness of a user-friendly and low-cost technique that may even rely on smart-phones, for the post-event analyses of i) bank erosion affecting agricultural channels, and ii) rill processes occurring on an agricultural plot. Two case studies were selected and located in the Veneto floodplain (northeast Italy) and Marche countryside (central Italy), respectively. The work is based on high-resolution topographic data obtained by the emerging, low-cost photogrammetric method named Structure-from-Motion (SfM). Extensive photosets of the case studies were obtained using both standalone reflex digital cameras and smart-phone built-in cameras. Digital Terrain Models (DTMs) derived from SfM revealed to be effective to estimate quantitatively erosion volumes and, in the case of the bank eroded, deposited materials as well. SfM applied to pictures taken by smartphones is useful for the analysis of the topography

  16. Self-Powered, Flexible, and Solution-Processable Perovskite Photodetector Based on Low-Cost Carbon Cloth.

    PubMed

    Sun, Haoxuan; Lei, Tianyu; Tian, Wei; Cao, Fengren; Xiong, Jie; Li, Liang

    2017-07-01

    Flexible perovskite photodetectors are usually constructed on indium-tin-oxide-coated polymer substrates, which are expensive, fragile, and not resistant to high temperature. Herein, for the first time, a high-performance flexible perovskite photodetector is fabricated based on low-cost carbon cloth via a facile solution processable strategy. In this device, perovskite microcrystal and Spiro-OMeTAD (hole transporting material) blended film act as active materials for light detection, and carbon cloth serves as both a flexible substrate and a conductive electrode. The as-fabricated photodetector shows a broad spectrum response from ultraviolet to near-infrared light, high responsivity, fast response speed, long-term stability, and self-powered capability. Flexible devices show negligible degradation after several tens of bending cycles and at the extremely bending angle of 180°. This work promises a new technique to construct flexible, high-performance photodetectors with low cost and self-powered capability. © 2017 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

  17. Evaluation of Selected Chemical Processes for Production of Low-cost Silicon, Phase 3

    NASA Technical Reports Server (NTRS)

    Blocher, J. M., Jr.; Browning, M. F.

    1979-01-01

    The construction of the 50 MT Si/year experimental process system development unit was deferred until FY 1980, and the fluidized bed, zinc vaporizer, by-product condenser, and electrolytic cell were combined with auxiliary units, capable of supporting 8-hour batchwise operation, to form the process development unit (PDU), which is scheduled to be in operation by October 1, 1979. The design of the PDU and objectives of its operation are discussed. Experimental program support activities described relate to: (1) a wetted-wall condensor; (2) fluidized-bed modeling; (3) zinc chloride electrolysis; and (4) zinc vaporizer.

  18. Design of Bench-Scale Silicone Process for Low-Cost CO{sub 2} Capture

    SciTech Connect

    Wood, Benjamin

    2012-06-30

    The major goal of the project is to design and optimize a bench-scale process for novel silicone CO{sub 2}-capture solvents and establish scalability and potential for commercialization of post-combustion capture of CO{sub 2} from coal-fired power plants. This system should be capable of 90% capture efficiency and demonstrate that less than 35% increase in the cost of energy services can be achieved upon scale-up. Experiments were conducted to obtain data required for design of the major unit operations. The bench-scale system design has been completed, including sizing of major unit operations and the development of a detailed Process and Instrument Diagram (P&ID). The system has been designed to be able to operate over a wide range of process conditions so that the effect of various process variables on performance can be determined. To facilitate flexibility in operation, the absorption column has been designed in a modular manner, so that the height of the column can be varied. The desorber has also been designed to allow for a range of residence times, temperatures, and pressures. The system will be fabricated at Techniserv Inc.

  19. Low-cost bump-bonding processes for high energy physics pixel detectors

    NASA Astrophysics Data System (ADS)

    Caselle, M.; Blank, T.; Colombo, F.; Dierlamm, A.; Husemann, U.; Kudella, S.; Weber, M.

    2016-01-01

    In the next generation of collider experiments detectors will be challenged by unprecedented particle fluxes. Thus large detector arrays of highly pixelated detectors with minimal dead area will be required at reasonable costs. Bump-bonding of pixel detectors has been shown to be a major cost-driver. KIT is one of five production centers of the CMS barrel pixel detector for the Phase I Upgrade. In this contribution the SnPb bump-bonding process and the production yield is reported. In parallel to the production of the new CMS pixel detector, several alternatives to the expensive photolithography electroplating/electroless metal deposition technologies are developing. Recent progress and challenges faced in the development of bump-bonding technology based on gold-stud bonding by thin (15 μm) gold wire is presented. This technique allows producing metal bumps with diameters down to 30 μm without using photolithography processes, which are typically required to provide suitable under bump metallization. The short setup time for the bumping process makes gold-stud bump-bonding highly attractive (and affordable) for the flip-chipping of single prototype ICs, which is the main limitation of the current photolithography processes.

  20. Quality management of manufacturing process based on manufacturing execution system

    NASA Astrophysics Data System (ADS)

    Zhang, Jian; Jiang, Yang; Jiang, Weizhuo

    2017-04-01

    Quality control elements in manufacturing process are elaborated. And the approach of quality management of manufacturing process based on manufacturing execution system (MES) is discussed. The functions of MES for a microcircuit production line are introduced conclusively.

  1. A low-cost solid–liquid separation process for enzymatically hydrolyzed corn stover slurries

    SciTech Connect

    Sievers, David A.; Lischeske, James J.; Biddy, Mary J.; Stickel, Jonathan J.

    2015-07-01

    Solid-liquid separation of intermediate process slurries is required in some process configurations for the conversion of lignocellulosic biomass to transportation fuels. Thermochemically pretreated and enzymatically hydrolyzed corn stover slurries have proven difficult to filter due to formation of very low permeability cakes that are rich in lignin. Treatment of two different slurries with polyelectrolyte flocculant was demonstrated to increase mean particle size and filterability. Filtration flux was greatly improved, and thus scaled filter unit capacity was increased approximately 40-fold compared with unflocculated slurry. Although additional costs were accrued using polyelectrolyte, techno-economic analysis revealed that the increase in filter capacity significantly reduced overall production costs. Fuel production cost at 95% sugar recovery was reduced by $1.35 US per gallon gasoline equivalent for dilute-acid pretreated and enzymatically hydrolyzed slurries and $3.40 for slurries produced using an additional alkaline de-acetylation preprocessing step that is even more difficult to natively filter.

  2. A low-cost solid-liquid separation process for enzymatically hydrolyzed corn stover slurries.

    PubMed

    Sievers, David A; Lischeske, James J; Biddy, Mary J; Stickel, Jonathan J

    2015-01-01

    Solid-liquid separation of intermediate process slurries is required in some process configurations for the conversion of lignocellulosic biomass to transportation fuels. Thermochemically pretreated and enzymatically hydrolyzed corn stover slurries have proven difficult to filter due to formation of very low permeability cakes that are rich in lignin. Treatment of two different slurries with polyelectrolyte flocculant was demonstrated to increase mean particle size and filterability. Filtration flux was greatly improved, and thus scaled filter unit capacity was increased approximately 40-fold compared with unflocculated slurry. Although additional costs were accrued using polyelectrolyte, techno-economic analysis revealed that the increase in filter capacity significantly reduced overall production costs. Fuel production cost at 95% sugar recovery was reduced by $1.35 US per gallon gasoline equivalent for dilute-acid pretreated and enzymatically hydrolyzed slurries and $3.40 for slurries produced using an additional alkaline de-acetylation preprocessing step that is even more difficult to natively filter.

  3. Evaluation of selected chemical processes for production of low-cost silicon, phase 3

    NASA Technical Reports Server (NTRS)

    Blocher, J. M., Jr.; Browning, M. F.; Seifert, D. A.

    1981-01-01

    A Process Development Unit (PDU), which consisted of the four major units of the process, was designed, installed, and experimentally operated. The PDU was sized to 50MT/Yr. The deposition took place in a fluidized bed reactor. As a consequences of the experiments, improvements in the design an operation of these units were undertaken and their experimental limitations were partially established. A parallel program of experimental work demonstrated that Zinc can be vaporized for introduction into the fluidized bed reactor, by direct induction-coupled r.f. energy. Residual zinc in the product can be removed by heat treatment below the melting point of silicon. Current efficiencies of 94 percent and above, and power efficiencies around 40 percent are achievable in the laboratory-scale electrolysis of ZnCl2.

  4. Considerations in developing geographic informations systems based on low-cost digital image processing

    NASA Technical Reports Server (NTRS)

    Henderson, F. M.; Dobson, M. W.

    1981-01-01

    The potential of digital image processing systems costing $20,000 or less for geographic information systems is assessed with the emphasis on the volume of data to be handled, the commercial hardware systems available, and the basic software for: (1) data entry, conversion and digitization; (2) georeferencing and geometric correction; (3) data structuring; (4) editing and updating; (5) analysis and retrieval; (6) output drivers; and (7) data management. Costs must also be considered as tangible and intangible factors.

  5. Diazo processing of LANDSAT imagery: A low-cost instructional technique

    NASA Technical Reports Server (NTRS)

    Lusch, D. P.

    1981-01-01

    Diazo processing of LANDSAT imagery is a relatively simple and cost effective method of producing enhanced renditions of the visual LANDSAT products. This technique is capable of producing a variety of image enhancements which have value in a teaching laboratory environment. Additionally, with the appropriate equipment, applications research which relys on accurate and repeatable results is possible. Exposure and development equipment options, diazo materials, and enhancement routines are discussed.

  6. Considerations in developing geographic informations systems based on low-cost digital image processing

    NASA Technical Reports Server (NTRS)

    Henderson, F. M.; Dobson, M. W.

    1981-01-01

    The potential of digital image processing systems costing $20,000 or less for geographic information systems is assessed with the emphasis on the volume of data to be handled, the commercial hardware systems available, and the basic software for: (1) data entry, conversion and digitization; (2) georeferencing and geometric correction; (3) data structuring; (4) editing and updating; (5) analysis and retrieval; (6) output drivers; and (7) data management. Costs must also be considered as tangible and intangible factors.

  7. Low-cost Approaches for Flux-pinning Enhancements in YBCO Films Using Solution Processing

    SciTech Connect

    Sathyamurthy, Srivatsan; Leonard, Keith J; Bhuiyan, Md S; Aytug, Tolga; Kang, Sukill; Martin, Patrick M; Hunt, Rodney Dale; Paranthaman, Mariappan Parans

    2007-01-01

    Nanoparticles of several oxides have been synthesized using reverse micelle process. Microemulsions containing n-octane as the oil phase, cetyl trimethylammonium bromide and 1-butanol as surfactants, and an aqueous solution of metal nitrates and sodium hydroxide were used as the reaction medium. The nanoparticles obtained were characterized using differential thermal analysis, x-ray diffraction, and transmission electron microscopy. The application of these particles for flux-pinning enhancements has been studied.

  8. New Design Methods And Algorithms For High Energy-Efficient And Low-cost Distillation Processes

    SciTech Connect

    Agrawal, Rakesh

    2013-11-21

    This project sought and successfully answered two big challenges facing the creation of low-energy, cost-effective, zeotropic multi-component distillation processes: first, identification of an efficient search space that includes all the useful distillation configurations and no undesired configurations; second, development of an algorithm to search the space efficiently and generate an array of low-energy options for industrial multi-component mixtures. Such mixtures are found in large-scale chemical and petroleum plants. Commercialization of our results was addressed by building a user interface allowing practical application of our methods for industrial problems by anyone with basic knowledge of distillation for a given problem. We also provided our algorithm to a major U.S. Chemical Company for use by the practitioners. The successful execution of this program has provided methods and algorithms at the disposal of process engineers to readily generate low-energy solutions for a large class of multicomponent distillation problems in a typical chemical and petrochemical plant. In a petrochemical complex, the distillation trains within crude oil processing, hydrotreating units containing alkylation, isomerization, reformer, LPG (liquefied petroleum gas) and NGL (natural gas liquids) processing units can benefit from our results. Effluents from naphtha crackers and ethane-propane crackers typically contain mixtures of methane, ethylene, ethane, propylene, propane, butane and heavier hydrocarbons. We have shown that our systematic search method with a more complete search space, along with the optimization algorithm, has a potential to yield low-energy distillation configurations for all such applications with energy savings up to 50%.

  9. Development of Hot Pressing as a Low Cost Processing Technique for Fuel Cell Fabrication

    SciTech Connect

    Sarin, V

    2003-01-14

    Dependable, plentiful, and economical energy has been the driving force for financial, industrial, and political growth in the US since the mid 19th century. For a country whose progress is so deeply rooted in abundant energy and whose current political agenda involves stabilizing world fossil fuel prices, the development of a reliable, efficient and environmentally friendly power generating source seems compulsory. The maturing of high technology fuel cells may be the panacea the country will find indispensable to free itself from foreign dependence. Fuel cells offer an efficient, combustion-less, virtually pollution-free power source, capable of being sited in downtown urban areas or in remote regions. Fuel cells have few moving parts and run almost silently. Fuel cells are electrochemical devices that convert the chemical energy of a fuel directly to electrical energy. Unlike batteries, which store a finite amount of energy, fuel cells will generate electricity continuously, as long as fuel and oxidant are available to the electrodes. Additionally, fuel cells offer clean, efficient, and reliable power and they can be operated using a variety of fuels. Hence, the fuel cell is an extremely promising technology. Over the course of this research, the fundamental knowledge related to ceramic processing, sintering, and hot pressing to successfully hot press a single operational SOFC in one step has been developed. Ceramic powder processing for each of the components of an SOFC has bene tailored towards this goal. Processing parameter for the electrolyte and cathode have been studied and developed until they converted. Several anode fabrication techniques have been developed. Additionally, a novel anode structured has been developed and refined. These individual processes have been cultivated until a single cell SOFC has been fabricated in one step.

  10. Low cost silicon solar array project large area silicon sheet task: Silicon web process development

    NASA Technical Reports Server (NTRS)

    Duncan, C. S.; Seidensticker, R. G.; Mchugh, J. P.; Blais, P. D.; Davis, J. R., Jr.

    1977-01-01

    Growth configurations were developed which produced crystals having low residual stress levels. The properties of a 106 mm diameter round crucible were evaluated and it was found that this design had greatly enhanced temperature fluctuations arising from convection in the melt. Thermal modeling efforts were directed to developing finite element models of the 106 mm round crucible and an elongated susceptor/crucible configuration. Also, the thermal model for the heat loss modes from the dendritic web was examined for guidance in reducing the thermal stress in the web. An economic analysis was prepared to evaluate the silicon web process in relation to price goals.

  11. Use of a programmable calculator for rapid, low-cost processing of echocardiographic records.

    PubMed

    Lust, R M; Boyer, B B; Lutherer, L O; Calvert, J E; Cooper, M W

    1984-01-01

    A comparative study was performed to determine the accuracy of a programmable calculator with supplemental digitizer in echocardiographic analysis. Twenty separate measurements were collected per heart beat from five different dogs, taking five heart beats from each dog. The measurements were made by an echocardiographic technician (ET), echocomputer (EC), and by a programmable calculator (HP). In a triple comparison (ET-HP, ET-EC, HP-EC) there were no significant differences in the values obtained, suggesting that the programmable calculator can provide a highly accurate and rapid means of processing echocardiographic measurements, thereby providing the advantages of the echocomputer without the cost of such a device.

  12. Evaluation of Selected Chemical Processes for Production of Low-cost Silicon, Phase 3

    NASA Technical Reports Server (NTRS)

    Blocher, J. M.; Browning, M. F.

    1979-01-01

    Refinements of the design of the 50 MT/year Experimental Process System Development Unit were made and competitive bids were received from mechanical, electrical, and structural contractors. Bids on most of the equipment were received and cataloged. Emergency procedures were defined to counter a variety of contingencies disclosed in operations and safety reviews. Experimental work with an electrolytic cell for zinc chloride disclosed no significant increase in power efficiency by steps taken to increase electrolyte circulation. On the basis of materials compatibility and permeability tests, 310 stainless steel was chosen for the shell of the fluidized-bed reactor and SiC-coated graphite for the liner.

  13. A low-cost solid–liquid separation process for enzymatically hydrolyzed corn stover slurries

    DOE PAGES

    Sievers, David A.; Lischeske, James J.; Biddy, Mary J.; ...

    2015-07-01

    Solid-liquid separation of intermediate process slurries is required in some process configurations for the conversion of lignocellulosic biomass to transportation fuels. Thermochemically pretreated and enzymatically hydrolyzed corn stover slurries have proven difficult to filter due to formation of very low permeability cakes that are rich in lignin. Treatment of two different slurries with polyelectrolyte flocculant was demonstrated to increase mean particle size and filterability. Filtration flux was greatly improved, and thus scaled filter unit capacity was increased approximately 40-fold compared with unflocculated slurry. Although additional costs were accrued using polyelectrolyte, techno-economic analysis revealed that the increase in filter capacity significantlymore » reduced overall production costs. Fuel production cost at 95% sugar recovery was reduced by $1.35 US per gallon gasoline equivalent for dilute-acid pretreated and enzymatically hydrolyzed slurries and $3.40 for slurries produced using an additional alkaline de-acetylation preprocessing step that is even more difficult to natively filter.« less

  14. Solution-processed colloidal quantum dot photodiodes for low-cost SWIR imaging

    NASA Astrophysics Data System (ADS)

    Klem, Ethan J. D.; Lewis, Jay; Gregory, Christopher; Cunningham, Garry; Temple, Dorota

    2012-06-01

    While InGaAs-based focal plane arrays (FPAs) provide excellent detectivity and low noise for SWIR imaging applications, wider scale adoption of systems capable of working in this spectral range is limited by high costs, limited spectral response, and costly integration with Si ROIC devices. RTI has demonstrated a novel photodiode technology based on IR-absorbing solution-processed PbS colloidal quantum dots (CQD) that can overcome these limitations of InGaAs FPAs. We have fabricated devices with quantum efficiencies exceeding 50%, and detectivities that are competitive with that of InGaAs. Dark currents of ~2 nA/cm2 were measured at temperatures compatible with solid state coolers. Additionally, by processing these devices entirely at room temperature we find them to be compatible with monolithic integration onto readout ICs, thereby removing any limitation on device size. We will show early efforts towards demonstrating a direct integration of this sensor technology onto a Si ROIC IC and describe a path towards fabricating sensors sensitive from the visible to 2200 nm at a cost comparable to that of CMOS based devices. This combination of high performance, dramatic cost reduction, and multispectral sensitivity is ideally suited to expand the use of SWIR imaging in current applications, as well as to address applications which require a multispectral sensitivity not met by existing technologies.

  15. Generic process for low-cost InP integrated photonics in industrial foundries

    NASA Astrophysics Data System (ADS)

    Augustin, Luc; Ambrosius, Huub; Thijs, Peter; Soares, Francisco; Grote, Norbert; Szymanski, Dominik; Wale, Mike; Smit, Meint

    2013-05-01

    Application Specific Photonic Integrated Circuits (ASPICs) are considered key elements to make photonic systems or subsystems cheap and ubiquitous. ASPICs still are several orders of magnitude more expensive than their microelectronic counterpart: ASICS, which has restricted their application to a few niche markets. A novel approach in photonic integration is emerging that will reduce the R&D costs of ASPICs by more than an order of magnitude. It will bring the application of ASPICs that integrate complex and advanced photonic functionality on a single chip within reach for a large number of small and larger companies and initiate a breakthrough in the application of Photonic ICs. In this paper the process is explained. A significant number of designs has been realized the last 4 years, for a variety of applications in telecoms, datacoms, medical and sensing, from parties all over the world.

  16. Evaluation of selected chemical processes for production of low-cost silicon, phases 1 and 2

    NASA Technical Reports Server (NTRS)

    Blocher, J. M.; Browning, M. F.

    1978-01-01

    A miniplant, consisting of a 5 cm-diameter fluidized-bed reactor and associated equipment was used to study the deposition parameters, temperature, reactant composition, seed particle size, bed depth, reactant throughput, and methods of reactant introduction. It was confirmed that the permissible range of fluidized-bed temperature was limited at the lower end by zinc condensation (918 C) and at higher temperatures by rapidly decreasing conversion efficiency. Use of a graded bed temperature was shown to increase the conversion efficiency over that obtained in an isothermal bed. Other aspects of the process such as the condensation and fused-salt electrolysis of the ZnCl2 by-product for recycle of zinc and chlorine were studied to provide information required for design of a 50 MT/year experimental facility. In view of the favorable technical and economic indications obtained, it was recommended that construction and operation of the 50 MT/year experimental facility be implemented.

  17. Bench-Scale Silicone Process for Low-Cost CO{sub 2} Capture

    SciTech Connect

    Vipperla, Ravikumar; Yee, Michael; Steele, Ray

    2012-11-01

    This report presents system and economic analysis for a carbon capture unit which uses an amino-silicone solvent for CO{sub 2} capture and sequestration (CCS) in a pulverized coal (PC) boiler. The amino-silicone solvent is based on GAP-1 with Tri-Ethylene Glycol (TEG) as a co-solvent. The report also shows results for a CCS unit based on a conventional approach using mono-ethanol amine (MEA). Models were developed for both processes and used to calculate mass and energy balances. Capital costs and energy penalty were calculated for both systems, as well as the increase in cost of electricity. The amino-silicone solvent based system demonstrates significant advantages compared to the MEA system.

  18. Pilot-Scale Silicone Process for Low-Cost Carbon Dioxide Capture

    SciTech Connect

    Singh, Surinder; Spiry, Irina; Wood, Benjamin; Hancu, Dan; Chen, Wei

    2014-07-01

    This report presents system and economicanalysis for a carbon-capture unit which uses an aminosilicone-based solvent for CO₂ capture in a pulverized coal (PC) boiler. The aminosilicone solvent is a 60/40 wt/wt mixture of 3-aminopropyl end-capped polydimethylsiloxane (GAP-1m) with tri-ethylene glycol (TEG) as a co-solvent. Forcomparison purposes, the report also shows results for a carbon-capture unit based on a conventional approach using mono-ethanol amine (MEA). The first year removal cost of CO₂ for the aminosilicone-based carbon-capture process is $46.04/ton of CO₂ as compared to $60.25/ton of CO₂ when MEA is used. The aminosilicone- based process has <77% of the CAPEX of a system using MEA solvent. The lower CAPEX is due to several factors, including the higher working capacity of the aminosilicone solvent compared the MEA, which reduces the solvent flow rate required, reducing equipment sizes. If it is determined that carbon steel can be used in the rich-lean heat exchanger in the carbon capture unit, the first year removal cost of CO₂ decreases to $44.12/ton. The aminosilicone-based solvent has a higherthermal stability than MEA, allowing desorption to be conducted at higher temperatures and pressures, decreasing the number of compressor stages needed. The aminosilicone-based solvent also has a lowervapor pressure, allowing the desorption to be conducted in a continuous-stirred tank reactor versus a more expensive packed column. The aminosilicone-based solvent has a lowerheat capacity, which decreases the heat load on the desorber. In summary, the amino-silicone solvent has significant advantages overconventional systems using MEA.

  19. A Low-Cost Environmental Monitoring System: How to Prevent Systematic Errors in the Design Phase through the Combined Use of Additive Manufacturing and Thermographic Techniques.

    PubMed

    Salamone, Francesco; Danza, Ludovico; Meroni, Italo; Pollastro, Maria Cristina

    2017-04-11

    nEMoS (nano Environmental Monitoring System) is a 3D-printed device built following the Do-It-Yourself (DIY) approach. It can be connected to the web and it can be used to assess indoor environmental quality (IEQ). It is built using some low-cost sensors connected to an Arduino microcontroller board. The device is assembled in a small-sized case and both thermohygrometric sensors used to measure the air temperature and relative humidity, and the globe thermometer used to measure the radiant temperature, can be subject to thermal effects due to overheating of some nearby components. A thermographic analysis was made to rule out this possibility. The paper shows how the pervasive technique of additive manufacturing can be combined with the more traditional thermographic techniques to redesign the case and to verify the accuracy of the optimized system in order to prevent instrumental systematic errors in terms of the difference between experimental and actual values of the above-mentioned environmental parameters.

  20. A Low-Cost Environmental Monitoring System: How to Prevent Systematic Errors in the Design Phase through the Combined Use of Additive Manufacturing and Thermographic Techniques

    PubMed Central

    Salamone, Francesco; Danza, Ludovico; Meroni, Italo; Pollastro, Maria Cristina

    2017-01-01

    nEMoS (nano Environmental Monitoring System) is a 3D-printed device built following the Do-It-Yourself (DIY) approach. It can be connected to the web and it can be used to assess indoor environmental quality (IEQ). It is built using some low-cost sensors connected to an Arduino microcontroller board. The device is assembled in a small-sized case and both thermohygrometric sensors used to measure the air temperature and relative humidity, and the globe thermometer used to measure the radiant temperature, can be subject to thermal effects due to overheating of some nearby components. A thermographic analysis was made to rule out this possibility. The paper shows how the pervasive technique of additive manufacturing can be combined with the more traditional thermographic techniques to redesign the case and to verify the accuracy of the optimized system in order to prevent instrumental systematic errors in terms of the difference between experimental and actual values of the above-mentioned environmental parameters. PMID:28398225

  1. Process for manufacturing slit collimators

    NASA Technical Reports Server (NTRS)

    Romanenko, V. P.; Yemelyanov, A. A.; Churbakov, K. I.

    1974-01-01

    Peculiarities are described of the manufacturing process and the control of elements of slit collimators, the structural design of the required equipment and the process or assembling the collimators.

  2. Low cost solar array project. Experimental process system development unit for producing semiconductor-grade silicon using the silane-to-silicon process

    NASA Technical Reports Server (NTRS)

    1980-01-01

    Technical activities are reported in the design of process, facilities, and equipment for producing silicon at a rate and price comensurate with production goals for low cost solar cell modules. The silane-silicone process has potential for providing high purity poly-silicon on a commercial scale at a price of fourteen dollars per kilogram by 1986, (1980 dollars). Commercial process, economic analysis, process support research and development, and quality control are discussed.

  3. Novel Low-Cost Process for the Gasification of Biomass and Low-Rank Coals

    SciTech Connect

    Thomas Barton

    2009-03-05

    Farm Energy envisaged a phased demonstration program, in which a pilot-scale straw gasifier will be installed on a farm. The synthesis gas product will be used to initially (i) generate electricity in a 300 kW diesel generator, and subsequently (ii) used as a feedstock to produce ethanol or mixed alcohols. They were seeking straw gasification and alcohol synthesis technologies that may be implemented on farm-scale. The consortium, along with the USDA ARS station in Corvallis, OR, expressed interest in the dual-bed gasification concept promoted by WRI and Taylor Energy, LLC. This process operated at atmospheric pressure and employed a solids-circulation type oxidation/reduction cycle significantly different from traditional fluidized-bed or up-draft type gasification reactors. The objectives of this project were to perform bench-scale testing to determine technical feasibility of gasifier concept, to characterize the syngas product, and to determine the optimal operating conditions and configuration. We used the bench-scale test data to complete a preliminary design and cost estimate for a 1-2 ton per hour pilot-scale unit that is also appropriate for on-farm scale applications. The gasifier configuration with the 0.375-inch stainless steel balls recirculating media worked consistently and for periods up to six hours of grass feed. The other principle systems like the boiler, the air pump, and feeder device also worked consistently during all feeding operations. Minor hiccups during operation tended to come from secondary systems like the flare or flammable material buildup in the exit piping. Although we did not complete the extended hour tests to 24 or 48 hours due to time and budget constraints, we developed the confidence that the gasifier in its current configuration could handle those tests. At the modest temperatures we operated the gasifier, slagging was not a problem. The solid wastes were dry and low density. The majority of the fixed carbon from the grass

  4. Low Cost, Upper Stage-Class Propulsion

    NASA Technical Reports Server (NTRS)

    Vickers, John

    2015-01-01

    The low cost, upper stage-class propulsion (LCUSP) element will develop a high strength copper alloy additive manufacturing (AM) process as well as critical components for an upper stage-class propulsion system that will be demonstrated with testing. As manufacturing technologies have matured, it now appears possible to build all the major components and subsystems of an upper stage-class rocket engine for substantially less money and much faster than traditionally done. However, several enabling technologies must be developed before that can happen. This activity will address these technologies and demonstrate the concept by designing, manufacturing, and testing the critical components of a rocket engine. The processes developed and materials' property data will be transitioned to industry upon completion of the activity. Technologies to enable the concept are AM copper alloy process development, AM post-processing finishing to minimize surface roughness, AM material deposition on existing copper alloy substrate, and materials characterization.

  5. Solar cells with low cost substrates, process of making same and article of manufacture

    DOEpatents

    Mitchell, K.W.

    A solar cell is disclosed having a substrate and an intermediate recrystallized film and a semiconductor material capable of absorbing light with the substrate being selected from one of a synthetic organic resin, graphite, glass and a crystalline material having a grain size less than about 1 micron/sup 2/. The intermediate recrystallized film has a grain size in the range of from about 10 microns/sup 2/ to about 10,000 microns/sup 2/ and a lattice mismatch with the semiconductor material not greater than about 4%. The semiconductor material has a grain size not less than about 10 microns/sup 2/. An anti-reflective layer and electrical contact means are provided. Also disclosed is a subcombination of substrate, intermediate recrystallized film and semiconductor material. Also, methods of formulating the solar cell and subcombination are disclosed.

  6. Feasibility and process scale-up low cost alumina fibers for advanced Re-usable Surface Insulation (RSI)

    NASA Technical Reports Server (NTRS)

    Pearson, A.

    1975-01-01

    The objective of this program was to establish feasibility of a process to produce low cost aluminum oxide fibers having sufficient strength, flexibility, and thermal stability for multiple re-use at temperatures to 1480 C in advanced RSI type heat shields for reentry vehicles. Using bench-scale processing apparatus, the Alcoa 'Saphiber' process was successfully modified to produce nominally 8 microns diameter polycrystalline alpha-alumina fiber. Thermal stability was demonstrated in vacuum reheating tests to 1371 C and in atmospheric reheating to 1483 C. Individual fiber properties of strength, modulus, and flexibility were not determined because of friability and short length of the fiber. Rigidized tile produced from fiber of nominally 8, 20 and 40 micron diameter had thermal conductivities significantly higher than those of RSI SiO2 or mullite at relatively low temperature but became comparable above about 1000 C. Tile densities were high due to short fiber length, especially in the coarser diameter fiber. No significant effect of fiber diameter on thermal properties could be determined form the data. Mechanical properties of tiles deteriorated as fiber diameter increased.

  7. Data processing workflows from low-cost digital survey to various applications: three case studies of Chinese historic architecture

    NASA Astrophysics Data System (ADS)

    Sun, Z.; Cao, Y. K.

    2015-08-01

    The paper focuses on the versatility of data processing workflows ranging from BIM-based survey to structural analysis and reverse modeling. In China nowadays, a large number of historic architecture are in need of restoration, reinforcement and renovation. But the architects are not prepared for the conversion from the booming AEC industry to architectural preservation. As surveyors working with architects in such projects, we have to develop efficient low-cost digital survey workflow robust to various types of architecture, and to process the captured data for architects. Although laser scanning yields high accuracy in architectural heritage documentation and the workflow is quite straightforward, the cost and portability hinder it from being used in projects where budget and efficiency are of prime concern. We integrate Structure from Motion techniques with UAV and total station in data acquisition. The captured data is processed for various purposes illustrated with three case studies: the first one is as-built BIM for a historic building based on registered point clouds according to Ground Control Points; The second one concerns structural analysis for a damaged bridge using Finite Element Analysis software; The last one relates to parametric automated feature extraction from captured point clouds for reverse modeling and fabrication.

  8. The mechanics of manufacturing processes

    SciTech Connect

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

    1996-10-01

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

  9. Manufacturing process applications team (MATeam)

    NASA Technical Reports Server (NTRS)

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

    1978-01-01

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

  10. A Low-cost, High-yield Process for the Direct Productin of High Energy Density Liquid Fuel from Biomass

    SciTech Connect

    Agrawal, Rakesh

    2014-02-21

    The primary objective and outcome of this project was the development and validation of a novel, low-cost, high-pressure fast-hydropyrolysis/hydrodeoxygenation (HDO) process (H{sub 2}Bioil) using supplementary hydrogen (H{sub 2}) to produce liquid hydrocarbons from biomass. The research efforts under the various tasks of the project have culminated in the first experimental demonstration of the H2Bioil process, producing 100% deoxygenated >C4+ hydrocarbons containing 36-40% of the carbon in the feed of pyrolysis products from biomass. The demonstrated H{sub 2}Bioil process technology (i.e. reactor, catalyst, and downstream product recovery) is scalable to a commercial level and is estimated to be economically competitive for the cases when supplementary H{sub 2} is sourced from coal, natural gas, or nuclear. Additionally, energy systems modeling has revealed several process integration options based on the H{sub 2}Bioil process for energy and carbon efficient liquid fuel production. All project tasks and milestones were completed or exceeded. Novel, commercially-scalable, high-pressure reactors for both fast-hydropyrolysis and hydrodeoxygenation were constructed, completing Task A. These reactors were capable of operation under a wide-range of conditions; enabling process studies that lead to identification of optimum process conditions. Model compounds representing biomass pyrolysis products were studied, completing Task B. These studies were critical in identifying and developing HDO catalysts to target specific oxygen functional groups. These process and model compound catalyst studies enabled identification of catalysts that achieved 100% deoxygenation of the real biomass feedstock, sorghum, to form hydrocarbons in high yields as part of Task C. The work completed during this grant has identified and validated the novel and commercially scalable H2Bioil process for production of hydrocarbon fuels from biomass. Studies on model compounds as well as real biomass

  11. A low-cost transportable ground station for capture and processing of direct broadcast EOS satellite data

    NASA Technical Reports Server (NTRS)

    Davis, Don; Bennett, Toby; Short, Nicholas M., Jr.

    1994-01-01

    The Earth Observing System (EOS), part of a cohesive national effort to study global change, will deploy a constellation of remote sensing spacecraft over a 15 year period. Science data from the EOS spacecraft will be processed and made available to a large community of earth scientists via NASA institutional facilities. A number of these spacecraft are also providing an additional interface to broadcast data directly to users. Direct broadcast of real-time science data from overhead spacecraft has valuable applications including validation of field measurements, planning science campaigns, and science and engineering education. The success and usefulness of EOS direct broadcast depends largely on the end-user cost of receiving the data. To extend this capability to the largest possible user base, the cost of receiving ground stations must be as low as possible. To achieve this goal, NASA Goddard Space Flight Center is developing a prototype low-cost transportable ground station for EOS direct broadcast data based on Very Large Scale Integration (VLSI) components and pipelined, multiprocessing architectures. The targeted reproduction cost of this system is less than $200K. This paper describes a prototype ground station and its constituent components.

  12. Low cost and compact analytical microsystem for carbon dioxide determination in production processes of wine and beer.

    PubMed

    Calvo-López, Antonio; Ymbern, Oriol; Izquierdo, David; Alonso-Chamarro, Julián

    2016-08-10

    The design, construction and evaluation of a low cost, cyclic olefin copolymer (COC)-based continuous flow microanalyzer, with optical detection, to monitor carbon dioxide in bottled wines and beers as well as in fermentation processes, is presented. The microsystem, constructed by computer numerically controlled (CNC) micromilling and using a multilayer approach, integrates microfluidics, gas-diffusion module and an optical flow-cell in a single polymeric substrate. Its size is slightly bigger than a credit card, exactly 45 × 60 × 4 mm in the microfluidic and diffusion module zone and 22.5 × 40 × 3 mm in the flow-cell zone. The gas-diffusion module is based on a hydrophobic polyvinylidene fluoride (PVDF) membrane, which allows the transfer of the carbon dioxide present in the sample to a bromothymol blue (BTB) pH-sensitive acceptor solution, where the color change is measured optically. The detection system consisted of a LED with an emission peak at 607 nm and a photodiode integrated in a printed circuit board (PCB). The obtained analytical features after the optimization of the microfluidic platform and hydrodynamic variables are a linear range from 255 to 10000 mg L(-1) of CO2 and a detection limit of 83 mg L(-1) with a sampling rate of 30 samples h(-1).

  13. Analysis and evaluation in the production process and equipment area of the low-cost solar array project

    NASA Technical Reports Server (NTRS)

    Wolf, M.

    1981-01-01

    The effect of solar cell metallization pattern design on solar cell performance and the costs and performance effects of different metallization processes are discussed. Definitive design rules for the front metallization pattern for large area solar cells are presented. Chemical and physical deposition processes for metallization are described and compared. An economic evaluation of the 6 principal metallization options is presented. Instructions for preparing Format A cost data for solar cell manufacturing processes from UPPC forms for input into the SAMIC computer program are presented.

  14. Large forging manufacturing process

    DOEpatents

    Thamboo, Samuel V.; Yang, Ling

    2002-01-01

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

  15. Analysis and Evaluation of Processes and Equipment in Tasks 2 and 4 of the Low-cost Solar Array Project

    NASA Technical Reports Server (NTRS)

    Wolf, M.

    1979-01-01

    To facilitate the task of objectively comparing competing process options, a methodology was needed for the quantitative evaluation of their relative cost effectiveness. Such a methodology was developed and is described, together with three examples for its application. The criterion for the evaluation is the cost of the energy produced by the system. The method permits the evaluation of competing design options for subsystems, based on the differences in cost and efficiency of the subsystems, assuming comparable reliability and service life, or of competing manufacturing process options for such subsystems, which include solar cells or modules. This process option analysis is based on differences in cost, yield, and conversion efficiency contribution of the process steps considered.

  16. LSSA (Low-cost Silicon Solar Array) project

    NASA Technical Reports Server (NTRS)

    1976-01-01

    Methods are explored for economically generating electrical power to meet future requirements. The Low-Cost Silicon Solar Array Project (LSSA) was established to reduce the price of solar arrays by improving manufacturing technology, adapting mass production techniques, and promoting user acceptance. The new manufacturing technology includes the consideration of new silicon refinement processes, silicon sheet growth techniques, encapsulants, and automated assembly production being developed under contract by industries and universities.

  17. New Skills in Process Manufacturing.

    ERIC Educational Resources Information Center

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

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

  18. Low Cost Chemical Feedstocks Using an Improved and Energy Efficient Natural Gas Liquid (NGL) Removal Process, Final Technical Report

    SciTech Connect

    Meyer, Howard, S.; Lu, Yingzhong

    2012-08-10

    The overall objective of this project is to develop a new low-cost and energy efficient Natural Gas Liquid (NGL) recovery process - through a combination of theoretical, bench-scale and pilot-scale testing - so that it could be offered to the natural gas industry for commercialization. The new process, known as the IROA process, is based on U.S. patent No. 6,553,784, which if commercialized, has the potential of achieving substantial energy savings compared to currently used cryogenic technology. When successfully developed, this technology will benefit the petrochemical industry, which uses NGL as feedstocks, and will also benefit other chemical industries that utilize gas-liquid separation and distillation under similar operating conditions. Specific goals and objectives of the overall program include: (i) collecting relevant physical property and Vapor Liquid Equilibrium (VLE) data for the design and evaluation of the new technology, (ii) solving critical R&D issues including the identification of suitable dehydration and NGL absorbing solvents, inhibiting corrosion, and specifying proper packing structure and materials, (iii) designing, construction and operation of bench and pilot-scale units to verify design performance, (iv) computer simulation of the process using commercial software simulation platforms such as Aspen-Plus and HYSYS, and (v) preparation of a commercialization plan and identification of industrial partners that are interested in utilizing the new technology. NGL is a collective term for C2+ hydrocarbons present in the natural gas. Historically, the commercial value of the separated NGL components has been greater than the thermal value of these liquids in the gas. The revenue derived from extracting NGLs is crucial to ensuring the overall profitability of the domestic natural gas production industry and therefore of ensuring a secure and reliable supply in the 48 contiguous states. However, rising natural gas prices have dramatically reduced

  19. Low cost composite materials for wind energy conversion systems

    NASA Technical Reports Server (NTRS)

    Weingart, O.

    1980-01-01

    A winding process utilizing a low-cost E-glass fabric called transverse-filament tape for low-cost production of wind turbine generators (WTG) is described. The process can be carried out continuously at high speed to produce large one-piece parts with tapered wall thicknesses on a tapered mandrel. It is being used to manufacture blades for the NASA/DOE 200-ft-diameter MOD-1 WTG and Rockwell/DOE 40-kW small wind energy conversion system (SWECS).

  20. Low cost composite materials for wind energy conversion systems

    NASA Astrophysics Data System (ADS)

    Weingart, O.

    1980-06-01

    A winding process utilizing a low-cost E-glass fabric called transverse-filament tape for low-cost production of wind turbine generators (WTG) is described. The process can be carried out continuously at high speed to produce large one-piece parts with tapered wall thicknesses on a tapered mandrel. It is being used to manufacture blades for the NASA/DOE 200-ft-diameter MOD-1 WTG and Rockwell/DOE 40-kW small wind energy conversion system (SWECS).

  1. Laser Material Processing in Manufacturing

    NASA Astrophysics Data System (ADS)

    Jones, Marshall

    2014-03-01

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

  2. Low cost solar array project production process and equipment task. A Module Experimental Process System Development Unit (MEPSDU)

    NASA Technical Reports Server (NTRS)

    1981-01-01

    Technical readiness for the production of photovoltaic modules using single crystal silicon dendritic web sheet material is demonstrated by: (1) selection, design and implementation of solar cell and photovoltaic module process sequence in a Module Experimental Process System Development Unit; (2) demonstration runs; (3) passing of acceptance and qualification tests; and (4) achievement of a cost effective module.

  3. Low cost concentrator

    NASA Technical Reports Server (NTRS)

    Bedard, R. J., Jr.; Overly, P.

    1981-01-01

    The key to concentrator cost effectiveness is the proper design of the reflector surface panels. The low cost concentrator reflective surface design is based on use of a thin, backsilvered mirror glass reflector bonded to a molded structural plastic substrate. This combination of reflective panel material offers excellent optical performance at low cost. The design approach, rationale for the selected configuration, and the development status are described. Reflective panel development and demonstration results are also presented.

  4. Manufacturing Process Applications Team (MATeam)

    NASA Technical Reports Server (NTRS)

    1978-01-01

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

  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. Low cost solar array project production process and equipment task: A Module Experimental Process System Development Unit (MEPSDU)

    NASA Technical Reports Server (NTRS)

    1981-01-01

    Several major modifications were made to the design presented at the PDR. The frame was deleted in favor of a "frameless" design which will provide a substantially improved cell packing factor. Potential shaded cell damage resulting from operation into a short circuit can be eliminated by a change in the cell series/parallel electrical interconnect configuration. The baseline process sequence defined for the MEPSON was refined and equipment design and specification work was completed. SAMICS cost analysis work accelerated, format A's were prepared and computer simulations completed. Design work on the automated cell interconnect station was focused on bond technique selection experiments.

  7. Process for manufacturing tantalum capacitors

    DOEpatents

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

    1993-01-01

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

  8. Process for manufacturing tantalum capacitors

    DOEpatents

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

    1993-02-02

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

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

    NASA Astrophysics Data System (ADS)

    Lakshminarayanan, Krishnan

    2011-12-01

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

  10. Boosting Manufacturing through Modular Chemical Process Intensification

    ScienceCinema

    None

    2017-01-06

    Manufacturing USA's Rapid Advancement in Process Intensification Deployment Institute will focus on developing breakthrough technologies to boost domestic energy productivity and energy efficiency by 20 percent in five years through manufacturing processes.

  11. Boosting Manufacturing through Modular Chemical Process Intensification

    SciTech Connect

    2016-12-09

    Manufacturing USA's Rapid Advancement in Process Intensification Deployment Institute will focus on developing breakthrough technologies to boost domestic energy productivity and energy efficiency by 20 percent in five years through manufacturing processes.

  12. Low Cost Large Space Antennas

    NASA Technical Reports Server (NTRS)

    Chmielewski, Artur B.; Freeland, Robert

    1997-01-01

    The mobile communication community could significantly benefit from the availability of low-cost, large space-deployable antennas. A new class of space structures, called inflatable deployable structures, will become an option for this industry in the near future. This new technology recently made significant progress with respect to reducing the risk of flying large inflatable structures in space. This progress can be attributed to the successful space flight of the Inflatable Antenna Experiment in May of 1996, which prompted the initiation of the NASA portion of the joint NASA/DOD coordinated Space Inflatables Program, which will develop the technology to be used in future mobile communications antennas along with other users. The NASA/DOD coordinated Space Inflatables Program was initiated in 1997 as a direct result of the Inflatable Antenna Experiment. The program adds a new NASA initiative to a substantial DOD program that involves developing a series of ground test hardware, starting with 3 meter diameter units and advancing the manufacturing techniques to fabricate a 25 meter ground demonstrator unit with surface accuracy exceeding the requirements for mobile communication applications. Simultaneously, the program will be advancing the state of the art in several important inflatable technology areas, such as developing rigidizable materials for struts and tori and investigating thin film technology issues, such as application of coatings, property measurement and materials processing and assembly techniques. A very important technology area being addressed by the program is deployment control techniques. The program will sponsor activities that will lead to understanding the effects of material strain energy release, residual air in the stowed structure, and the design of the launch restraint and release system needed to control deployment dynamics. Other technology areas directly applicable to developing inflatable mobile communication antennas in the near

  13. 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.

  14. Cold Spraying of Armstrong Process Titanium Powder for Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    MacDonald, D.; Fernández, R.; Delloro, F.; Jodoin, B.

    2016-12-01

    Titanium parts are ideally suited for aerospace applications due to their unique combination of high specific strength and excellent corrosion resistance. However, titanium as bulk material is expensive and challenging/costly to machine. Production of complex titanium parts through additive manufacturing looks promising, but there are still many barriers to overcome before reaching mainstream commercialization. The cold gas dynamic spraying process offers the potential for additive manufacturing of large titanium parts due to its reduced reactive environment, its simplicity to operate, and the high deposition rates it offers. A few challenges are to be addressed before the additive manufacturing potential of titanium by cold gas dynamic spraying can be reached. In particular, it is known that titanium is easy to deposit by cold gas dynamic spraying, but the deposits produced are usually porous when nitrogen is used as the carrier gas. In this work, a method to manufacture low-porosity titanium components at high deposition efficiencies is revealed. The components are produced by combining low-pressure cold spray using nitrogen as the carrier gas with low-cost titanium powder produced using the Armstrong process. The microstructure and mechanical properties of additive manufactured titanium components are investigated.

  15. Cold Spraying of Armstrong Process Titanium Powder for Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    MacDonald, D.; Fernández, R.; Delloro, F.; Jodoin, B.

    2017-04-01

    Titanium parts are ideally suited for aerospace applications due to their unique combination of high specific strength and excellent corrosion resistance. However, titanium as bulk material is expensive and challenging/costly to machine. Production of complex titanium parts through additive manufacturing looks promising, but there are still many barriers to overcome before reaching mainstream commercialization. The cold gas dynamic spraying process offers the potential for additive manufacturing of large titanium parts due to its reduced reactive environment, its simplicity to operate, and the high deposition rates it offers. A few challenges are to be addressed before the additive manufacturing potential of titanium by cold gas dynamic spraying can be reached. In particular, it is known that titanium is easy to deposit by cold gas dynamic spraying, but the deposits produced are usually porous when nitrogen is used as the carrier gas. In this work, a method to manufacture low-porosity titanium components at high deposition efficiencies is revealed. The components are produced by combining low-pressure cold spray using nitrogen as the carrier gas with low-cost titanium powder produced using the Armstrong process. The microstructure and mechanical properties of additive manufactured titanium components are investigated.

  16. Integrated lunar materials manufacturing process

    NASA Technical Reports Server (NTRS)

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

    1990-01-01

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

  17. Low Cost, Durable Seal

    SciTech Connect

    Roberts, George; Parsons, Jason; Friedman, Jake

    2010-12-17

    Seal durability is critical to achieving the 2010 DOE operational life goals for both stationary and transportation PEM fuel cell stacks. The seal material must be chemically and mechanically stable in an environment consisting of aggressive operating temperatures, humidified gases, and acidic membranes. The seal must also be producible at low cost. Currentlyused seal materials do not meet all these requirements. This project developed and demonstrated a high consistency hydrocarbon rubber seal material that was able to meet the DOE technical and cost targets. Significant emphasis was placed on characterization of the material and full scale molding demonstrations.

  18. Manufacturing process applications team (MATeam)

    NASA Technical Reports Server (NTRS)

    Bangs, E. R.

    1980-01-01

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

  19. Low-cost Solar Array Project. Feasibility of the Silane Process for Producing Semiconductor-grade Silicon

    NASA Technical Reports Server (NTRS)

    1979-01-01

    The feasibility of Union Carbide's silane process for commercial application was established. An integrated process design for an experimental process system development unit and a commercial facility were developed. The corresponding commercial plant economic performance was then estimated.

  20. Lean Manufacturing Principles Improving the Targeting Process

    DTIC Science & Technology

    2012-06-08

    targeting process, specifically the adaptability of the process. The thesis will analyze a proven business improvement model ( Lean Manufacturing ), compare...areas of improvement in the adaptability of the process. Thus, the problem statement is as follows: Can Lean Manufacturing methods employed by modern businesses improve identified weaknesses in the targeting process?

  1. Investigation of test methods, material properties, and processes for solar cell encapsulants. Encapsulation task of the low-cost silicon solar array project

    NASA Technical Reports Server (NTRS)

    1977-01-01

    During this quarter, flat-plate solar collector systems were considered and six basic construction elements were identified: outer coatings, superstrates, pottants, substrates, undercoats, and adhesives. Materials surveys were then initiated to discover either generic classes or/and specific products to function as each construction element. Cost data included in the surveys permit ready evaluation of each material. Silicones, fluorocarbons, glass, and acrylic polymers have the highest inherent weatherability of materials studied to date. Only acrylics, however, combine low costs, environmental resistance, and potential processability. This class will receive particular emphasis.

  2. 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

  3. Fundamental understanding and development of low-cost, high-efficiency silicon solar cells

    SciTech Connect

    ROHATGI,A.; NARASIMHA,S.; MOSCHER,J.; EBONG,A.; KAMRA,S.; KRYGOWSKI,T.; DOSHI,P.; RISTOW,A.; YELUNDUR,V.; RUBY,DOUGLAS S.

    2000-05-01

    The overall objectives of this program are (1) to develop rapid and low-cost processes for manufacturing that can improve yield, throughput, and performance of silicon photovoltaic devices, (2) to design and fabricate high-efficiency solar cells on promising low-cost materials, and (3) to improve the fundamental understanding of advanced photovoltaic devices. Several rapid and potentially low-cost technologies are described in this report that were developed and applied toward the fabrication of high-efficiency silicon solar cells.

  4. Development of Low Cost Sensors for Hydrogen Safety Applications

    SciTech Connect

    Hoffheins, B.S.; Holmes, W., Jr.; Lauf, R.J.; Maxey, L.C.; Salter, C.; Walker, D.

    1999-04-07

    We are developing rugged and reliable hydrogen safety sensors that can be easily manufactured. Potential applications also require an inexpensive sensor that can be easily deployed. Automotive applications demand low cost, while personnel safety applications emphasize light-weight, battery-operated, and wearable sensors. Our current efforts involve developing and optimizing sensor materials for stability and compatibility with typical thick-film manufacturing processes. We are also tailoring the sensor design and size along with various packaging and communication schemes for optimal acceptance by end users.

  5. News: Good chemical manufacturing process criteria

    EPA Science Inventory

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

  6. News: Good chemical manufacturing process criteria

    EPA Science Inventory

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

  7. Analysis and evaluation in the production process and equipment area of the low-cost solar array project

    NASA Technical Reports Server (NTRS)

    Goldman, H.; Wolf, M.

    1979-01-01

    Analyses of slicing processes and junction formation processes are presented. A simple method for evaluation of the relative economic merits of competing process options with respect to the cost of energy produced by the system is described. An energy consumption analysis was developed and applied to determine the energy consumption in the solar module fabrication process sequence, from the mining of the SiO2 to shipping. The analysis shows that, in current technology practice, inordinate energy use in the purification step, and large wastage of the invested energy through losses, particularly poor conversion in slicing, as well as inadequate yields throughout. The cell process energy expenditures already show a downward trend based on increased throughput rates. The large improvement, however, depends on the introduction of a more efficient purification process and of acceptable ribbon growing techniques.

  8. Analysis and Evaluation of Processes and Equipment in Tasks 2 and 4 of the Low-cost Solar Array Project

    NASA Technical Reports Server (NTRS)

    Goldman, H.; Wolf, M.

    1978-01-01

    The significant economic data for the current production multiblade wafering and inner diameter slicing processes were tabulated and compared to data on the experimental and projected multiblade slurry, STC ID diamond coated blade, multiwire slurry and crystal systems fixed abrasive multiwire slicing methods. Cost calculations were performed for current production processes and for 1982 and 1986 projected wafering techniques.

  9. Analysis and evaluation in the production process and equipment area of the low-cost solar array project

    NASA Technical Reports Server (NTRS)

    Wolf, M.; Goldman, H.

    1981-01-01

    The attributes of the various metallization processes were investigated. It is shown that several metallization process sequences will lead to adequate metallization for large area, high performance solar cells at a metallization add on price in the range of $6. to 12. m squared, or 4 to $.8/W(peak), assuming 15% efficiency. Conduction layer formation by thick film silver or by tin or tin/lead solder leads to metallization add-on prices significantly above the $6. to 12/m squared range c.) The wet chemical processes of electroless and electrolytic plating for strike/barrier layer and conduction layer formation, respectively, seem to be most cost effective.

  10. Analysis and evaluation of processes and equipment in tasks 2 and 4 of the low-cost solar array project

    NASA Technical Reports Server (NTRS)

    Goldman, H.; Wolf, M.

    1978-01-01

    Several experimental and projected Czochralski crystal growing process methods were studied and compared to available operations and cost-data of recent production Cz-pulling, in order to elucidate the role of the dominant cost contributing factors. From this analysis, it becomes apparent that the specific add-on costs of the Cz-process can be expected to be reduced by about a factor of three by 1982, and about a factor of five by 1986. A format to guide in the accumulation of the data needed for thorough techno-economic analysis of solar cell production processes was developed.

  11. Process research of non-cz silicon material. Low cost solar array project, cell and module formation research area

    NASA Technical Reports Server (NTRS)

    1982-01-01

    Liquid diffusion masks and liquid applied dopants to replace the CVD Silox masking and gaseous diffusion operations specified for forming junctions in the Westinghouse baseline process sequence for producing solar cells from dendritic web silicon were investigated.

  12. Analysis and evaluation of process and equipment in tasks 2 and 4 of the Low Cost Solar Array project

    NASA Technical Reports Server (NTRS)

    Goldman, H.; Wolf, M.

    1978-01-01

    Several experimental and projected Czochralski crystal growing process methods were studied and compared to available operations and cost-data of recent production Cz-pulling, in order to elucidate the role of the dominant cost contributing factors. From this analysis, it becomes apparent that substantial cost reductions can be realized from technical advancements which fall into four categories: an increase in furnace productivity; the reduction of crucible cost through use of the crucible for the equivalent of multiple state-of-the-art crystals; the combined effect of several smaller technical improvements; and a carry over effect of the expected availability of semiconductor grade polysilicon at greatly reduced prices. A format for techno-economic analysis of solar cell production processes was developed, called the University of Pennsylvania Process Characterization (UPPC) format. The accumulated Cz process data are presented.

  13. Analysis and evaluation in the production process and equipment area of the Low-Cost Solar Array Project

    SciTech Connect

    Wolf, M.

    1980-07-01

    The solar cell metallization processes show a wide range of technical limitations, which influence solar cell performance. These limitations interact with the metallization pattern design, which is particularly critical for large square or round cells. To lay the basis for a process capability-cost-solar cell performance-value evaluation and trade-off study, the theoretical background of the metallization design-solar cell performance relationship was examined. Conclusions are presented. (WHK)

  14. Application of off-line image processing for optimization in chest computed radiography using a low cost system.

    PubMed

    Muhogora, Wilbroad E; Msaki, Peter; Padovani, Renato

    2015-03-08

     The objective of this study was to improve the visibility of anatomical details by applying off-line postimage processing in chest computed radiography (CR). Four spatial domain-based external image processing techniques were developed by using MATLAB software version 7.0.0.19920 (R14) and image processing tools. The developed techniques were implemented to sample images and their visual appearances confirmed by two consultant radiologists to be clinically adequate. The techniques were then applied to 200 chest clinical images and randomized with other 100 images previously processed online. These 300 images were presented to three experienced radiologists for image quality assessment using standard quality criteria. The mean and ranges of the average scores for three radiologists were characterized for each of the developed technique and imaging system. The Mann-Whitney U-test was used to test the difference of details visibility between the images processed using each of the developed techniques and the corresponding images processed using default algorithms. The results show that the visibility of anatomical features improved significantly (0.005 ≤ p ≤ 0.02) with combinations of intensity values adjustment and/or spatial linear filtering techniques for images acquired using 60 ≤ kVp ≤ 70. However, there was no improvement for images acquired using 102 ≤ kVp ≤ 107 (0.127 ≤ p ≤ 0.48). In conclusion, the use of external image processing for optimization can be effective in chest CR, but should be implemented in consultations with the radiologists.

  15. Low cost solar array project cell and module formation research area: Process research of non-CZ silicon material

    NASA Technical Reports Server (NTRS)

    1981-01-01

    Liquid diffusion masks and liquid applied dopants to replace the CVD Silox masking and gaseous diffusion operations specified for forming junctions in the Westinghouse baseline process sequence for producing solar cells from dendritic web silicon were investigated. The baseline diffusion masking and drive processes were compared with those involving direct liquid applications to the dendritic web silicon strips. Attempts were made to control the number of variables by subjecting dendritic web strips cut from a single web crystal to both types of operations. Data generated reinforced earlier conclusions that efficiency levels at least as high as those achieved with the baseline back junction formation process can be achieved using liquid diffusion masks and liquid dopants. The deliveries of dendritic web sheet material and solar cells specified by the current contract were made as scheduled.

  16. Investigation of Proposed Process Sequence for the Array Automated Assembly Task, Phase 2. [low cost silicon solar array fabrication

    NASA Technical Reports Server (NTRS)

    Mardesich, N.; Garcia, A.; Bunyan, S.; Pepe, A.

    1979-01-01

    The technological readiness of the proposed process sequence was reviewed. Process steps evaluated include: (1) plasma etching to establish a standard surface; (2) forming junctions by diffusion from an N-type polymeric spray-on source; (3) forming a p+ back contact by firing a screen printed aluminum paste; (4) forming screen printed front contacts after cleaning the back aluminum and removing the diffusion oxide; (5) cleaning the junction by a laser scribe operation; (6) forming an antireflection coating by baking a polymeric spray-on film; (7) ultrasonically tin padding the cells; and (8) assembling cell strings into solar circuits using ethylene vinyl acetate as an encapsulant and laminating medium.

  17. Evaluation of Selected Chemical Processes for Production of Low-cost Silicon, Phase 3. [using a fluidized bed reactor

    NASA Technical Reports Server (NTRS)

    Blocher, J. M., Jr.; Browning, M. F.

    1979-01-01

    The construction and operation of an experimental process system development unit (EPSDU) for the production of granular semiconductor grade silicon by the zinc vapor reduction of silicon tetrachloride in a fluidized bed of seed particles is presented. The construction of the process development unit (PDU) is reported. The PDU consists of four critical units of the EPSDU: the fluidized bed reactor, the reactor by product condenser, the zinc vaporizer, and the electrolytic cell. An experimental wetted wall condenser and its operation are described. Procedures are established for safe handling of SiCl4 leaks and spills from the EPSDU and PDU.

  18. Bench-Scale Process for Low-Cost Carbon Dioxide (CO2) Capture Using a Phase-Changing Absorbent

    SciTech Connect

    Westendorf, Tiffany; Caraher, Joel; Chen, Wei; Farnum, Rachael; Perry, Robert; Spiry, Irina; Wilson, Paul; Wood, Benjamin

    2015-03-31

    The objective of this project is to design and build a bench-scale process for a novel phase-changing aminosilicone-based CO2-capture solvent. The project will establish scalability and technical and economic feasibility of using a phase-changing CO2-capture absorbent for post-combustion capture of CO2 from coal-fired power plants with 90% capture efficiency and 95% CO2 purity at a cost of $40/tonne of CO2 captured by 2025 and a cost of <$10/tonne of CO2 captured by 2035. In the first budget period of this project, the bench-scale phase-changing CO2 capture process was designed using data and operating experience generated under a previous project (ARPA-e project DE-AR0000084). Sizing and specification of all major unit operations was completed, including detailed process and instrumentation diagrams. The system was designed to operate over a wide range of operating conditions to allow for exploration of the effect of process variables on CO2 capture performance.

  19. Encapsulation Processing and Manufacturing Yield Analysis

    NASA Technical Reports Server (NTRS)

    Willis, P. B.

    1984-01-01

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

  20. 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.

  1. Analysis and evalaution in the production process and equipment area of the low-cost solar array project. [including modifying gaseous diffusion and using ion implantation

    NASA Technical Reports Server (NTRS)

    Goldman, H.; Wolf, M.

    1979-01-01

    The manufacturing methods for photovoltaic solar energy utilization are assessed. Economic and technical data on the current front junction formation processes of gaseous diffusion and ion implantation are presented. Future proposals, including modifying gaseous diffusion and using ion implantation, to decrease the cost of junction formation are studied. Technology developments in current processes and an economic evaluation of the processes are included.

  2. Silicon materials task of the Low Cost Solar Array Project: Effect of impurities and processing on silicon solar cells

    NASA Technical Reports Server (NTRS)

    Hopkins, R. H.; Davis, J. R.; Rohatgi, A.; Hanes, M. H.; Rai-Choudhury, P.; Mollenkopf, H. C.

    1982-01-01

    The effects of impurities and processing on the characteristics of silicon and terrestrial silicon solar cells were defined in order to develop cost benefit relationships for the use of cheaper, less pure solar grades of silicon. The amount of concentrations of commonly encountered impurities that can be tolerated in typical p or n base solar cells was established, then a preliminary analytical model from which the cell performance could be projected depending on the kinds and amounts of contaminants in the silicon base material was developed. The impurity data base was expanded to include construction materials, and the impurity performace model was refined to account for additional effects such as base resistivity, grain boundary interactions, thermal processing, synergic behavior, and nonuniform impurity distributions. A preliminary assessment of long term (aging) behavior of impurities was also undertaken.

  3. Analysis and evaluation in the production process and equipment area of the low-cost solar array project

    NASA Technical Reports Server (NTRS)

    Wolf, M.

    1982-01-01

    It was found that the Solarex metallization design and process selection should be modified to yield substantially higher output of the 10 cm x 10 cm cells, while the Westinghouse design is extremely close to the optimum. In addition, further attention to the Solarex pn junction and base high/low junction formation processes could be beneficial. For the future efficiency improvement, it was found that refinement of the various minority carrier lifetime measurement methods is needed, as well as considerably increased sophistication in the interpretation of the results of these methods. In addition, it was determined that further experimental investigation of the Auger lifetime is needed, to conclusively determine the Auger coefficients for the direct Auger recombination at high majority carrier concentrations.

  4. Low cost solar array project. Cell and module formation research area. Process research of non-CZ silicon material

    NASA Technical Reports Server (NTRS)

    1983-01-01

    Liquid diffusion masks and liquid dopants to replace the more expensive CVD SiO2 mask and gaseous diffusion processes were investigated. Silicon pellets were prepared in the silicon shot tower; and solar cells were fabricated using web grown where the pellets were used as a replenishment material. Verification runs were made using the boron dopant and liquid diffusion mask materials. The average of cells produced in these runs was 13%. The relationship of sheet resistivity, temperature, gas flows, and gas composition for the diffusion of the P-8 liquid phosphorus solution was investigated. Solar cells processed from web grown from Si shot material were evaluated, and results qualified the use of the material produced in the shot tower for web furnace feed stock.

  5. A low-cost, high-quality new drug discovery process using patient-derived induced pluripotent stem cells.

    PubMed

    Giri, Shibashish; Bader, Augustinus

    2015-01-01

    Knockout, knock-in and conditional mutant gene-targeted mice are routinely used for disease modeling in the drug discovery process, but the human response is often difficult to predict from these models. It is believed that patient-derived induced pluripotent stem cells (iPSCs) could replace millions of animals currently sacrificed in preclinical testing and provide a route to new safer pharmaceutical products. In this review, we discuss the use of IPSCs in the drug discovery process. We highlight how they can be used to assess the toxicity and clinical efficacy of drug candidates before the latter are moved into costly and lengthy preclinical and clinical trials. Copyright © 2014 Elsevier Ltd. All rights reserved.

  6. A low-cost batch process for high-performance melt-textured GdBaCuO pellets

    NASA Astrophysics Data System (ADS)

    Muralidhar, M.; Tomita, M.; Suzuki, K.; Jirsa, M.; Fukumoto, Y.; Ishihara, A.

    2010-04-01

    High-Tc superconducting magnets promise a variety of industrial, medical, public, and research applications. However, the potential large-scale applications of these materials need excellent and uniform properties and a cheap production method. The batch process developed for the fabrication of GdBa2Cu3Oy pellets in air fulfils all of these requirements. The samples were melt-processed using a cold seeding method with thin film Nd-123 seeds grown on MgO crystals. We used self-made Gd-123 and Gd-211 powders mixed with 0.1 wt% of Pt. Up to 1-1.5 kg of melt-grown Gd-123 bulks could be prepared in one run. XRD analysis confirmed that all of the bulks were c-axis oriented. The superconducting and magnetic performance of the pellets was checked on several small test samples cut out at various standard positions within the bulk. The values were reasonably uniform and the performance was similar to the oxygen-controlled melt-grown Gd-123 samples. The average trapped field at 77 K in the 24 mm diameter batch samples was between 0.8 and 0.9 T, close to the maximum value of 1 T reported so far for Gd-123 single grains processed in air. The present results prove that a high-performance good-quality LREBa2Cu3Oy material can be scaled up from laboratory to industrial production.

  7. Low-cost, high-speed back-end processing system for high-frequency ultrasound B-mode imaging.

    PubMed

    Chang, Jin Ho; Sun, Lei; Yen, Jesse T; Shung, K Kirk

    2009-07-01

    For real-time visualization of the mouse heart (6 to 13 beats per second), a back-end processing system involving high-speed signal processing functions to form and display images has been developed. This back-end system was designed with new signal processing algorithms to achieve a frame rate of more than 400 images per second. These algorithms were implemented in a simple and cost-effective manner with a single field-programmable gate array (FPGA) and software programs written in C++. The operating speed of the back-end system was investigated by recording the time required for transferring an image to a personal computer. Experimental results showed that the back-end system is capable of producing 433 images per second. To evaluate the imaging performance of the back-end system, a complete imaging system was built. This imaging system, which consisted of a recently reported high-speed mechanical sector scanner assembled with the back-end system, was tested by imaging a wire phantom, a pig eye (in vitro), and a mouse heart (in vivo). It was shown that this system is capable of providing high spatial resolution images with fast temporal resolution.

  8. Low-Cost, High-Speed Back-End Processing System for High-Frequency Ultrasound B-Mode Imaging

    PubMed Central

    Chang, Jin Ho; Sun, Lei; Yen, Jesse T.; Shung, K. Kirk

    2009-01-01

    For real-time visualization of the mouse heart (6 to 13 beats per second), a back-end processing system involving high-speed signal processing functions to form and display images has been developed. This back-end system was designed with new signal processing algorithms to achieve a frame rate of more than 400 images per second. These algorithms were implemented in a simple and cost-effective manner with a single field-programmable gate array (FPGA) and software programs written in C++. The operating speed of the back-end system was investigated by recording the time required for transferring an image to a personal computer. Experimental results showed that the back-end system is capable of producing 433 images per second. To evaluate the imaging performance of the back-end system, a complete imaging system was built. This imaging system, which consisted of a recently reported high-speed mechanical sector scanner assembled with the back-end system, was tested by imaging a wire phantom, a pig eye (in vitro), and a mouse heart (in vivo). It was shown that this system is capable of providing high spatial resolution images with fast temporal resolution. PMID:19574160

  9. Device, Interface, Process and Electrode Engineering Towards Low Cost and High Efficiency Polymer Solar Cells in Inverted Structure

    NASA Astrophysics Data System (ADS)

    Zou, Jingyu

    As a promising technology for economically viable alternative energy source, polymer solar cells (PSCs) have attracted substantial interests and made significant progress in the past few years, due the advantages of being potentially easily solution processed into large areas, flexible, light weight, and have the versatility of material design. In this dissertation, an integrated approach is taken to improve the overall performance of polymer solar cells by the development of new polymer materials, device architectures, interface engineering of the contacts between layers, and new transparent electrodes. First, several new classes of polymers are explored as potential light harvesting materials for solar cells. Processing has been optimized and efficiency as high as 6.24% has been demonstrated. Then, with the development of inverted device structure, which has better air stability by utilizing more air stable, high work function metals, newly developed high efficiency polymers have been integrated into inverted structure device with integrated engineering approach. A comprehensive characterization and optical modeling based on conventional and inverted devices have been performed to understand the effect of device geometry on photovoltaic performance based on a newly developed high performance polymer poly(indacenodithiophene-co-phananthrene-quinoxaline) (PIDT-PhanQ). By modifying anode with a bilayer combining graphene oxide (GO) and poly(3,4-ethylenedioxylenethiophene):poly(styrenesulfonic acid) (PEDOT:PSS) as hole transporter/electron blocker, it further improved device performance of inverted structured to 6.38%. A novel processing method of sequentially bilayer deposition for active layer has been conducted based on a low band-gap polymer poly[2, 6-(4, 4-bis-(2-ethylhexyl)-4 H-cyclopenta [2,1-b;3,4-b‧] dithiophene)- alt-4,7-(2, 1, 3- fluorobenzothiadiazole)] (PCPDT-FBT). Inverted structure devices processed from bilayer deposition shows even higher

  10. Phonon processes in vertically aligned silicon nanowire arrays produced by low-cost all-solution galvanic displacement method

    NASA Astrophysics Data System (ADS)

    Banerjee, Debika; Trudeau, Charles; Gerlein, Luis Felipe; Cloutier, Sylvain G.

    2016-03-01

    The nanoscale engineering of silicon can significantly change its bulk optoelectronic properties to make it more favorable for device integration. Phonon process engineering is one way to enhance inter-band transitions in silicon's indirect band structure alignment. This paper demonstrates phonon localization at the tip of silicon nanowires fabricated by galvanic displacement using wet electroless chemical etching of a bulk silicon wafer. High-resolution Raman micro-spectroscopy reveals that such arrayed structures of silicon nanowires display phonon localization behaviors, which could help their integration into the future generations of nano-engineered silicon nanowire-based devices such as photodetectors and solar cells.

  11. Low-cost digital image processing on a university mainframe computer. [considerations in selecting and/or designing instructional systems

    NASA Technical Reports Server (NTRS)

    Williams, T. H. L.

    1981-01-01

    The advantages and limitations of using university mainframe computers in digital image processing instruction are listed. Aspects to be considered when designing software for this purpose include not only two general audience, but also the capabilities of the system regarding the size of the image/subimage, preprocessing and enhancement functions, geometric correction and registration techniques; classification strategy, classification algorithm, multitemporal analysis, and ancilliary data and geographic information systems. The user/software/hardware interaction as well as acquisition and operating costs must also be considered.

  12. A HIgh Current Density Low Cost Niobium 3 Tin Titanium Doped Conductor Utilizing A Novel Internal Tin Process

    SciTech Connect

    Bruce A Zeitlin

    2005-02-23

    An internal tin conductor has been developed using a Mono Element Internal Tin (MEIT) with an integral Nb barrier surrounding the Nb filaments. High current densities of 3000 A/mm2+ at 12 T and 1800 A/mm2 at 15 T have been achieved in conductors as small as 0.152 mm with the use of Nb7.5Ta filaments and Ti in the Sn core. In contrast, conductors with pure Nb and Ti in the Sn achieved 2700 A/mm2 at 12 T. Two internal fins, developed and patented on the project, were introduced into the filament array and reduced the effective filament diameter (Deff) by 38%. Additional fins will further reduce Deff The conductor was produced from 152.4 mm diameter billets to produce wire as small as 0.152 mm. The process promises be scaleable to 304 mm diameter billets yielding wire of 0.304 mm diameter. The MEIT process wire was easy to draw with relatively few breaks. The cost of this conductor in large production quantities based on the cost model presented could meet the 1.5 $/kilo amp meter(KAM) target of the HEP community

  13. Low Cost Hydrogen Production Platform

    SciTech Connect

    Timothy M. Aaron, Jerome T. Jankowiak

    2009-10-16

    conducted to identify any potential design deficiency related to the concept. The analysis showed that no fundamental design flaw existed with the concept, but additional simulations and prototypes would be required to verify the design prior to fabricating a production unit. These identified risks were addressed in detail during Phase II of the development program. Along with the models of the high temperature components, a detailed process and 3D design model of the remainder of system, including PSA, compression, controls, water treatment and instrumentation was developed and evaluated. Also, in Phase II of the program, laboratory/fullscale testing of the high temperature components was completed and stable operation/control of the system was verified. The overall design specifications and test results were then used to develop accurate hydrogen costs for the optimized system. Praxair continued development and testing of the system beyond the Phase II funding provided by the DOE through the end of 2008. This additional testing is not documented in this report, but did provide significant additional data for development of a prototype system as detailed in the Phase III proposal. The estimated hydrogen product costs were developed (2007 basis) for the 4.8 kg/h system at production rates of 1, 5, 10, 100 and 1,000 units built per year. With the low cost SMR approach, the product hydrogen costs for the 4.8 kg/h units at 50 units produced per year were approximately $3.02 per kg. With increasing the volume production to 1,000 units per year, the hydrogen costs are reduced by about 12% to $2.67 per kg. The cost reduction of only 12% is a result of significant design and fabrication efficiencies being realized in all levels of production runs through utilizing the DFMA principles. A simplified and easily manufactured design does not require large production volumes to show significant cost benefits. These costs represent a significant improvement and a new benchmark in the

  14. Pilot-Scale Silicone Process for Low-Cost Carbon Dioxide Capture Preliminary Techno-Economic Analysis

    SciTech Connect

    Singh, Surinder; Spiry, Irina; Wood, Benjamin; Hance, Dan; Chen, Wei; Kehmna, Mark; McDuffie, Dwayne

    2014-03-31

    This report presents system and economic analysis for a carbon-capture unit which uses an aminosilicone-based solvent for CO{sub 2} capture in a pulverized coal (PC) boiler. The aminosilicone solvent is a 60/40 wt/wt mixture of 3-aminopropyl end-capped polydimethylsiloxane (GAP-1m) with tri-ethylene glycol (TEG) as a co-solvent. For comparison purposes, the report also shows results for a carbon-capture unit based on a conventional approach using mono-ethanol amine (MEA). The first year removal cost of CO{sub 2} for the aminosilicone-based carbon-capture process is $46.04/ton of CO2 as compared to $60.25/ton of CO{sub 2} when MEA is used. The aminosilicone-based process has <77% of the CAPEX of a system using MEA solvent. The lower CAPEX is due to several factors, including the higher working capacity of the aminosilicone solvent compared the MEA, which reduces the solvent flow rate required, reducing equipment sizes. If it is determined that carbon steel can be used in the rich-lean heat exchanger in the carbon capture unit, the first year removal cost of CO{sub 2} decreases to $44.12/ton. The aminosilicone-based solvent has a higher thermal stability than MEA, allowing desorption to be conducted at higher temperatures and pressures, decreasing the number of compressor stages needed. The aminosilicone-based solvent also has a lower vapor pressure, allowing the desorption to be conducted in a continuous-stirred tank reactor versus a more expensive packed column. The aminosilicone-based solvent has a lower heat capacity, which decreases the heat load on the desorber. In summary, the amino-silicone solvent has significant advantages over conventional systems using MEA.

  15. Energetic additive manufacturing process with feed wire

    DOEpatents

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

    2000-11-07

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

  16. Silicon materials task of the low-cost solar array project. Phase 4: Effects of impurities and processing on silicon solar cells

    NASA Technical Reports Server (NTRS)

    Hopkins, R. H.; Hanes, M. H.; Davis, J. R.; Rohatgi, A.; Rai-Choudhury, P.; Mollenkopf, H. C.

    1981-01-01

    The effects of impurities, various thermochemical processes, and any impurity-process interactions upon the performance of terrestrial solar cells are defined. The results form a basis for silicon producers, wafer manufacturers, and cell fabricators to develop appropriate cost benefit relationships for the use of less pure, less costly solar grade silicon.

  17. Ultra-precision processes for optics manufacturing

    NASA Astrophysics Data System (ADS)

    Martin, William R.

    1991-12-01

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

  18. Ultra-precision processes for optics manufacturing

    NASA Technical Reports Server (NTRS)

    Martin, William R.

    1991-01-01

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

  19. Change Detection Experiments Using Low Cost UAVs

    NASA Technical Reports Server (NTRS)

    Logan, Michael J.; Vranas, Thomas L.; Motter, Mark; Hines, Glenn D.; Rahman, Zia-ur

    2005-01-01

    This paper presents the progress in the development of a low-cost change-detection system. This system is being developed to provide users with the ability to use a low-cost unmanned aerial vehicle (UAV) and image processing system that can detect changes in specific fixed ground locations using video provided by an autonomous UAV. The results of field experiments conducted with the US Army at Ft. A.P.Hill are presented.

  20. Roughness parameter selection for novel manufacturing processes.

    PubMed

    Ham, M; Powers, B M

    2014-01-01

    This work proposes a method of roughness parameter (RP) selection for novel manufacturing processes or processes where little knowledge exists about which RPs are important. The method selects a single parameter to represent a group of highly correlated parameters. Single point incremental forming (SPIF) is used as the case study for the manufacturing process. This methodology was successful in reducing the number of RPs investigated from 18 to 8 in the case study. © Wiley Periodicals, Inc.

  1. Investigation of test methods, material properties, and processes for solar cell encapsulants. Encapsulation task of the Low-Cost Silicon Solar Array project. Thirteenth quarterly progress report, May 12, 1979-August 12, 1979

    SciTech Connect

    1980-01-01

    Springborn Laboratories is engaged in a study of evaluating potentially useful encapsulating materials for Task 3 of the Low-Cost Silicon Solar Array project (LSA) funded by DOE. The goal of this program is to identify, evaluate, and recommend encapsulant materials and processes for the product of cost-effective, long-life solar cell modules. Current technical activities are directed primarily towards the development of a solar module encapsulation technology that employs ethylene/vinyl acetate copolymer as the pottant. Due to the surface tack of EVA, a slip sheet of release paper is required between each layer to prevent the plies from adhering. Manufacturers were surveyed and a source for inexpensive release paper in roll form was identified. A survey of separator materials was also conducted. Corrosion studies using a standard salt spray test were used to determine the degree of protection offered to a variety of metals by encapsulation in EVA pottant. Due to the low surface hardness of EVA and the remaining sensitivity to ultraviolet light, outer covers are required to prevent soiling and improve the weatherability. Two candidate films (Korad 212 and Tedlar UT) have been identified for this function. These films are somewhat scratch and abrasion sensitive, however, and their useful life can be prolonged with the application of thin layers of abrasion resistant hard coats. A survey of manufacturers of these coatings was performed and the products compared. Field trials of outdoor performance must be performed to fully assess the durability of these coatings.

  2. 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.

  3. 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.

  4. Low Cost Digital Vibration Meter.

    PubMed

    Payne, W Vance; Geist, Jon

    2007-01-01

    This report describes the development of a low cost, digital Micro Electro Mechanical System (MEMS) vibration meter that reports an approximation to the RMS acceleration of the vibration to which the vibration meter is subjected. The major mechanical element of this vibration meter is a cantilever beam, which is on the order of 500 µm in length, with a piezoresistor deposited at its base. Vibration of the device in the plane perpendicular to the cantilever beam causes it to bend, which produces a measurable change in the resistance of a piezoresistor. These changes in resistance along with a unique signal-processing scheme are used to determine an approximation to the RMS acceleration sensed by the device.

  5. Development and commercialization of low cost, nonmetallic solar system. Final report

    SciTech Connect

    Not Available

    1984-01-01

    The project goal was to develop and commercialize a low cost non-metallic flat plate solar collector made from a synthetic rubber called ethylene-propylene-diene-monomer (EPDM). To insure a reliable product, a considerabe portion of the development effort centered around economical manufacture by mechanized processes.

  6. A scalable low-cost cGMP process for clinical grade production of the HIV inhibitor 5P12-RANTES in Pichia pastoris.

    PubMed

    Cerini, Fabrice; Gaertner, Hubert; Madden, Knut; Tolstorukov, Ilya; Brown, Scott; Laukens, Bram; Callewaert, Nico; Harner, Jay C; Oommen, Anna M; Harms, John T; Sump, Anthony R; Sealock, Robert C; Peterson, Dustin J; Johnson, Scott K; Abramson, Stephan B; Meagher, Michael; Offord, Robin; Hartley, Oliver

    2016-03-01

    In the continued absence of an effective anti-HIV vaccine, approximately 2 million new HIV infections occur every year, with over 95% of these in developing countries. Calls have been made for the development of anti-HIV drugs that can be formulated for topical use to prevent HIV transmission during sexual intercourse. Because these drugs are principally destined for use in low-resource regions, achieving production costs that are as low as possible is an absolute requirement. 5P12-RANTES, an analog of the human chemokine protein RANTES/CCL5, is a highly potent HIV entry inhibitor which acts by achieving potent blockade of the principal HIV coreceptor, CCR5. Here we describe the development and optimization of a scalable low-cost production process for 5P12-RANTES based on expression in Pichia pastoris. At pilot (150 L) scale, this cGMP compliant process yielded 30 g of clinical grade 5P12-RANTES. As well as providing sufficient material for the first stage of clinical development, this process represents an important step towards achieving production of 5P12-RANTES at a cost and scale appropriate to meet needs for topical HIV prevention worldwide.

  7. A scalable low-cost cGMP process for clinical grade production of the HIV inhibitor 5P12-RANTES in Pichia pastoris

    PubMed Central

    Cerini, Fabrice; Gaertner, Hubert; Madden, Knut; Tolstorukov, Ilya; Brown, Scott; Laukens, Bram; Callewaert, Nico; Harner, Jay C.; Oommen, Anna M.; Harms, John T.; Sump, Anthony R.; Sealock, Robert C.; Peterson, Dustin J.; Johnson, Scott K.; Abramson, Stephan B.; Meagher, Michael; Offord, Robin; Hartley, Oliver

    2016-01-01

    In the continued absence of an effective anti-HIV vaccine, approximately 2 million new HIV infections occur every year, with over 95% of these in developing countries. Calls have been made for the development of anti-HIV drugs that can be formulated for topical use to prevent HIV transmission during sexual intercourse. Because these drugs are principally destined for use in low-resource regions, achieving production costs that are as low as possible is an absolute requirement. 5P12-RANTES, an analog of the human chemokine protein RANTES/CCL5, is a highly potent HIV entry inhibitor which acts by achieving potent blockade of the principal HIV coreceptor, CCR5. Here we describe the development and optimization of a scalable low-cost production process for 5P12-RANTES based on expression in Pichia pastoris. At pilot (150 L) scale, this cGMP compliant process yielded 30 g of clinical grade 5P12-RANTES. As well as providing sufficient material for the first stage of clinical development, this process represents an important step towards achieving production of 5P12-RANTES at a cost and scale appropriate to meet needs for topical HIV prevention worldwide. PMID:26506568

  8. Dramatic property enhancement in polyetherimide using low-cost commercially functionalized multi-walled carbon nanotubes via a facile solution processing method

    NASA Astrophysics Data System (ADS)

    Kumar, Sandeep; Li, Bin; Caceres, Santiago; Maguire, Russ G.; Zhong, Wei-Hong

    2009-11-01

    Polyetherimide (PEI) has excellent mechanical and thermal properties, and exceptional fire resistance. Developing even broader multi-functionality in PEI/carbon nanotube (CNT) composites for industrial applications is an alluring but challenging goal, due to processing difficulties related to the high pressure and temperature needed to achieve effective flow for this polymer, and costly and complex treatments of the CNTs. Here we report the fabrication of PEI nanocomposite films using low-cost commercially functionalized multi-walled carbon nanotubes (MWNTs), and a simple and innovative process, achieving exceptional properties with only 0.5 wt% of MWNTs, including an increase in electrical conductivity of 12 orders of magnitude, accompanied by an unprecedented increase of 86 °C in thermal decomposition temperature (higher service temperature). Field emission scanning electron microscopy revealed a high degree of uniform dispersion among the MWNTs, superb polymer-MWNT interaction and formation of a spatially homogeneous nanotube network within the matrix. The enhancement in these properties suggests great potential use for this developed processing approach and the resulting nanocomposites for multi-functional coating or interfacing materials in aerospace and electronic industries.

  9. Dip coating process: Silicon sheet growth development for the large-area silicon sheet task of the low-cost silicon solar array project

    NASA Technical Reports Server (NTRS)

    Heaps, J. D.; Maciolek, R. B.; Zook, J. D.; Harrison, W. B.; Scott, M. W.; Hendrickson, G.; Wolner, H. A.; Nelson, L. D.; Schuller, T. L.; Peterson, A. A.

    1976-01-01

    The technical and economic feasibility of producing solar cell quality sheet silicon by dip-coating one surface of carbonized ceramic substrates with a thin layer of large grain polycrystalline silicon was investigated. The dip-coating methods studied were directed toward a minimum cost process with the ultimate objective of producing solar cells with a conversion efficiency of 10% or greater. The technique shows excellent promise for low cost, labor-saving, scale-up potentialities and would provide an end product of sheet silicon with a rigid and strong supportive backing. An experimental dip-coating facility was designed and constructed, several substrates were successfully dip-coated with areas as large as 25 sq cm and thicknesses of 12 micron to 250 micron. There appears to be no serious limitation on the area of a substrate that could be coated. Of the various substrate materials dip-coated, mullite appears to best satisfy the requirement of the program. An inexpensive process was developed for producing mullite in the desired geometry.

  10. Low-cost thermoforming of micro fluidic analysis chips

    NASA Astrophysics Data System (ADS)

    Truckenmüller, R.; Rummler, Z.; Schaller, Th; Schomburg, W. K.

    2002-07-01

    We present a new method for the low-cost manufacture of micro fluidic devices from polymers for single use. Within a one-step or two-step process inside a hot embossing press, micro channels are thermoformed into a thin plastic film and welded on to a thicker plastic film or sheet. Sterile, hermetically sealed micro fluidic structures were fabricated from polystyrene for easy opening immediately before use. It even appears to be possible to produce micro fluidic analysis chips from polymers on a coil from which single devices are cut off for use.

  11. Engineering in the Manufacturing Process

    DTIC Science & Technology

    1993-03-01

    create the right conditions to attract such suppliers and take advantage of the rapidly advancing commercial manufacturi g processes and product capability...production cost analysiz). o Alignment of DoD’s technology plans with best commercial manufacturinq trends and practices, including lean and agile

  12. Low-Cost Aqueous Coal Desulfurization

    NASA Technical Reports Server (NTRS)

    Kalvinskas, J. J.; Vasilakos, N.; Corcoran, W. H.; Grohmann, K.; Rohatgi, N. K.

    1982-01-01

    Water-based process for desulfurizing coal not only eliminates need for costly organic solvent but removes sulfur more effectively than an earlier solvent-based process. New process could provide low-cost commercial method for converting high-sulfur coal into environmentally acceptable fuel.

  13. Manufacturing process applications team (MATeam)

    NASA Technical Reports Server (NTRS)

    Bangs, E. R.

    1980-01-01

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

  14. Low cost silicon solar array project silicon materials task: Establishment of the feasibility of a process capable of low-cost, high volume production of silane (step 1) and the pyrolysis of silane to semiconductor-grade silicon (step 2)

    NASA Technical Reports Server (NTRS)

    Breneman, W. C.; Farrier, E. G.; Rexer, J.

    1977-01-01

    Extended operation of a small process-development unit routinely produced high quality silane in 97+% yield from dichlorosilane. The production rate was consistent with design loadings for the fractionating column and for the redistribution reactor. A glass fluid-bed reactor was constructed for room temperature operation. The behavior of a bed of silcon particles was observed as a function of various feedstocks, component configurations, and operating conditions. For operating modes other than spouting, the bed behaved in an erratic and unstable manner. A method was developed for casting molten silicon powder into crack-free solid pellets for process evaluation. The silicon powder was melted and cast into thin walled quartz tubes that sacrificially broke on cooling.

  15. Low-Cost Illumination-Grade LEDs

    SciTech Connect

    Epler, John

    2013-08-31

    technology was commercialized in our LUXEON Q product in Sept., 2013. Also, the retention of the sapphire increased the robustness of the device, enabling sales of low-cost submount-free chips to lighting manufacturers. Thus, blue LED die sales were initiated in the form of a PSS-FC in February, 2013.

  16. Development of advanced Czochralski Growth Process to produce low cost 150 KG silicon ingots from a single crucible for technology readiness

    NASA Technical Reports Server (NTRS)

    1981-01-01

    The goals in this program for advanced czochralski growth process to produce low cost 150 kg silicon ingots from a single crucible for technology readiness are outlined. To provide a modified CG2000 crystal power capable of pulling a minimum of five crystals, each of approximately 30 kg in weight, 150 mm diameter from a single crucible with periodic melt replenishment. Crystals to have: resistivity of 1 to 3 ohm cm, p-type; dislocation density below 1- to the 6th power per cm; orientation (100); after growth yield of greater than 90%. Growth throughput of greater than 2.5 kg per hour of machine operation using a radiation shield. Prototype equipment suitable for use as a production facility. The overall cost goal is $.70 per peak watt by 1986. To accomplish these goals, the modified CG2000 grower and development program includes: (1) increased automation with a microprocessor based control system; (2) sensors development which will increase the capability of the automatic controls system, and provide technology transfer of the developed systems.

  17. Fabrication of low-cost beta-type Ti-Mn alloys for biomedical applications by metal injection molding process and their mechanical properties.

    PubMed

    Santos, Pedro Fernandes; Niinomi, Mitsuo; Liu, Huihong; Cho, Ken; Nakai, Masaaki; Itoh, Yoshinori; Narushima, Takayuki; Ikeda, Masahiko

    2016-06-01

    Titanium and its alloys are suitable for biomedical applications owing to their good mechanical properties and biocompatibility. Beta-type Ti-Mn alloys (8-17 mass% Mn) were fabricated by metal injection molding (MIM) as a potential low cost material for use in biomedical applications. The microstructures and mechanical properties of the alloys were evaluated. For up to 13 mass% Mn, the tensile strength (1162-938MPa) and hardness (308-294HV) of the MIM fabricated alloys are comparable to those of Ti-Mn alloys fabricated by cold crucible levitation melting. Ti-9Mn exhibits the best balance of ultimate tensile strength (1046MPa) and elongation (4.7%) among the tested alloys, and has a Young's modulus of 89GPa. The observed low elongation of the alloys is attributed to the combined effects of high oxygen content, with the presence of interconnected pores and titanium carbides, the formation of which is due to carbon pickup during the debinding process. The elongation and tensile strength of the alloys decrease with increasing Mn content. The Ti-Mn alloys show good compressive properties, with Ti-17Mn showing a compressive 0.2% proof stress of 1034MPa, and a compressive strain of 50%.

  18. Coping With Spatial Attention in Real Space: A Low-Cost Portable Testing System for the Investigation of Visuo-Spatial Processing in the Human Brain

    PubMed Central

    Wolfe, Benjamin; Rushmore, Richard J.; Valero-Cabré, Antoni

    2010-01-01

    While two-dimensional stimuli may be easily presented with any computer, an apparatus which allows a range of stimuli to be presented in three dimensions is not easily or cheaply available to researchers or clinicians. To fill this gap, we have developed the Realspace Testing System (RTS) which addresses the need for a flexible and multimodal stimulus presentation system capable of displaying stimuli in a three dimensional space with a high degree of temporal accuracy. The RTS is able to control twenty-six channels of visual or audio stimuli, to send trigger pulses during each trial to external devices, such as a Transcranial Magnetic Stimulator, and to record subject responses during the testing sessions. The RTS is flexible, portable and can be used in laboratory or clinical settings as required while being built at a low cost using off the shelf components. We have tested the RTS by performing an exploratory experiment on the role of right posterior parietal cortex in visuospatial processing in conjunction with online Transcranial Magnetic Stimulation (TMS) and verified that the system can accurately present stimuli as needed while triggering a TMS pulse during each trial at the required time. The RTS could be appealing and useful to a range of researchers or clinicians who may choose to use it much as we have designed it, or use it in its current state as a starting point to customize their stimulus control systems in real space. PMID:20079374

  19. LCX: Proposal for a low-cost commercial transport

    NASA Technical Reports Server (NTRS)

    Hartman, Troy; Hayatdavoudi, Maziar; Hettinga, Joel; Hooper, Matt; Nguyen, Phong

    1994-01-01

    The LCX has been developed in response to a request for proposal for an aircraft with 153 passenger capacity and a range of 3000 nautical miles. The goals of the LCX are to provide an aircraft which will achieve the stated mission requirements at the lowest cost possible, both for the manufacturer and the operator. Low cost in this request is defined as short and long term profitability. To achieve this objective, modern technologies attributing to low-cost operation without greatly increasing the cost of manufacturing were employed. These technologies include hybrid laminar flow control and the use of developing new manufacturing processes and philosophies. The LCX will provide a competitive alternative to the use of the Airbus A319/320/321 and the Boeing 737 series of aircraft. The LCX has a maximum weight of 150,000 lb. carried by a wing of 1140 ft(exp 2) and an aspect ratio of 10. The selling price of the LCX is 31 million in 1994 US dollars.

  20. Performance Evaluation Of A Low Cost Vision-Based Inspection System

    NASA Astrophysics Data System (ADS)

    Hoang, Khoi; Gibson, Peter R.; Lin, Grier C. I.; Tanoto, Johanes

    1989-03-01

    In manufacturing industry, visual inspection plays a vital role in quality control. Traditionally, this is performed manually, leading to human errors and a time consuming process. There is a major need for a reliable, low cost system which can keep tip with production speed and enhance Quality Assurance. This project involves the development of a low cost automatic visual inspection system for manufacturing industry. The steps to provision of the system are discussed. A program evaluating the performance of the developed system is presented in detail. This work has found that the system is capable of performing many 2D visual inspection tasks in manufacturing industry, at speeds of up to 15 samples per second to within a repeatability of 0.01 mm. The system described is now at the stage of development which is allowing implementation in the Pharmaceutical industries, printing business, cable manufacture and sheet metal shops.

  1. Evaluation of Manufacturing Processes for Microfluidic Devices

    NASA Astrophysics Data System (ADS)

    Laura Jáuregui, Ana; Siller, Héctor R.; Rodriguez, Ciro A.; Elías-Zúñiga, Alex

    2009-11-01

    In this paper several micro-mechanical manufacturing technologies were studied in order to characterize their performance for making miniaturized geometries known as micro-channels, which are the main geometric features of micro-fluidic devices. The technologies used were Micro-End Milling, Wire Electro Discharge Machiningesol Sandblasting and Abrasive Water Jet. Their capabilities were compared with Lithography capabilities, which is the conventional process for micro-channel manufacturing. The evaluation consists in a comprehensive study of surface quality and topography, made with the help of advanced contact and non-contact devices over each prototype made by each technology. Also economical considerations have been taken into account in order to choose the most appropriate manufacturing process for the prototyping of micro-fluidic devices. The results show that Micro-End Milling process can compete with Lithography, in terms of achieving acceptable levels of product quality and economics.

  2. Evaluation of selected chemical processes for production of low-cost silicon: Phase III. Silicon Material Task, Low-Cost Solar Array Project. Sixteenth/seventeenth quarterly progress report, July-December 31, 1979

    SciTech Connect

    Blocher, J.M. Jr.; Browning, M.F.

    1980-03-07

    The method under development for the production of semiconductor grade silicon is based on the zinc vapor reduction of silicon tetrachloride in a fluidized bed of seed particles. Construction of the PDU was completed during the report period, the fluidized-bed reactor was coated internally with silicon/SiC, and the operation of several systems was checked out. However, problems with the zinc feed system, unrelated to its basic operability, delayed introduction of zinc vapor to the PDU. At the end of the report period, the zinc feed system stood ready for tests of the control of zinc vapor feed rate by regulation of r.f. induction heating directly coupled to the liquid zinc. A study of the zinc distribution in miniplant silicon products containing zinc at the 300 and 3000 ppM levels suggests that the occlusion of zinc is caused by zinc mist entrained from the vaporizer, and it should be possible to drive the level to below 300 ppM by proper equipment design and process control.

  3. Silicon materials task of the low-cost solar-array project. Effect of impurities and processing on silicon solar cells. Final report

    SciTech Connect

    Hopkins, R.H.; Davis, J.R.; Rohatgi, A.; Hanes, M.H.; Rai-Choudhury, P.; Mollenkopf, H.C.

    1982-02-01

    The object of the program has been to investigate the effects of various processes, metal contaminants, and contaminant-process interactions on the properties of silicon and on the performance of terrestrial silicon solar cells. The study has encompassed topics such as thermochemical (gettering) treatments, base-doping concentration, base-doping type (n vs. p), grain boundary-impurity interaction in polycrystalline devices, and long-term effects of impurities and impurity impacts on high-efficiency cells, as well as a preliminary evaluation of some potential low-cost silicon materials. The effects have been studied of various metallic impurities, introduced singly or in combination into Czochralski, float zone, and polycrystalline silicon ingots and into silicon ribbons grown by the dendritic web process. The solar cell data indicate that impurity-induced performance loss is caused primarily by a reduction in base diffusion length. An analytical model based on this observation has been developed and verified experimentally for both n- and p-base material. Studies of polycrystalline ingots containing impurities indicate that solar cell behavior is species sensitive and that a fraction of the impurities are segregated to the grain boundaries. HCl and POCl gettering improve the performance of single-crystal solar cells containing Fe, Cr, and Ti. In contrast Mo-doped material is barely affected. The efficiencies of solar cells fabricated on impurity-doped wafers is lower when the front junction is formed by ion implantation than when conventional diffusion techniques are used. For most impurity-doped solar cells stability is expected for projected times beyond 20 years. Feedstock impurity concentrations below one part per million for elements like V, or 100 parts per million for more benign impurities like Cu or Ni, will be required.

  4. Low-cost image analysis system

    SciTech Connect

    Lassahn, G.D.

    1995-01-01

    The author has developed an Automatic Target Recognition system based on parallel processing using transputers. This approach gives a powerful, fast image processing system at relatively low cost. This system scans multi-sensor (e.g., several infrared bands) image data to find any identifiable target, such as physical object or a type of vegetation.

  5. 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.

  6. Computational Fluid Dynamics - Applications in Manufacturing Processes

    NASA Astrophysics Data System (ADS)

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

    2012-11-01

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

  7. A versatile and low-cost 3D acquisition and processing pipeline for collecting mass of archaeological findings on the field

    NASA Astrophysics Data System (ADS)

    Gattet, E.; Devogelaere, J.; Raffin, R.; Bergerot, L.; Daniel, M.; Jockey, Ph.; De Luca, L.

    2015-02-01

    In recent years, advances in the fields of photogrammetry and computer vision have produced several solutions for generating 3D reconstruction starting from simple images. Even if the potentialities of the image-based 3D reconstruction approach are nowadays very well-known in terms of reliability, accuracy and flexibility, there is still a lack of low-cost, open-source and automated solutions for collecting mass of archaeological findings, specially if one consider the real (and non theoretical) contextual aspects of a digitization campaign on the field (number of objects to acquire, available time, lighting conditions, equipment transport, budget, etc...) as well as the accuracy requirements for an in-depth shape analysis and classification purpose. In this paper we present a prototype system (integrating hardware and software) for the 3D acquisition, geometric reconstruction, documentation and archiving of large collections of archaeological findings. All the aspects of our approach are based on high-end image-based modeling techniques and designed basing on an accurate analysis of the typical field conditions of an archaeological campaign, as well as on the specific requirements of archaeological finding documentation and analysis. This paper presents all the aspects integrated into the prototype: - a hardware development of a transportable photobooth for the automated image acquisition consisting of a turntable and three DSLR controlled by a microcontroller; - an automatic image processing pipeline (based on Apero/Micmac) including mask generation, tie-point extraction, bundle adjustment, multi-view stereo correlation, point cloud generation, surface reconstruction; - a versatile (off-line/on-line) portable database for associating descriptive attributes (archaeological description) to the 3D digitizations on site; - a platform for data-gathering, archiving and sharing collections of 3D digitizations on the Web. The presentation and the assessment of this

  8. Silicon-on-ceramic process: Silicon sheet growth and device development for the large-area silicon sheet task of the low-cost solar array project

    NASA Technical Reports Server (NTRS)

    Whitehead, A. B.; Zook, J. D.; Grung, B. L.; Heaps, J. D.; Schmit, F.; Schuldt, S. B.; Chapman, P. W.

    1981-01-01

    The technical feasibility of producing solar cell quality sheet silicon to meet the DOE 1986 cost goal of 70 cents/watt was investigated. The silicon on ceramic approach is to coat a low cost ceramic substrate with large grain polycrystalline silicon by unidirectional solidification of molten silicon. Results and accomplishments are summarized.

  9. An Alternative Low-Cost Process for Deposition of MCrAlY Bond Coats for Advanced Syngas/Hydrogen Turbine Applications

    SciTech Connect

    Zhang, Ying

    2015-09-11

    The objective of this project was to develop and optimize MCrAlY bond coats for syngas/hydrogen turbine applications using a low-cost electrolytic codeposition process. Prealloyed CrAlY-based powders were codeposited into a metal matrix of Ni, Co or Ni-Co during the electroplating process, and a subsequent post-deposition heat treatment converted it to the MCrAlY coating. Our research efforts focused on: (1) investigation of the effects of electro-codeposition configuration and parameters on the CrAlY particle incorporation in the NiCo-CrAlY composite coatings; (2) development of the post-deposition heat treating procedure; (3) characterization of coating properties and evaluation of coating oxidation performance; (4) exploration of a sulfurfree electroplating solution; (5) cost analysis of the present electrolytic codeposition process. Different electro-codeposition configurations were investigated, and the rotating barrel system demonstrated the capability of depositing NiCo-CrAlY composite coatings uniformly on the entire specimen surface, with the CrAlY particle incorporation in the range 37-42 vol.%. Post-deposition heat treatment at 1000-1200 °C promoted interdiffusion between the CrAlY particles and the Ni-Co metal matrix, resulting in β/γ’/γ or β/γ’ phases in the heat-treated coatings. The results also indicate that the post-deposition heat treatment should be conducted at temperatures ≤1100 °C to minimize Cr evaporation and outward diffusion of Ti. The electro-codeposited NiCrAlY coatings in general showed lower hardness and surface roughness than thermal spray MCrAlY coatings. Coating oxidation performance was evaluated at 1000-1100 °C in dry and wet air environments. The initial electro-codeposited NiCoCrAlY coatings containing relatively high sulfur did not show good oxidation resistance. After modifications of the coating process, the cleaner NiCoCrAlY coating exhibited good oxidation performance at 1000 °C during the 2,000 1-h cyclic

  10. Computational Process Modeling for Additive Manufacturing

    NASA Technical Reports Server (NTRS)

    Bagg, Stacey; Zhang, Wei

    2014-01-01

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

  11. 15 CFR 400.31 - Manufacturing and processing activity; criteria.

    Code of Federal Regulations, 2012 CFR

    2012-01-01

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

  12. 15 CFR 400.31 - Manufacturing and processing activity; criteria.

    Code of Federal Regulations, 2010 CFR

    2010-01-01

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

  13. 15 CFR 400.31 - Manufacturing and processing activity; criteria.

    Code of Federal Regulations, 2011 CFR

    2011-01-01

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

  14. 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.

  15. Process economics of industrial monoclonal antibody manufacture.

    PubMed

    Farid, Suzanne S

    2007-03-15

    Pressures for cost-effective manufacture of antibodies are growing given their high doses and increasing market potential that have resulted in significant increases in total site capacities of up to 200,000 L. This paper focuses on the process economic issues associated with manufacturing antibodies and reviews the cost studies published in the literature; many of the issues highlighted are not only specific to antibodies but also apply to recombinant proteins. Data collated at UCL suggest current benchmark investment costs of $660-$1580/ft2 ($7130-$17,000/m2) and $1765-$4220/L for antibody manufacturing facilities with total site capacities in the range of 20,000-200,000 L; the limitations of the data are highlighted. The complications with deriving benchmark cost of goods per gram (COG/g) values are discussed, stressing the importance of stating the annual production rate and either titre or fermentation capacity with the cost so as to allow comparisons. The uses and limitations of the methods for cost analysis and the available software tools for process economics are presented. Specific examples found in the literature of process economic studies related to antibody manufacture for different expression systems are reviewed. The key economic drivers are identified; factors such as fermentation titre and overall yield are critical determinants of economic success. Future trends in antibody manufacture that are driven by economic pressures are discussed, such as the use of alternative expression systems (e.g. transgenics, E. coli and yeast), disposables, and improvements to downstream technology. The hidden costs and the challenges in each case are highlighted.

  16. Graphene radio frequency and microwave passive components for low cost wearable electronics

    NASA Astrophysics Data System (ADS)

    Huang, Xianjun; Leng, Ting; Hsin Chang, Kuo; Cing Chen, Jia; Novoselov, Kostya S.; Hu, Zhirun

    2016-06-01

    Graphene RF and microwave passive components such as coplanar waveguide transmission lines, open/short-circuited resonators and wideband antenna on paper substrate were designed, screen printed and characterized in this work. The experimental results demonstrate that the screen printed graphene passive components can be used for RF signal transmitting, processing and radiating/receiving; revealing that graphene ink can be a low cost alternative to much more expensive metal nanoparticle inks, such as silver nanoparticle ink. The screen printed graphene is processed at low temperature so that it is compatible with heat-sensitive flexible materials like papers, PTFE (Polytetrafluoroethylene) and textiles. The screen printed graphene passive components reported here are of high conductivity, high flexibility, light weight and low cost, making them ideal candidate for low cost wearable electronics. This work makes it prospective to manufacture RF and microwave passive components in mass production by screen printing in much lower cost to any other known techniques.

  17. New Low Cost Resin Systems

    DTIC Science & Technology

    2006-05-31

    difference between resins 1 and 2 was the type of phosphorous containing compound, where resin 3 was the same as resin 1 with the addition of melamine ...SBIR N03-120 New Low Cost Resin Systems Applied Poleramic, Inc. Final Report Report Documentation Page Form ApprovedOMB No. 0704-0188 Public...Feb 2004 4. TITLE AND SUBTITLE New Low Cost Resin Systems 5a. CONTRACT NUMBER N00014-03-M-0304 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 6

  18. Small, Low Cost, Launch Capability Development

    NASA Technical Reports Server (NTRS)

    Brown, Thomas

    2014-01-01

    A recent explosion in nano-sat, small-sat, and university class payloads has been driven by low cost electronics and sensors, wide component availability, as well as low cost, miniature computational capability and open source code. Increasing numbers of these very small spacecraft are being launched as secondary payloads, dramatically decreasing costs, and allowing greater access to operations and experimentation using actual space flight systems. While manifesting as a secondary payload provides inexpensive rides to orbit, these arrangements also have certain limitations. Small, secondary payloads are typically included with very limited payload accommodations, supported on a non interference basis (to the prime payload), and are delivered to orbital conditions driven by the primary launch customer. Integration of propulsion systems or other hazardous capabilities will further complicate secondary launch arrangements, and accommodation requirements. The National Aeronautics and Space Administration's Marshall Space Flight Center has begun work on the development of small, low cost launch system concepts that could provide dedicated, affordable launch alternatives to small, high risk university type payloads and spacecraft. These efforts include development of small propulsion systems and highly optimized structural efficiency, utilizing modern advanced manufacturing techniques. This paper outlines the plans and accomplishments of these efforts and investigates opportunities for truly revolutionary reductions in launch and operations costs. Both evolution of existing sounding rocket systems to orbital delivery, and the development of clean sheet, optimized small launch systems are addressed.

  19. 21 CFR 1005.25 - Service of process on manufacturers.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... 21 Food and Drugs 8 2010-04-01 2010-04-01 false Service of process on manufacturers. 1005.25....25 Service of process on manufacturers. (a) Every manufacturer of electronic products, prior to... United States as the manufacturer's agent upon whom service of all processes, notices, orders,...

  20. Space manufacturing utilizing the directional electrostatic accretion process

    NASA Technical Reports Server (NTRS)

    Mortensen, A.

    1986-01-01

    The Directional Electrostatic Accretion Process (DEAP) is described with respect to both the physical process and its application to manufacturing in space. This high precision portable manufacturing method will revolutionize current practices in manufacturing and repair of spacecraft and space structures. The cost effectiveness of this process will be invaluable to future space manufacturing projects.

  1. Space manufacturing utilizing the directional electrostatic accretion process

    NASA Technical Reports Server (NTRS)

    Mortensen, A.

    1986-01-01

    The Directional Electrostatic Accretion Process (DEAP) is described with respect to both the physical process and its application to manufacturing in space. This high precision portable manufacturing method will revolutionize current practices in manufacturing and repair of spacecraft and space structures. The cost effectiveness of this process will be invaluable to future space manufacturing projects.

  2. Low Cost Mission to Deimos

    NASA Astrophysics Data System (ADS)

    Quantius, Dominik; Püsler, H.; Braukhane, A.; Gülzow, P.; Bauer, W.; Vollhardt, A.; Romberg, O.; Scheibe, K.; Hoffmann, H.; Bürner, A.

    The German non-profit amateur satellite organisation AMSAT-Deutschland successfully de-signed, built and launched four HEO satellites in the last three decades. Now they are going to build a satellite to leave the Earth orbit based on their flight-proven P3-D satellite design. Due to energetic constraints the most suitable launch date for the planned P5-A satellite to Mars will be in 2018. To efficiently use the relatively long time gap until launch a possible prior Moon mission came into mind. In co-operation with the DLR-Institute of Space Systems in Bremen, Germany, two studies on systems level for a first P5 satellite towards Moon and a following one towards Mars have been performed. By using the DLR's Concurrent Engineering Facility (CEF) two consistent satellite concepts were designed including mission analysis, configuration, propulsion, subsystem dimensioning, payload selection, budgeting and cost. The present paper gives an insight in the accomplished design process and the results of the performed study towards Mars. The developed Mars orbiter is designed to carry the following four main instruments besides flexible communication abilities: • multispectral line scanner for Martian cloud investigations and Deimos (and Phobos) stereo pictures during close flybys • Deimos framing camera for high resolution pictures of Deimos (and Phobos) including video mode • sensor imaging infrared spectrometer for mineralogy of Martian (also Deimos and Phobos) silicates and surface temperature measurements • radio science for research of Deimos ( Phobos) gravity, profiling of Mars ionosphere, occurrence of third meteoritic ionosphere layer; sounding of neutral atmosphere; solar corona activity This study presents a non-industrial satellite concept that could be launched as piggyback load on Ariane 5 into GTO. It promises a low cost mission into a Mars orbit that allows close approaches to Deimos and Phobos.

  3. Low Cost Graphics. Second Edition.

    ERIC Educational Resources Information Center

    Tinker, Robert F.

    This manual describes the CALM TV graphics interface, a low-cost means of producing quality graphics on an ordinary TV. The system permits the output of data in graphic as well as alphanumeric form and the input of data from the face of the TV using a light pen. The integrated circuits required in the interface can be obtained from standard…

  4. Low Cost Sensor Calibration Options

    EPA Science Inventory

    Low-cost sensors ($1 D0-500) represent a unique class of air monitoring devices that may provide for more ubiquitous pollutant monitoring. They vary widely in design and measure pollutants, ranging from ozone, particulate matter, to volatile organic compounds. Many of these senso...

  5. Low Cost Sensor Calibration Options

    EPA Science Inventory

    Low-cost sensors ($1 D0-500) represent a unique class of air monitoring devices that may provide for more ubiquitous pollutant monitoring. They vary widely in design and measure pollutants, ranging from ozone, particulate matter, to volatile organic compounds. Many of these senso...

  6. Aggregates in monoclonal antibody manufacturing processes.

    PubMed

    Vázquez-Rey, María; Lang, Dietmar A

    2011-07-01

    Monoclonal antibodies have proved to be a highly successful class of therapeutic products. Large-scale manufacturing of pharmaceutical antibodies is a complex activity that requires considerable effort in both process and analytical development. If a therapeutic protein cannot be stabilized adequately, it will lose partially or totally its therapeutic properties or even cause immunogenic reactions thus potentially further endangering the patients' health. The phenomenon of protein aggregation is a common issue that compromises the quality, safety, and efficacy of antibodies and can happen at different steps of the manufacturing process, including fermentation, purification, final formulation, and storage. Aggregate levels in drug substance and final drug product are a key factor when assessing quality attributes of the molecule, since aggregation might impact biological activity of the biopharmaceutical. In this review it is analyzed how aggregates are formed during monoclonal antibody industrial production, why they have to be removed and the manufacturing process steps that are designed to either minimize or remove aggregates in the final product. Copyright © 2011 Wiley Periodicals, Inc.

  7. 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.

  8. Low-cost directionally-solidified turbine blades, volume 1

    NASA Technical Reports Server (NTRS)

    Sink, L. W.; Hoppin, G. S., III; Fujii, M.

    1979-01-01

    A low cost process of manufacturing high stress rupture strength directionally-solidified high pressure turbine blades was successfully developed for the TFE731-3 Turbofan Engine. The basic processing parameters were established using MAR-M 247 and employing the exothermic directional-solidification process in trial castings of turbine blades. Nickel-based alloys were evaluated as directionally-solidified cast blades. A new turbine blade, disk, and associated components were then designed using previously determined material properties. Engine tests were run and the results were analyzed and compared to the originally established goals. The results showed that the stress rupture strength of exothermically heated, directionally-solidified MAR-M 247 turbine blades exceeded program objectives and that the performance and cost reduction goals were achieved.

  9. A simulation study on garment manufacturing process

    NASA Astrophysics Data System (ADS)

    Liong, Choong-Yeun; Rahim, Nur Azreen Abdul

    2015-02-01

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

  10. Big Data Analysis of Manufacturing Processes

    NASA Astrophysics Data System (ADS)

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

    2015-11-01

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

  11. Manufacturing process of nanofluidics using afm probe

    NASA Astrophysics Data System (ADS)

    Karingula, Varun Kumar

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

  12. Process and control systems for composites manufacturing

    NASA Technical Reports Server (NTRS)

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

    1992-01-01

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

  13. Very-Low-Cost, Rugged Vacuum System

    NASA Technical Reports Server (NTRS)

    Kline-Schoder, Robert; Sorensen, Paul; Passow, Christian; Bilski, Steve

    2013-01-01

    NASA, DoD, DHS, and commercial industry have a need for miniaturized, rugged, low-cost vacuum systems. Recent advances in sensor technology have led to the development of very small mass spectrometer detectors as well as other miniature analytical instruments. However, the vacuum systems to support these sensors remain large, heavy, and power-hungry. To meet this need, a miniaturized vacuum system was created based on a very small, rugged, and inexpensive- to-manufacture molecular drag pump (MDP). The MDP is enabled by the development of a miniature, veryhigh- speed, rugged, low-power, brushless DC motor optimized for wide temperature operation and long life. Such a pump represents an order-of-magnitude reduction in mass, volume, and cost over current, commercially available, state-ofthe- art vacuum pumps. The vacuum system consists of the MDP coupled to a ruggedized rough pump (for terrestrial applications or for planets with substantial atmospheres). The rotor in the MDP consists of a simple smooth cylinder of aluminum spinning at approximately 200,000 RPM inside an outer stator housing. The pump stator comprises a cylindrical aluminum housing with one or more specially designed grooves that serve as flow channels. To minimize the length of the pump, the gas is forced down the flow channels of the outer stator to the base of the pump. The gas is then turned and pulled toward the top through a second set of channels cut into an inner stator housing that surrounds the motor. The compressed gas then flows down channels in the motor housing to the exhaust port of the pump. The exhaust port of the pump is connected to a diaphragm or scroll pump. This pump delivers very high performance in a very small envelope. The design was simplified so that a smaller compression ratio, easier manufacturing process, and enhanced ruggedness can be achieved at the lowest possible cost. The machining of the rotor and stators is very simple compared to that necessary to fabricate TMP

  14. 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.

  15. Encapsulation task of the low-cost silicon solar array project. Investigation of test methods, material properties, and processes for solar cell encapsulants

    NASA Technical Reports Server (NTRS)

    Willis, P. B.; Baum, B.; White, R. A.

    1978-01-01

    The results of an investigation of solar module encapsulation systems applicable to the Low-Cost Solar Array Project 1986 cost and performance goals are presented. Six basic construction elements were identified and their specific uses in module construction defined. A uniform coating basis was established for each element. The survey results were also useful in revealing price ranges for classes of materials and estimating the cost allocation for each element within the encapsulating cost goal. The six construction elements were considered to be substrates, superstrates, pottants, adhesives, outer covers and back covers.

  16. Low cost solar array project: Experimental process system development unit for producing semiconductor-grade silicon using silane-to-silicon process

    NASA Technical Reports Server (NTRS)

    1980-01-01

    The design, fabrication, and installation of an experimental process system development unit (EPSDU) were analyzed. Supporting research and development were performed to provide an information data base usable for the EPSDU and for technological design and economical analysis for potential scale-up of the process. Iterative economic analyses were conducted for the estimated product cost for the production of semiconductor grade silicon in a facility capable of producing 1000-MT/Yr.

  17. Improving drug manufacturing with process analytical technology.

    PubMed

    Rodrigues, Licinia O; Alves, Teresa P; Cardoso, Joaquim P; Menezes, José C

    2006-01-01

    Within the process analytical technology (PAT) framework, as presented in the US Food and Drug Administration guidelines, the aim is to design, develop and operate processes consistently to ensure a pre-defined level of quality at the end of the manufacturing process. Three PAT implementation scenarios can be envisaged. Firstly, PAT could be used in its most modest version (in an almost non-PAT manner) to simply replace an existing quality control protocol (eg, using near-infrared spectroscopy for an in-process quality control, such as moisture content). Secondly, the use of in-process monitoring and process analysis could be integrated to enhance process understanding and operation for an existing industrial process. Thirdly, PAT could be used extensively and exclusively throughout development, scale-up and full-scale production of a new product and process. Although the first type of implementations are well known, reports of the second and third types remain scarce. Herein, results obtained from PAT implementations of the second and third types are described for two industrial processes for preparing bulk active pharmaceutical ingredients, demonstrating the benefits in terms of increased process understanding and process control.

  18. Low-Cost "Vacuum Desiccator"

    NASA Astrophysics Data System (ADS)

    Sweet, Frederick

    2004-10-01

    Described are individualized, low-cost, and safe desiccators that can be efficiently and rapidly made with an inexpensive kitchen aid sold for shrink-wrapping food. The device can be used for enclosing small vials or bottles and also jars that are too large to be placed in conventional glass or plastic desiccators. This shrink-wrapping device is proposed for producing "vacuum desiccators" in large undergraduate chemistry laboratories or in graduate and research laboratories.

  19. Low cost solar aray project: Experimental process system development unit for producing semiconductor-grade silicon using the silane-to-silicon process

    NASA Technical Reports Server (NTRS)

    1981-01-01

    This phase consists of the engineering design, fabrication, assembly, operation, economic analysis, and process support R&D for an Experimental Process System Development Unit (EPSDU). The mechanical bid package was issued and the bid responses are under evaluation. Similarly, the electrical bid package was issued, however, responses are not yet due. The majority of all equipment is on order or has been received at the EPSDU site. The pyrolysis/consolidation process design package was issued. Preparation of process and instrumentation diagram for the free-space reactor was started. In the area of melting/consolidation, Kayex successfully melted chunk silicon and have produced silicon shot. The free-space reactor powder was successfully transported pneumatically from a storage bin to the auger feeder twenty-five feet up and was melted. The fluid-bed PDU has successfully operated at silane feed concentrations up to 21%. The writing of the operating manual has started. Overall, the design phase is nearing completion.

  20. Low-Cost Optical Character Recognition System

    NASA Astrophysics Data System (ADS)

    Cheng, Charles C. K.

    1980-02-01

    Optical Character Recognition (OCR) equipment previously has been complex, massive, and very expensive, hence really practical only for large credit-card operations, insurance companies, and postal applications. However, because of the rapid advance in large scale integrated (LSI) circuit technology and the need for a low cost OCR device to improve business data entry operations, designing and engineering such a low cost OCR system is feasible. The described system is capable of reading directly from a human readable information source, thus eliminating manual keying of data for conversion to a computer processable form. The optical front-end for data acquisition, image conversion and correlation, and recognition processing subsystems using LSI circuits and high speed microprocessors, the algorithms of feature analysis and contextual editing, as well as output and control operational considerations are all essential segments of the described system.

  1. Low Cost Upper Stage-Class Propulsion (LCUSP)

    NASA Technical Reports Server (NTRS)

    Vickers, John

    2015-01-01

    NASA is making space exploration more affordable and viable by developing and utilizing innovative manufacturing technologies. Technology development efforts at NASA in propulsion are committed to continuous innovation of design and manufacturing technologies for rocket engines in order to reduce the cost of NASA's journey to Mars. The Low Cost Upper Stage-Class Propulsion (LCUSP) effort will develop and utilize emerging Additive Manufacturing (AM) to significantly reduce the development time and cost for complex rocket propulsion hardware. Benefit of Additive Manufacturing (3-D Printing) Current rocket propulsion manufacturing techniques are costly and have lengthy development times. In order to fabricate rocket engines, numerous complex parts made of different materials are assembled in a way that allow the propellant to collect heat at the right places to drive the turbopump and simultaneously keep the thrust chamber from melting. The heat conditioned fuel and oxidizer come together and burn inside the combustion chamber to provide thrust. The efforts to make multiple parts precisely fit together and not leak after experiencing cryogenic temperatures on one-side and combustion temperatures on the other is quite challenging. Additive manufacturing has the potential to significantly reduce the time and cost of making rocket parts like the copper liner and Nickel-alloy jackets found in rocket combustion chambers where super-cold cryogenic propellants are heated and mixed to the extreme temperatures needed to propel rockets in space. The Selective Laser Melting (SLM) machine fuses 8,255 layers of copper powder to make a section of the chamber in 10 days. Machining an equivalent part and assembling it with welding and brazing techniques could take months to accomplish with potential failures or leaks that could require fixes. The design process is also enhanced since it does not require the 3D model to be converted to 2-D drawings. The design and fabrication process

  2. Low-cost uncooled VOx infrared camera development

    NASA Astrophysics Data System (ADS)

    Li, Chuan; Han, C. J.; Skidmore, George D.; Cook, Grady; Kubala, Kenny; Bates, Robert; Temple, Dorota; Lannon, John; Hilton, Allan; Glukh, Konstantin; Hardy, Busbee

    2013-06-01

    The DRS Tamarisk® 320 camera, introduced in 2011, is a low cost commercial camera based on the 17 µm pixel pitch 320×240 VOx microbolometer technology. A higher resolution 17 µm pixel pitch 640×480 Tamarisk®640 has also been developed and is now in production serving the commercial markets. Recently, under the DARPA sponsored Low Cost Thermal Imager-Manufacturing (LCTI-M) program and internal project, DRS is leading a team of industrial experts from FiveFocal, RTI International and MEMSCAP to develop a small form factor uncooled infrared camera for the military and commercial markets. The objective of the DARPA LCTI-M program is to develop a low SWaP camera (<3.5 cm3 in volume and <500 mW in power consumption) that costs less than US $500 based on a 10,000 units per month production rate. To meet this challenge, DRS is developing several innovative technologies including a small pixel pitch 640×512 VOx uncooled detector, an advanced digital ROIC and low power miniature camera electronics. In addition, DRS and its partners are developing innovative manufacturing processes to reduce production cycle time and costs including wafer scale optic and vacuum packaging manufacturing and a 3-dimensional integrated camera assembly. This paper provides an overview of the DRS Tamarisk® project and LCTI-M related uncooled technology development activities. Highlights of recent progress and challenges will also be discussed. It should be noted that BAE Systems and Raytheon Vision Systems are also participants of the DARPA LCTI-M program.

  3. Precision replenishable grinding tool and manufacturing process

    SciTech Connect

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

    1998-01-01

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

  4. Precision replenishable grinding tool and manufacturing process

    DOEpatents

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

    1998-06-09

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

  5. Development of low cost custom hybrid microcircuit technology

    NASA Technical Reports Server (NTRS)

    Perkins, K. L.; Licari, J. J.

    1981-01-01

    Selected potentially low cost, alternate packaging and interconnection techniques were developed and implemented in the manufacture of specific NASA/MSFC hardware, and the actual cost savings achieved by their use. The hardware chosen as the test bed for this evaluation ws the hybrids and modules manufactured by Rockwell International fo the MSFC Flight Accelerometer Safety Cut-Off System (FASCOS). Three potentially low cost packaging and interconnection alternates were selected for evaluation. This study was performed in three phases: hardware fabrication and testing, cost comparison, and reliability evaluation.

  6. Laser processing of ceramics for microelectronics manufacturing

    NASA Astrophysics Data System (ADS)

    Sposili, Robert S.; Bovatsek, James; Patel, Rajesh

    2017-03-01

    Ceramic materials are used extensively in the microelectronics, semiconductor, and LED lighting industries because of their electrically insulating and thermally conductive properties, as well as for their high-temperature-service capabilities. However, their brittleness presents significant challenges for conventional machining processes. In this paper we report on a series of experiments that demonstrate and characterize the efficacy of pulsed nanosecond UV and green lasers in machining ceramics commonly used in microelectronics manufacturing, such as aluminum oxide (alumina) and aluminum nitride. With a series of laser pocket milling experiments, fundamental volume ablation rate and ablation efficiency data were generated. In addition, techniques for various industrial machining processes, such as shallow scribing and deep scribing, were developed and demonstrated. We demonstrate that lasers with higher average powers offer higher processing rates with the one exception of deep scribes in aluminum nitride, where a lower average power but higher pulse energy source outperformed a higher average power laser.

  7. Laser Beam Processing - A Manufacturer's Viewpoint

    NASA Astrophysics Data System (ADS)

    Peng, Y. C. J.

    1985-09-01

    The ability of continuous wave high power CO2 Lasers to generate power densities of up to 108 watts Cm makes them useful for a variety of material processing tasks. Deep-penetration laser welding, high precision laser cutting, surface heat treating by martensitic phase transformation hardening, and surface alloying are the four major areas which are accepting laser processes. This paper will cover these four primary laser applications existing in production within a variety of industries. Each individual area will be discussed in detail, describing the advantages and various parameters to achieve maximum productivity and quality. Beam config-uration, integration, and manipulation are included also. Production examples of laser welding, cutting, surface hardening and surface alloying, are examined to demonstrate the laser processing advantages. This paper also reviews the present and future status of the laser metalsworking industry in respect to the growth potential, research and development, manufacturers responsibilities etc.

  8. Defective Reduction in Automotive Headlining Manufacturing Process

    NASA Astrophysics Data System (ADS)

    Rittichai, Saranya; Chutima, Parames

    2016-05-01

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

  9. Low cost design of microprocessor EDAC circuit

    NASA Astrophysics Data System (ADS)

    Li, Hao; Lixin, Yu; Heping, Peng; Wei, Zhuang

    2015-11-01

    An optimization method of error detection and correction (EDAC) circuit design is proposed. The method involves selecting or constructing EDAC codes of low cost hardware, associated with operation scheduling implementation based on 2-input XOR gates structure, and two actions for reducing hardware cells, which can reduce the delay penalties and area costs of the EDAC circuit effectively. The 32-bit EDAC circuit hardware implementation is selected to make a prototype, based on the 180 nm process. The delay penalties and area costs of the EDAC circuit are evaluated. Results show that the time penalty and area cost of the EDAC circuitries are affected with different parity-check matrices and different hardware implementation for the EDAC codes with the same capability of correction and detection code. This method can be used as a guide for low-cost radiation-hardened microprocessor EDAC circuit design and for more advanced technologies.

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

    NASA Astrophysics Data System (ADS)

    Vatani, Morteza

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

  11. Cost Models for MMC Manufacturing Processes

    NASA Technical Reports Server (NTRS)

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

    1996-01-01

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

  12. Low cost omega navigation receiver

    NASA Technical Reports Server (NTRS)

    Lilley, R. W.

    1974-01-01

    The development of a low cost Omega navigation receiver is discussed. Emphasis is placed on the completion and testing of a modular, multipurpose Omega receiver which utilizes a digital memory-aided, phase-locked loop to provide phase measurement data to a variety of applications interfaces. The functional units contained in the prototype device are described. The receiver is capable of receiving and storing phase measurements for up to eight Omega signals and computes two switch-selectable lines of position, displaying this navigation data in chart-recorded form.

  13. A Low Cost Single Chip VDL Compatible Transceiver ASIC

    NASA Technical Reports Server (NTRS)

    Becker, Robert

    2004-01-01

    Recent trends in commercial communications system components have focussed almost exclusively on cellular telephone technology. As many of the traditional sources of receiver components have discontinued non-cellular telephone products, the designers of avionics and other low volume radio applications find themselves increasingly unable to find highly integrated components. This is particularly true for low power, low cost applications which cannot afford the lavish current consumption of the software defined radio approach increasingly taken by certified device manufacturers. In this paper, we describe a low power transceiver chip targeting applications from low VHF to low UHF frequencies typical of avionics systems. The chip encompasses a selectable single or double conversion design for the receiver and a low power IF upconversion transmitter. All local oscillators are synthesized and integrated into the chip. An on-chip I-Q modulator and demodulator provide baseband modulation and demodulation capability allowing the use of low power, fixed point signal processing components for signal demodulation. The goal of this program is to demonstrate a low cost VDL mode-3 transceiver using this chip to receive text weather information sent using 4-slot TDMA with no support for voice. The data will be sent from an experimental ground station. This work is funded by NASA Glenn Research Center.

  14. CHARACTERIZATION OF ADDITIVE MANUFACTURING FOR PROCESS TUBING

    SciTech Connect

    Korinko, John S.; BobbittIII, John T.; Morgan, Michael J.; Reigel, Marissa; List III, Frederick Alyious; Babu, Suresh S.

    2016-01-01

    Additive Manufacturing has garnered significant levels of interest in recent years as a primary manufacturing method. While the general technology has been around for over 20 years, with increased computing capacity, higher powered directed energy sources, e.g., lasers and electron beams, it is coming of age as a viable technique for high value added, low production quantity components. The Savannah River National Laboratory is interested in AM as a technique to build hydrogen isotope separation components called Thermal Cycling Absorption Process (TCAP) columns. The TCAP operates from cryogenic to moderate temperatures in a cyclic manner and is a pressure boundary. The current technique for fabricating TCAP columns is to form a flat coil of 0.375 to 0.5 inch diameter tube and braze two coils together. During the brazing operation, the two nested coils often move and this movement results in gaps between the coils. Since one coil contains the working fluid, i.e., liquid nitrogen, and the other the process fluid, hydrogen isotopes, these gaps result in poor heat transfer. Additive manufacturing is being explored as a replacement technology since the adjacent tubes can be fabricated simultaneously and in intimate contact and they can also share a common wall to improve heat transfer. AM allows designers to develop unique tube structures that overcome several of the shortcomings of the coil and braze technique, such as the braze gap in fabrication and slow cooling during operation. Simple test samples with various internal geometries were designed and built from Type 316L stainless steel using a laser powder bed process. Three test article geometries that were built include a simple tube, a pair of stacked tubes, and a tube partially surrounded by two kidney shaped tubes with cooling fins that would extend into the process fluid, these tube sections incorporated thermowells or heat trace channels, selectively. The test samples will be subjected to heat transfer

  15. Low-Cost Spectral Sensor Development Description.

    SciTech Connect

    Armijo, Kenneth Miguel; Yellowhair, Julius

    2014-11-01

    Solar spectral data for all parts of the US is limited due in part to the high cost of commercial spectrometers. Solar spectral information is necessary for accurate photovoltaic (PV) performance forecasting, especially for large utility-scale PV installations. A low-cost solar spectral sensor would address the obstacles and needs. In this report, a novel low-cost, discrete- band sensor device, comprised of five narrow-band sensors, is described. The hardware is comprised of commercial-off-the-shelf components to keep the cost low. Data processing algorithms were developed and are being refined for robustness. PV module short-circuit current ( I sc ) prediction methods were developed based on interaction-terms regression methodology and spectrum reconstruction methodology for computing I sc . The results suggest the computed spectrum using the reconstruction method agreed well with the measured spectrum from the wide-band spectrometer (RMS error of 38.2 W/m 2 -nm). Further analysis of computed I sc found a close correspondence of 0.05 A RMS error. The goal is for ubiquitous adoption of the low-cost spectral sensor in solar PV and other applications such as weather forecasting.

  16. Modeling the VARTM Composite Manufacturing Process

    NASA Technical Reports Server (NTRS)

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

    2004-01-01

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

  17. Process for manufacturing a petroleum resin

    SciTech Connect

    Iwashita, T.; Nagano, M.; Tanaka, K.

    1981-08-11

    The present invention relates to a process for manufacturing a petroleum resin wherein a fraction (Component a) containing an aromatic hydrocarbon obtained by cracking of petroleum and a thermally polymerized oil (Component b) obtained by previously thermal-polymerizing the component a are mixed and then the mixture of the components a and B is subjected to polymerization by employing a Friedel-Crafts catalyst. It is also directed to propose a petroleum resin of a superior quality having a softening point optionally in a range of 30-120/sup 0/C and various bromine value in such a manner that a mixing ratio of the components a and B is properly adjusted.

  18. Silicon-on ceramic process: Silicon sheet growth and device development for the large-area silicon sheet task of the low-cost solar array project

    NASA Technical Reports Server (NTRS)

    Grung, B. L.; Heaps, J. D.; Schmit, F. M.; Schuldt, S. B.; Zook, J. D.

    1981-01-01

    The technical feasibility of producing solar-cell-quality sheet silicon to meet the Department of Energy (DOE) 1986 overall price goal of $0.70/watt was investigated. With the silicon-on-ceramic (SOC) approach, a low-cost ceramic substrate is coated with large-grain polycrystalline silicon by unidirectional solidification of molten silicon. This effort was divided into several areas of investigation in order to most efficiently meet the goals of the program. These areas include: (1) dip-coating; (2) continuous coating designated SCIM-coating, and acronym for Silicon Coating by an Inverted Meniscus (SCIM); (3) material characterization; (4) cell fabrication and evaluation; and (5) theoretical analysis. Both coating approaches were successful in producing thin layers of large grain, solar-cell-quality silicon. The dip-coating approach was initially investigated and considerable effort was given to this technique. The SCIM technique was adopted because of its scale-up potential and its capability to produce more conventiently large areas of SOC.

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

    NASA Astrophysics Data System (ADS)

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

    2014-03-01

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

  20. Adhesive materials and processing selection for environmentally conscious manufacturing

    SciTech Connect

    Tira, J.S.

    1995-06-01

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

  1. Low-cost production of solar-cell panels

    NASA Technical Reports Server (NTRS)

    Bickler, D. B.; Gallagher, B. D.; Sanchez, L. E.

    1980-01-01

    Large-scale production model combines most modern manufacturing techniques to produce silicon-solar-cell panels of low costs by 1982. Model proposes facility capable of operating around the clock with annual production capacity of 20 W of solar cell panels.

  2. Dry process for economic cell manufacturing

    NASA Astrophysics Data System (ADS)

    Donon, J.; Lauvray, H.; Aubril, P.; David, G.; Loubly, P.

    Plasma dry etching technologies and screen printing processes for the dopant and the contacts were employed in an attempt to develop a completely dry process for solar cell manufacturing. Plasma etching within a barrel reactor produced etch rates of 0.3 and 0.6 micron/min, compared with acid etching rates of 13 microns/min and basic etching rates of 5 microns/min. Ring etching was also carried out in a barrel reactor with 200 wafers positioned in a stack, power levels of 850 W, a CF4 + 8 pct O2 plasma, a flow rate of 200 cc/min, and a run time of 15 min. The ring etching process was also tested and proven to have good reproducibility. A doping paste was employed, together with a thermal treatment at 850 C for 1 hr, to obtain good diffusion homogeneity. The results included cell efficiencies more than half those from chemical etching with both monocrystalline and polycrystalline materials. The techniques are concluded to produce negligible pollution, waste little material, and be amenable to automation.

  3. 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.

  4. Simulating the Composite Propellant Manufacturing Process

    NASA Technical Reports Server (NTRS)

    Williamson, Suzanne; Love, Gregory

    2000-01-01

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

  5. Simulating the Composite Propellant Manufacturing Process

    NASA Technical Reports Server (NTRS)

    Williamson, Suzanne; Love, Gregory

    2000-01-01

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

  6. Polymeric MST - high precision at low cost

    NASA Astrophysics Data System (ADS)

    Elderstig, Håkan; Larsson, Olle

    1997-09-01

    A low-cost production process for fabrication of polymeric microstructures from micromachined silicon is demonstrated in a splice for the splicing of optical fibers and an optical motherboard. Measurements on splices showed less than 0.5 dB insertion losses. The prototype polymeric motherboard concisted of an optical receiver module. The detector that was mounted on the polymeric optical motherboard detected about 70% of the transferred light. Measurements with modulated light indicates an optical bandwidth of 5 GHz at 2 V reverse current on the pin-diode.

  7. Low cost subpixel method for vibration measurement

    SciTech Connect

    Ferrer, Belen; Espinosa, Julian; Perez, Jorge; Acevedo, Pablo; Mas, David; Roig, Ana B.

    2014-05-27

    Traditional vibration measurement methods are based on devices that acquire local data by direct contact (accelerometers, GPS) or by laser beams (Doppler vibrometers). Our proposal uses video processing to obtain the vibration frequency directly from the scene, without the need of auxiliary targets or devices. Our video-vibrometer can obtain the vibration frequency at any point in the scene and can be implemented with low-cost devices, such as commercial cameras. Here we present the underlying theory and some experiments that support our technique.

  8. Low Cost Mission Operations Workshop. [Space Missions

    NASA Technical Reports Server (NTRS)

    1994-01-01

    The presentations given at the Low Cost (Space) Mission Operations (LCMO) Workshop are outlined. The LCMO concepts are covered in four introductory sections: Definition of Mission Operations (OPS); Mission Operations (MOS) Elements; The Operations Concept; and Mission Operations for Two Classes of Missions (operationally simple and complex). Individual presentations cover the following topics: Science Data Processing and Analysis; Mis sion Design, Planning, and Sequencing; Data Transport and Delivery, and Mission Coordination and Engineering Analysis. A list of panelists who participated in the conference is included along with a listing of the contact persons for obtaining more information concerning LCMO at JPL. The presentation of this document is in outline and graphic form.

  9. Low cost subpixel method for vibration measurement

    NASA Astrophysics Data System (ADS)

    Ferrer, Belen; Espinosa, Julian; Roig, Ana B.; Perez, Jorge; Acevedo, Pablo; Mas, David

    2014-05-01

    Traditional vibration measurement methods are based on devices that acquire local data by direct contact (accelerometers, GPS) or by laser beams (Doppler vibrometers). Our proposal uses video processing to obtain the vibration frequency directly from the scene, without the need of auxiliary targets or devices. Our video-vibrometer can obtain the vibration frequency at any point in the scene and can be implemented with low-cost devices, such as commercial cameras. Here we present the underlying theory and some experiments that support our technique.

  10. End-user perspective of low-cost sensors for outdoor air pollution monitoring.

    PubMed

    Rai, Aakash C; Kumar, Prashant; Pilla, Francesco; Skouloudis, Andreas N; Di Sabatino, Silvana; Ratti, Carlo; Yasar, Ansar; Rickerby, David

    2017-12-31

    Low-cost sensor technology can potentially revolutionise the area of air pollution monitoring by providing high-density spatiotemporal pollution data. Such data can be utilised for supplementing traditional pollution monitoring, improving exposure estimates, and raising community awareness about air pollution. However, data quality remains a major concern that hinders the widespread adoption of low-cost sensor technology. Unreliable data may mislead unsuspecting users and potentially lead to alarming consequences such as reporting acceptable air pollutant levels when they are above the limits deemed safe for human health. This article provides scientific guidance to the end-users for effectively deploying low-cost sensors for monitoring air pollution and people's exposure, while ensuring reasonable data quality. We review the performance characteristics of several low-cost particle and gas monitoring sensors and provide recommendations to end-users for making proper sensor selection by summarizing the capabilities and limitations of such sensors. The challenges, best practices, and future outlook for effectively deploying low-cost sensors, and maintaining data quality are also discussed. For data quality assurance, a two-stage sensor calibration process is recommended, which includes laboratory calibration under controlled conditions by the manufacturer supplemented with routine calibration checks performed by the end-user under final deployment conditions. For large sensor networks where routine calibration checks are impractical, statistical techniques for data quality assurance should be utilised. Further advancements and adoption of sophisticated mathematical and statistical techniques for sensor calibration, fault detection, and data quality assurance can indeed help to realise the promised benefits of a low-cost air pollution sensor network. Copyright © 2017 Elsevier B.V. All rights reserved.

  11. Auxetic polyurethane foam: Manufacturing and processing analysis

    NASA Astrophysics Data System (ADS)

    Jahan, Md Deloyer

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

  12. Low Cost Structures, but How Much are we Paying for Them?

    NASA Astrophysics Data System (ADS)

    Gomez Molinero, Vincent

    2014-06-01

    Based on more than 37 years developing spacecraft structures - both for launchers starting with Ariane-1 up to the most modern ones and for satellites of any type - a critical review of the current trends, aiming specially to low cost solutions, will be presented.Airbus Defence and Space (CASA Espacio previously) has been developing structures for launchers and satellites during more than 4 decades. All types of spacecraft structures - primary and secondary ones, high stability ones and special critical cases like antenna reflectors, high stiffness structures and load carrying ones - have been developed using different types of materials and structural constructions. Although our main expertise is concentrated on composite structures, we have also developed many types of metallic ones, when the best solution was that one, not necessarily only based on pure technical reasons.From that perspective and experience, this paper tries to review the current trend of imposing the low cost as the main requirement for the development of satellites and launchers and its intrinsic characteristic of being a non- ending process: the spacecraft structures are never sufficiently cheaper.The main ways used today to justify low cost spacecraft structures will be reviewed trying to understand their rationale and some prejudices always present when the trade-off studies are performed. Some of the reviewed cost-killing factors will be (non-exhaustive list) Material type (i.e.: metallic vs composite). Low cost materials in general. Manufacturing process (i.e.: autoclave curing vs out-of-autoclave one). Automation in manufacturing. Automation in assembly. Automation in inspection and verification. Lean manufacturing techniques. Standardization. Some insight about how to solve this problem without losing our distinctive nature (we are developing high performance systems many of them unique prototypes and thought to work in environments not perfectly known and highly unknown in some cases

  13. Powder metallurgy process for manufacturing core projectile

    NASA Astrophysics Data System (ADS)

    Akbar, Taufik; Setyowati, Vuri Ayu; Widyastuti

    2013-09-01

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

  14. Low-cost satellite mechanical design and construction

    NASA Astrophysics Data System (ADS)

    Boisjolie-Gair, Nathaniel; Straub, Jeremy

    2017-05-01

    This paper presents a discussion of techniques for low-cost design and construction of a CubeSat mechanical structure that can serve as a basis for academic programs and a starting point for government, military and commercial large-scale sensing networks, where the cost of each node must be minimized to facilitate system affordability and lower the cost and associated risk of losing any node. Spacecraft Design plays a large role in manufacturability. An intentionally simplified mechanical design is presented which reduces machining costs, as compared to more intricate designs that were considered. Several fabrication approaches are evaluated relative to the low-cost goal.

  15. Low cost balancing unit design

    NASA Astrophysics Data System (ADS)

    Golembiovsky, Matej; Dedek, Jan; Slanina, Zdenek

    2017-06-01

    This article deals with the design of a low-cost balancing system which consist of battery balancing units, accumulator pack units and coordinator unit with interface for higher level of battery management system. This solution allows decentralized mode of operation and the aim of this work is implementation of controlling and diagnostic mechanism into an electric scooter project realized at Technical university of Ostrava. In todays world which now fully enjoys the prime of electromobility, off-grid battery systems and other, it is important to seek the optimal balance between functionality and the economy side of BMS that being electronics which deals with secondary cells of batery packs. There were numerous sophisticated, but not too practical BMS models in the past, such as centralized system or standalone balance modules of individual cells. This article aims at development of standalone balance modules which are able to communicate with the coordinator, adjust their parameters and ensure their cells safety in case of a communication failure. With the current worldwide cutting cost trend in mind, the emphasis was put on the lowest price possible for individual component. The article is divided into two major categories, the first one being desing of power electronics with emphasis on quality, safety (cooling) and also cost. The second part describes development of a communication interface with reliability and cost in mind. The article contains numerous graphs from practical measurements. The outcome of the work and its possible future is defined in the conclusion.

  16. Friction Stir Processing for Efficient Manufacturing

    SciTech Connect

    Mr. Christopher B. Smith; Dr. Oyelayo Ajayi

    2012-01-31

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

  17. Developing the Manufacturing Process for Hylene MP Curing Agent

    SciTech Connect

    Eastwood, Eric

    2009-02-16

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

  18. Silicon materials task of the low-cost solar array project. Phase 4: Effects of impurities and processing on silicon solar cells

    NASA Technical Reports Server (NTRS)

    Hopkins, R. H.; Hanes, M. H.; Davis, J. R.; Rohatgi, A.; Raichoudhury, P.; Mollenkopf, H. C.

    1981-01-01

    The results of the study form a basis for silicon producers, wafer manufacturers, and cell fabricators to develop appropriate cost-benefit relationships for the use of less pure, less costly solar grade silicon. Cr is highly mobile in silicon even at temperatures as low as 600 C. Contrasting with earlier data for Mo, Ti, and V, Cr concentrations vary from place to place in polycrystalline silicon wafers and the electrically-active Cr concentration in the polysilicon is more than an order of magnitude smaller than would be projected from single crystal impurity data. We hypothesize that Cr diffuses during ingot cooldown after growth, preferentially segregates to grain and becomes electrically deactivated. Accelerated aging data from Ni-contaminated silicon imply that no significant impurity-induced cell performance reduction should be expected over a twenty year device lifetime.

  19. Printing Processes Used to Manufacture Photovoltaic Solar Cells

    ERIC Educational Resources Information Center

    Rardin, Tina E.; Xu, Renmei

    2011-01-01

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

  20. LSA: Low-cost Solar Array project

    NASA Technical Reports Server (NTRS)

    1978-01-01

    Topics discussed include silicon material processing; large-area silicon sheet development; encapsulation materials testing and development; project engineering and operations activities, and manufacturing techniques. The steps taken to integrate these efforts, are described.

  1. Low-cost airborne synthetic aperture radar

    NASA Astrophysics Data System (ADS)

    McCandless, Samuel W.; Huxtable, Barton D.; Jackson, Christopher R.

    1997-06-01

    This paper describes the rudiments of a design and implementation approach that will produce low-cost and quick turnaround airborne synthetic aperture radar (SAR) systems including designs for remotely piloted vehicles (RPVs). The concept is based on strict adherence to a discipline of simplicity in application boundary definition, the corresponding design that follows, extension of this core of simplicity through the build and test cycle and continuation of this theme when system modification and upgrades are considered. As this paper points out, the tenets for low-cost development of SAR systems are not new. Indeed, several such developments validate the guidelines advocated in this paper. The crux of this end-to-end development simplicity is to minimize the functions assigned to the on-board radar systems, transferring them to less expensive ground-based information processing assets that will perform motion compensation, image signal processing and target identification/classification. This cause limitations in the applications sheath of the airborne system, but in many cases this is an acceptable compromise.

  2. Using Low Cost Environmental Sensors in Geoscience Education

    NASA Astrophysics Data System (ADS)

    Leeman, J.; Ammon, C. J.; Anandakrishnan, S.

    2014-12-01

    Advances in process technology have drastically reduced the cost of manufacturing almost every type of sensor and micro-controller, putting low-to-mid grade sensor technology in the reach of educators and hobbyists. We demonstrate how a low cost magnetometer and an Arduino micro-controller can be used in education. Students can easily connect the sensor to the Arduino and collect three-component magnetic field data. Experiments can easily be turned into long-term monitoring projects by connecting sensors to the internet and providing an Internet-of-Things interface to store and to display the data in near-real time. Low-cost sensors are generally much noisier than their research grade counterparts, but can still provide an opportunity for students to learn about fundamental concepts such as signal quality, sampling, averaging, and filtering and to gain hands-on, concrete experience with observations. Sensors can be placed at different locations and compared both qualitatively and quantitatively. For example, with an inexpensive magnetometer, students can examine diurnal magnetic field variations and look for magnetic storms. Magnetic field orientation can be calculated and compared to the predicted geomagnetic field orientation at a given location. Data can be stored in simple text files to facilitate analysis with any convenient package. We illustrate the idea using Python notebooks, allowing students to explore the data interactively and to learn the basic principles of programming and reproducible research. Using an Arduino encourages students to interact with open-source data collection hardware and to experiment with ways to quickly, cheaply, and effectively measure the environment. Analysis of these data can lead to a deeper understanding of both geoscience and data processing.

  3. Low-cost far infrared bolometer camera for automotive use

    NASA Astrophysics Data System (ADS)

    Vieider, Christian; Wissmar, Stanley; Ericsson, Per; Halldin, Urban; Niklaus, Frank; Stemme, Göran; Källhammer, Jan-Erik; Pettersson, Håkan; Eriksson, Dick; Jakobsen, Henrik; Kvisterøy, Terje; Franks, John; VanNylen, Jan; Vercammen, Hans; VanHulsel, Annick

    2007-04-01

    A new low-cost long-wavelength infrared bolometer camera system is under development. It is designed for use with an automatic vision algorithm system as a sensor to detect vulnerable road users in traffic. Looking 15 m in front of the vehicle it can in case of an unavoidable impact activate a brake assist system or other deployable protection system. To achieve our cost target below €100 for the sensor system we evaluate the required performance and can reduce the sensitivity to 150 mK and pixel resolution to 80 x 30. We address all the main cost drivers as sensor size and production yield along with vacuum packaging, optical components and large volume manufacturing technologies. The detector array is based on a new type of high performance thermistor material. Very thin Si/SiGe single crystal multi-layers are grown epitaxially. Due to the resulting valence barriers a high temperature coefficient of resistance is achieved (3.3%/K). Simultaneously, the high quality crystalline material provides very low 1/f-noise characteristics and uniform material properties. The thermistor material is transferred from the original substrate wafer to the read-out circuit using adhesive wafer bonding and subsequent thinning. Bolometer arrays can then be fabricated using industry standard MEMS process and materials. The inherently good detector performance allows us to reduce the vacuum requirement and we can implement wafer level vacuum packaging technology used in established automotive sensor fabrication. The optical design is reduced to a single lens camera. We develop a low cost molding process using a novel chalcogenide glass (GASIR®3) and integrate anti-reflective and anti-erosion properties using diamond like carbon coating.

  4. Low-cost periodontal therapy.

    PubMed

    Slots, Jørgen

    2012-10-01

    Periodontitis is a complex infectious disease that affects low-income individuals disproportionately. Periodontitis is associated with specific bacterial species and herpesviruses, and successful prevention and treatment of the disease is contingent upon effective control of these pathogens. This article presents an efficacious, highly safe, minimally invasive, practical and low-cost periodontal therapy that involves professional and patient-administered mechanical therapy and antimicrobial agents. The major components are scaling for calculus removal, periodontal pocket irrigation with potent antiseptics, and treatment with systemic antibiotics for advanced disease. Povidone-iodine and sodium hypochlorite have all the characteristics for becoming the first-choice antiseptics in the management of periodontal diseases. Both agents show excellent antibacterial and antiviral properties, are readily available throughout the world, have been safely used in periodontal therapy for decades, offer significant benefits for individuals with very limited financial resources, and are well accepted by most dental professionals and patients. Four per cent chlorhexidine applied with a toothbrush to the most posterior part to the tongue dorsum can markedly reduce or eliminate halitosis in most individuals. Systemic antibiotics are used to treat periodontopathic bacteria that are not readily reached by topical therapy, such as pathogens within gingival tissue, within furcation defects, at the base of periodontal pockets, and on the tongue, tonsils and buccal mucosae. Valuable antibiotic therapies are amoxicillin-metronidazole (250 mg of amoxicillin and 250 mg of metronidazole, three times daily for 8 days) for young and middle-aged patients, and ciprofloxacin-metronidazole (500 mg of each, twice daily for 8 days) for elderly patients and for patients in developing countries who frequently harbor enteric rods subgingivally. Scaling to remove dental calculus and the prudent

  5. A microcomputer-based low-cost Omega navigation system

    NASA Technical Reports Server (NTRS)

    Lilley, R. W.; Salter, R. J., Jr.

    1976-01-01

    The application of a low cost, commercially available microcomputer as the navigation processor for a simplified OMEGA navigation system is an area of current research. The interface of a low cost front end OMEGA sensor is described and an example of the phase processing software and navigation routines is given. Emphasis is placed on the description of results obtained with the software version of the OMEGA burst filter known as the memory aided phase locked loop.

  6. A 10W Low Cost OFDM Transceiver (LCOT)

    DTIC Science & Technology

    2013-02-19

    AFFTC-PA-12422 A 10W Low Cost OFDM Transceiver (LCOT) Pallavi Sandhiya AIR FORCE FLIGHT TEST CENTER EDWARDS AFB, CA 2/19/13 A F...19-02-2013) 2. REPORT TYPE Technical 3. DATES COVERED (From - To) 3/12 -- 10/12 4. TITLE AND SUBTITLE A 10W Low Cost OFDM Transceiver (LCOT... OFDM waveform uses space, frequency and time diversity, as well as innovative signal processing techniques to achieve five times the spectral

  7. Low Cost Air Combat Training System

    NASA Astrophysics Data System (ADS)

    Flynn, Earl

    1987-10-01

    Air combat training has evolved into a highly sophisticated and expensive process. To effectively train fighter pilots in air-to-air combat, interaction between pilots is essential. This interaction can be accomplished using multiple low cost laser image projections of friend and/or foe aircraft controlled by pilots in a multiple dome configuration. A Laser Target Projector (LTP) produces a calligraphically written aircraft model comprised of up to 200 vectors which are updated at a 60 Hz rate. The resulting wire frame image imparts both position, velocity, distance and altitude information to the pilots. Using a laser light source guarantees high luminance levels and provides large depths of field. This large depth of field allows for unique packaging arrangements and cost saving attributes. The LTP has total dome coverage via a computer-controlled, servo-driven, gimb-alled two-axis assembly that projects the wire frame aircraft image onto the dome surface. To unburden the host computer, all dome-to-dome communication, real world-to-dome coordinate transformations and all geometry corrections are done by a special purpose high-speed computer called a Dome Master. Each dome has one Dome Master that can drive up to six LTP's. This paper will deal with the technical aspects of the design and development of the LTP and Dome Master as a low cost air combat training system.

  8. Platform for 3D inline process control in additive manufacturing

    NASA Astrophysics Data System (ADS)

    Preissler, Marc; Zhang, Chen; Rosenberger, Maik; Notni, Gunther

    2017-06-01

    3D - Inline - Process - Control is getting more attention in any fields of manufacturing processes to increase productivity and quality. Sensor systems are necessary to capture the currently process status and are basement for Inline-Process- Control. The presented work is a possibility to get inline information's about the additive manufacturing process Fused Filament Fabrication. The requirement is the ability to manipulate the machine code to get free field of view to the topside of the object after every manufactured layer. The adaptable platform layout makes possible to create different approaches for inline process control. One approach is the single camera layout from bird view to get 2,5D information's about the manufactured object and the other one is the active stereoscopic camera layout with pattern projection. Both approaches are showing a possibility to get information's of the manufactured object in process. Additional this cases allow a view inside the manufactured object and defects can be located. Deviations in the manufacturing process can be corrected and relevant parameters can be adapted during slicing process to increase the manufacturing quality.

  9. Development of an innovative, low-cost solar collector

    NASA Astrophysics Data System (ADS)

    Squires, M. P.

    1987-06-01

    A low cost domestic water heating system, one that could be sold at a retail price of $500, was developed and produced. The primary effort was to reduce solar collector plate costs and, more specifically, the collector absorber plate costs. Plastic adhesive research resulted in the extensive use of silicone adhesives in a high performance solar collector which was also durable, reliable and easy to manufacture at a low cost. High thermal performance resulted from development of a silicone based conductive bond. The new collector has full pressure capability, and can be manufactured in quantity at a materials cost of $55 and a labor cost of $3.35. Detailed design descriptions, drawings, and photographs, of four different low cost solar collectors that were designed and built are included. Also, material listings and a step-by-step procedure for manufacturing the selected collector are included. NMSEI Performance Data for the new collector are compared to the certification data of the model SL-100 collector previously manufactured by American Solar Products.

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

    SciTech Connect

    Rozzell, Thomas

    1999-10-01

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

  11. Nonterrestrial material processing and manufacturing of large space systems

    NASA Technical Reports Server (NTRS)

    Vontiesenhausen, G. F.

    1978-01-01

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

  12. A simple, low-cost conductive composite material for 3D printing of electronic sensors.

    PubMed

    Leigh, Simon J; Bradley, Robert J; Purssell, Christopher P; Billson, Duncan R; Hutchins, David A

    2012-01-01

    3D printing technology can produce complex objects directly from computer aided digital designs. The technology has traditionally been used by large companies to produce fit and form concept prototypes ('rapid prototyping') before production. In recent years however there has been a move to adopt the technology as full-scale manufacturing solution. The advent of low-cost, desktop 3D printers such as the RepRap and Fab@Home has meant a wider user base are now able to have access to desktop manufacturing platforms enabling them to produce highly customised products for personal use and sale. This uptake in usage has been coupled with a demand for printing technology and materials able to print functional elements such as electronic sensors. Here we present formulation of a simple conductive thermoplastic composite we term 'carbomorph' and demonstrate how it can be used in an unmodified low-cost 3D printer to print electronic sensors able to sense mechanical flexing and capacitance changes. We show how this capability can be used to produce custom sensing devices and user interface devices along with printed objects with embedded sensing capability. This advance in low-cost 3D printing with offer a new paradigm in the 3D printing field with printed sensors and electronics embedded inside 3D printed objects in a single build process without requiring complex or expensive materials incorporating additives such as carbon nanotubes.

  13. A Simple, Low-Cost Conductive Composite Material for 3D Printing of Electronic Sensors

    PubMed Central

    Leigh, Simon J.; Bradley, Robert J.; Purssell, Christopher P.; Billson, Duncan R.; Hutchins, David A.

    2012-01-01

    3D printing technology can produce complex objects directly from computer aided digital designs. The technology has traditionally been used by large companies to produce fit and form concept prototypes (‘rapid prototyping’) before production. In recent years however there has been a move to adopt the technology as full-scale manufacturing solution. The advent of low-cost, desktop 3D printers such as the RepRap and Fab@Home has meant a wider user base are now able to have access to desktop manufacturing platforms enabling them to produce highly customised products for personal use and sale. This uptake in usage has been coupled with a demand for printing technology and materials able to print functional elements such as electronic sensors. Here we present formulation of a simple conductive thermoplastic composite we term ‘carbomorph’ and demonstrate how it can be used in an unmodified low-cost 3D printer to print electronic sensors able to sense mechanical flexing and capacitance changes. We show how this capability can be used to produce custom sensing devices and user interface devices along with printed objects with embedded sensing capability. This advance in low-cost 3D printing with offer a new paradigm in the 3D printing field with printed sensors and electronics embedded inside 3D printed objects in a single build process without requiring complex or expensive materials incorporating additives such as carbon nanotubes. PMID:23185319

  14. Study on Process Planning System for Holonic Manufacturing

    NASA Astrophysics Data System (ADS)

    Rais, Suyoto; Sugimura, Nobuhiro; Kokubun, Atsushi

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

  15. Overview of ARPA low-cost ceramic composites (LC{sup 3}) program

    SciTech Connect

    Adler, P.N.

    1996-12-31

    Grumman is currently leading an approximate $10M ARPA cost-shared program aimed at developing low-cost fabrication methodology for manufacturing ceramic matrix composite (CMC) structural components. One of the program goals is to demonstrate the effectiveness of an advanced materials partnership. A vertically integrated collaboration now exists that combines the talents of three large private sector organizations, two smaller private sector organizations, three universities, and three federal government laboratories. Work in progress involves preceramic polymer (Blackglas{trademark}) CMC materials technology, RTM and pyrolysis process modeling & simulation, and utilization of low-cost approaches for fabricating a CMC demonstration engine seal component. This paper reviews the program organization, functioning, and some of the highlights of the technical work, which is of interest to the DoD as well as the commercial sector.

  16. Optimization of steel bar manufacturing process using six sigma

    NASA Astrophysics Data System (ADS)

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

    2016-03-01

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

  17. Low cost attitude control system scanwheel development

    NASA Technical Reports Server (NTRS)

    Bialke, William; Selby, Vaughn

    1991-01-01

    In order to satisfy a growing demand for low cost attitude control systems for small spacecraft, development of low cost scanning horizon sensor coupled to a low cost/low power consumption Reaction Wheel Assembly was initiated. This report addresses the details of the versatile design resulting from this effort. Tradeoff analyses for each of the major components are included, as well as test data from an engineering prototype of the hardware.

  18. Bench Scale Process for Low Cost CO2 Capture Using a Phase-Changing Absorbent: Topical Report EH&S Risk Assessment

    SciTech Connect

    Westendorf, Tiffany; Farnum, Rachel; Perry, Robert; Herwig, Mark; Giolando, Salvatore; Green, Dianne; Morall, Donna

    2016-05-11

    GE Global Research was contracted by the Department of Energy to design and build a bench-scale process for a novel phase-changing aminosilicone-based CO2 capture solvent (award number DEFE0013687). As part of this program, a technology EH&S assessment (Subtask 5.1) has been completed for a CO2 capture system for a 550 MW coal-fired power plant. The assessment focuses on two chemicals used in the process, the aminosilicone solvent, GAP-0, and dodecylbenzenesulfonic acid (DDBSA), the GAP-0 carbamate formed upon reaction of the GAP-0 with CO2, and two potential byproducts formed in the process, GAP-0/SOx salts and amine-terminated, urea-containing silicone (also referred to as “ureas” in this report). The EH&S assessment identifies and estimates the magnitude of the potential air and water emissions and solid waste generated by the process and reviews the toxicological profiles of the chemicals associated with the process. Details regarding regulatory requirements, engineering controls, and storage and handling procedures are also provided in the following sections.

  19. 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

  20. Development of advanced Czochralski growth process to produce low cost 150 kg silicon ingots from a single crucible for technology readiness

    NASA Technical Reports Server (NTRS)

    1980-01-01

    The design and development of an advanced Czochralski crystal grower are described. Several exhaust gas analysis system equipment specifications studied are discussed. Process control requirements were defined and design work began on the melt temperature, melt level, and continuous diameter control. Sensor development included assembly and testing of a bench prototype of a diameter scanner system.

  1. Pilot-Scale Demonstration of a Novel, Low-Cost Oxygen Supply Process and its Integration with Oxy-Fuel Coal-Fired Boilers

    SciTech Connect

    Krish Krishnamurthy; Divy Acharya; Frank Fitch

    2008-09-30

    In order to achieve DOE targets for carbon dioxide capture, it is crucial not only to develop process options that will generate and provide oxygen to the power cycle in a cost-effective manner compared to the conventional oxygen supply methods based on cryogenic air separation technology, but also to identify effective integration options for these new technologies into the power cycle with carbon dioxide capture. The Linde/BOC developed Ceramic Autothermal Recovery (CAR) process remains an interesting candidate to address both of these issues by the transfer of oxygen from the air to a recycled CO{sub 2} rich flue-gas stream in a cyclic process utilizing the high temperature sorption properties of perovskites. Good progress was made on this technology in this project, but significant challenges remain to be addressed before CAR oxygen production technology is ready for commercial exploitation. Phase 1 of the project was completed by the end of September 2008. The two-bed 0.7 tons/day O2 CAR process development unit (PDU) was installed adjacent to WRI's pilot scale coal combustion test facility (CTF). Start-up and operating sequences for the PDU were developed and cyclic operation of the CAR process demonstrated. Controlled low concentration methane addition allowed the beds to be heated up to operational temperature (800-900 C) and then held there during cyclic operation of the 2-bed CAR process, in this way overcoming unavoidable heat losses from the beds during steady state operation. The performance of the PDU was optimized as much as possible, but equipment limitations prevented the system from fully achieving its target performance. Design of the flue gas recirculation system to integrate CAR PDU with the CTF and the system was completed and integrated tests successfully performed at the end of the period. A detailed techno-economic analysis was made of the CAR process for supplying the oxygen in oxy-fuel combustion retrofit option using AEP's 450 MW

  2. Wellbore manufacturing processes for in situ heat treatment processes

    DOEpatents

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

    2012-12-11

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

  3. Computer simulation of gear tooth manufacturing processes

    NASA Technical Reports Server (NTRS)

    Mavriplis, Dimitri; Huston, Ronald L.

    1990-01-01

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

  4. Silicon Materials Task of the Low Cost Solar Array Project, Phase 3. Effect of Impurities and Processing on Silicon Solar Cells

    NASA Technical Reports Server (NTRS)

    Hopkins, R. H.; Davis, J. R.; Blais, P. D.; Rohatgi, A.; Campbell, R. B.; Rai-Choudhury, P.; Stapleton, R. E.; Mollenkopf, H. C.; Mccormick, J. R.

    1979-01-01

    The effects of impurities, various thermochemical processes, and any impurity process interactions on the performance of terrestrial silicon solar cells are defined. Determinations of the segregation coefficients of tungsten, tantalum, and cobalt for the Czochralski pulling of silicon single crystals are reported. Sensitive neutron activation analysis was used to determine the metal impurity content of the silicon while atomic absorption was used to measure the metal content of the residual liquid from which the doped crystals were grown. Gettering of Ti doped silicon wafers improved cell performance by one to two percent for the highest temperatures and longest times. The HCl is more effective than POCl3 treatments for deactivating Ti but POCl3 and HCl produced essentially identical results for Mo or Fe.

  5. Low Cost Solar Array Project cell and module formation research area. Process research of non-CZ silicon material. Final report, November 26, 1980-September 30, 1983

    SciTech Connect

    Campbell, R.B.

    1983-01-01

    The primary objective of the work reported was to investigate high-risk, high-payoff research areas associated with the Westinghouse process for producing photovoltaic modules using non-Czochralski sheet material. These tasks were addressed: technical feasibility study of forming front and back junctions using liquid dopant techniques, liquid diffusion mask feasibility study, application studies of antireflective material using a meniscus coater, ion implantation compatibility/feasibility study, and cost analysis. (LEW)

  6. Development of advanced Czochralski growth process to produce low-cost 150 kG silicon ingots from a single crucible for technology readiness

    NASA Technical Reports Server (NTRS)

    1981-01-01

    The modified CG2000 crystal grower construction, installation, and machine check out was completed. The process development check out proceeded with several dry runs and one growth run. Several machine calibrations and functional problems were discovered and corrected. Exhaust gas analysis system alternatives were evaluated and an integrated system approved and ordered. Several growth runs on a development CG2000 RC grower show that complete neck, crown, and body automated growth can be achieved with only one operator input.

  7. 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.

  8. Systematic Classifier OF Manufacturing Processes For Medium Size Shafts

    NASA Astrophysics Data System (ADS)

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

    2016-04-01

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

  9. Current manufacturing processes of drug-eluting sutures.

    PubMed

    Champeau, Mathilde; Thomassin, Jean-Michel; Tassaing, Thierry; Jérôme, Christine

    2017-02-24

    Drug-eluting sutures represent the next generation of surgical sutures since they fulfill their mechanical functions but also deliver the drug in their vicinity after implantation. These implants are produced by a variety of manufacturing processes. Drug-eluting sutures represent the next generation of surgical sutures since they fulfill their mechanical functions but also deliver the drug in their vicinity after implantation. These implants are produced by a variety of manufacturing processes. Two general approaches can be followed: (i) the ones that add the API into the material during the manufacturing process of the suture and (ii) the ones that load the API to an already manufactured suture. Areas covered: This review provides an overview of the current manufacturing processes for drug-eluting suture production and discusses their benefits and drawbacks depending on the type of drugs. The mechanical properties and the drug delivery profile of drug-eluting sutures are highlighted since these implants must fulfill both criteria. Expert opinion: For limited drug contents, melt extrusion and electrospinning are the emerging processes since the drug is added during the suture manufacture process. Advantageously, the drug release profile can be tuned by controlling the processing parameters specific to each process and the composition of the drug-containing polymer. If high drug content is targeted, the coating or grafting of a drug layer on a pre-manufactured suture allows for preservation of the tensile strength requirements of the suture.

  10. Dimethyl adipimidate/Thin film Sample processing (DTS); A simple, low-cost, and versatile nucleic acid extraction assay for downstream analysis.

    PubMed

    Shin, Yong; Lim, Swee Yin; Lee, Tae Yoon; Park, Mi Kyoung

    2015-09-15

    Sample processing, especially that involving nucleic acid extraction, is a prerequisite step for the isolation of high quantities of relatively pure DNA for downstream analyses in many life science and biomedical engineering studies. However, existing methods still have major problems, including labor-intensive time-consuming methods and high costs, as well as requirements for a centrifuge and the complex fabrication of filters and membranes. Here, we first report a versatile Dimethyl adipimidate/Thin film based Sample processing (DTS) procedure without the limitations of existing methods. This procedure is useful for the extraction of DNA from a variety of sources, including 6 eukaryotic cells, 6 bacteria cells, and 2 body fluids in a single step. Specifically, the DTS procedure does not require a centrifuge and has improved time efficiency (30 min), affordability, and sensitivity in downstream analysis. We validated the DTS procedure for the extraction of DNA from human body fluids, as well as confirmed that the quality and quantity of the extracted DNA were sufficient to allow robust detection of genetic and epigenetic biomarkers in downstream analysis.

  11. Dimethyl adipimidate/Thin film Sample processing (DTS); A simple, low-cost, and versatile nucleic acid extraction assay for downstream analysis

    PubMed Central

    Shin, Yong; Lim, Swee Yin; Lee, Tae Yoon; Park, Mi Kyoung

    2015-01-01

    Sample processing, especially that involving nucleic acid extraction, is a prerequisite step for the isolation of high quantities of relatively pure DNA for downstream analyses in many life science and biomedical engineering studies. However, existing methods still have major problems, including labor-intensive time-consuming methods and high costs, as well as requirements for a centrifuge and the complex fabrication of filters and membranes. Here, we first report a versatile Dimethyl adipimidate/Thin film based Sample processing (DTS) procedure without the limitations of existing methods. This procedure is useful for the extraction of DNA from a variety of sources, including 6 eukaryotic cells, 6 bacteria cells, and 2 body fluids in a single step. Specifically, the DTS procedure does not require a centrifuge and has improved time efficiency (30 min), affordability, and sensitivity in downstream analysis. We validated the DTS procedure for the extraction of DNA from human body fluids, as well as confirmed that the quality and quantity of the extracted DNA were sufficient to allow robust detection of genetic and epigenetic biomarkers in downstream analysis. PMID:26370251

  12. Development of advanced Czochralski growth process to produce low cost 150 kg silicon ingots from a single crucible for technology readiness

    NASA Technical Reports Server (NTRS)

    1981-01-01

    The process development continued, with a total of nine crystal growth runs. One of these was a 150 kg run of 5 crystals of approximately 30 kg each. Several machine and process problems were corrected and the 150 kg run was as successful as previous long runs on CG2000 RC's. The accelerated recharge and growth will be attempted when the development program resumes at full capacity in FY '82. The automation controls (Automatic Grower Light Computer System) were integrated to the seed dip temperature, shoulder, and diameter sensors on the CG2000 RC development grower. Test growths included four crystals, which were grown by the computer/sensor system from seed dip through tail off. This system will be integrated on the Mod CG2000 grower during the next quarter. The analytical task included the completion and preliminary testing of the gas chromatograph portion of the Furnace Atmosphere Analysis System. The system can detect CO concentrations and will be expanded to oxygen and water analysis in FY '82.

  13. A complete low cost radon detection system.

    PubMed

    Bayrak, A; Barlas, E; Emirhan, E; Kutlu, Ç; Ozben, C S

    2013-08-01

    Monitoring the (222)Rn activity through the 1200 km long Northern Anatolian fault line, for the purpose of earthquake precursory, requires large number of cost effective radon detectors. We have designed, produced and successfully tested a low cost radon detection system (a radon monitor). In the detector circuit of this monitor, First Sensor PS100-7-CER-2 windowless PIN photodiode and a custom made transempedence/shaping amplifier were used. In order to collect the naturally ionized radon progeny to the surface of the PIN photodiode, a potential of 3500 V was applied between the conductive hemi-spherical shell and the PIN photodiode. In addition to the count rate of the radon progeny, absolute pressure, humidity and temperature were logged during the measurements. A GSM modem was integrated to the system for transferring the measurements from the remote locations to the data process center.

  14. Low-cost solar flat-plate-collector development

    NASA Astrophysics Data System (ADS)

    Wilhelm, W. G.

    Cost goals were developed for the collector which led to the rejection of conventional approaches and to the exploration of thin film technology. A thin film solar absorber suited for high speed continous-roll manufacture at low cost was designed. The absorber comprises two sheets of aluminum-foil/polmeric-material laminate bonded together at intervals to form channels with water as the heat transfer fluid. Several flat-plate panels were fabricated and tested.

  15. Development of Advanced Czochralski Growth Process to produce low cost 150 KG silicon ingots from a single crucible for technology readiness

    NASA Technical Reports Server (NTRS)

    1981-01-01

    The modified CG2000 crystal grower construction, installation, and machine check-out was completed. The process development check-out proceeded with several dry runs and one growth run. Several machine calibrations and functional problems were discovered and corrected. Several exhaust gas analysis system alternatives were evaluated and an integrated system approved and ordered. A contract presentation was made at the Project Integration Meeting at JPL, including cost-projections using contract projected throughput and machine parameters. Several growth runs on a development CG200 RC grower show that complete neck, crown, and body automated growth can be achieved with only one operator input. Work continued for melt level, melt temperature, and diameter sensor development.

  16. Development of New Low-Cost, High-Performance, PV Module Encapsulant/Packaging Materials: Final Technical Progress Report, 22 October 2002 - 15 November 2007

    SciTech Connect

    Tucker, R.

    2008-04-01

    Report on objectives to work with U.S.-based PV module manufacturers (c-Si, a-Si, CIS, other thin films) to develop/qualify new low-cost, high-performance PV module encapsulant/packaging materials, and processes using the packaging materials.

  17. 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.

  18. Manufacturing Process Simulation of Large-Scale Cryotanks

    NASA Technical Reports Server (NTRS)

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

    2002-01-01

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

  19. Environmental Strategies for Sustainable Manufacturing Process of Composites

    NASA Astrophysics Data System (ADS)

    Kireitseu, Maxim

    2017-09-01

    This research is focused on the strategic road mapping of composite manufacturing process and aims to understand the sustainability and related costs of composite part manufacturing. A manufacturing route of a serial automotive component is mapped and modelled using the following steps: (1) a holistic, cradle to grave product model for both manuflacturing and assembly operations, (2) development of life-cycle model and analytical tools, and (3) direct data collection and measure of environmental impacts of manufacturing. Besides the theoretical outcomes recommendations are given considering further recycling and recovery of materials so as to provide further direction for sustainability research in carbon and glass fibre composites.

  20. Low cost UVA-LED as a radiation source for the photo-Fenton process: a new approach for micropollutant removal from urban wastewater.

    PubMed

    de la Obra, I; Esteban García, B; García Sánchez, J L; Casas López, J L; Sánchez Pérez, J A

    2017-01-18

    Light Emitting Diode (LED) technology has matured sufficiently to be considered as an alternative UVA radiation source in photoreactors. Currently, low energy consuming LEDs with a wide range of wavelengths and radiant flux are readily available. In this study, UVA-LEDs were used as a radiation source for the photo-Fenton process as tertiary treatment. The water matrix used was a simulated secondary effluent doped with 200 μg L(-1) of the pesticide acetamiprid (ACTM) due to its recalcitrant nature. All experiments were carried out in a LED-box reactor at pH 2.8. The main purpose of this research was to gain some insight into the relationships among energy supply, LED consumption, UVA irradiance and reaction rate. The effect of LED wavelength on energy efficiency for ACTM degradation was studied by varying the iron concentration and liquid depth. Three wavelengths (365, 385 and 400 nm) and two iron concentrations (5 and 11 mg L(-1)) for two different liquid depths (5 and 15 cm) were evaluated in order to obtain more energy efficient conditions. The results suggest that while the wavelength of 365 nm with 11 mg Fe(2+) L(-1) was the best condition for ACTM degradation, the wavelength of 385 nm had slower kinetics, but higher energy efficiency.

  1. SDIO producibility and manufacturing intelligent processing programs

    NASA Astrophysics Data System (ADS)

    Stottlemyer, Greg

    1992-04-01

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

  2. SDIO Producibility and Manufacturing Intelligent Processing Programs

    NASA Technical Reports Server (NTRS)

    Stottlemyer, Greg

    1992-01-01

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

  3. SDIO Producibility and Manufacturing Intelligent Processing Programs

    NASA Technical Reports Server (NTRS)

    Stottlemyer, Greg

    1992-01-01

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

  4. Low-cost real-time automatic wheel classification system

    NASA Astrophysics Data System (ADS)

    Shabestari, Behrouz N.; Miller, John W. V.; Wedding, Victoria

    1992-11-01

    This paper describes the design and implementation of a low-cost machine vision system for identifying various types of automotive wheels which are manufactured in several styles and sizes. In this application, a variety of wheels travel on a conveyor in random order through a number of processing steps. One of these processes requires the identification of the wheel type which was performed manually by an operator. A vision system was designed to provide the required identification. The system consisted of an annular illumination source, a CCD TV camera, frame grabber, and 386-compatible computer. Statistical pattern recognition techniques were used to provide robust classification as well as a simple means for adding new wheel designs to the system. Maintenance of the system can be performed by plant personnel with minimal training. The basic steps for identification include image acquisition, segmentation of the regions of interest, extraction of selected features, and classification. The vision system has been installed in a plant and has proven to be extremely effective. The system properly identifies the wheels correctly up to 30 wheels per minute regardless of rotational orientation in the camera's field of view. Correct classification can even be achieved if a portion of the wheel is blocked off from the camera. Significant cost savings have been achieved by a reduction in scrap associated with incorrect manual classification as well as a reduction of labor in a tedious task.

  5. Low cost electrode development and performance in Ballard advanced stack hardware

    SciTech Connect

    Hards, G.A.; Ralph, T.R.; Wilkinson, D.P.; Campbell, S.A.

    1996-12-31

    Cost reduction is a critical requirement for the widespread commercial application of proton exchange membrane fuel cell (PEMFC) technology. Significant stack cost savings are available through materials cost reductions and the development of low cost, high volume, manufacturing processes. This paper summarizes progress made by Ballard Power Systems and Johnson Matthey in the development of lower cost stack component technology. Single cell performance in Ballard Mark V hardware, of membrane electrode assemblies (NEAs) employing volume manufactured electrodes with catalyst loadings below 1.0 mgPtcm{sup -2}, are comparable to current stack MEAs comprising unsupported platinum based catalysts with loadings of 8.0 mgPtcm{sup -2}. In the advanced stack hardware, under development for motive and utility applications, the low cost MEAs exhibit high performance and minimal voltage decays after over 3,000 hours of stack operation. Cell to cell reproducibility is excellent, highlighting the high consistency of product available from the manufacturing processes. The MEAs represent a significant progress in the commercialization of PEMFC systems. Incorporation of the technology in commercial prototype stacks is underway.

  6. Nonterrestrial material processing and manufacturing of large space systems

    NASA Technical Reports Server (NTRS)

    Von Tiesenhausen, G.

    1979-01-01

    Nonterrestrial processing of materials and manufacturing of large space system components from preprocessed lunar materials at a manufacturing site in space is described. Lunar materials mined and preprocessed at the lunar resource complex will be flown to the space manufacturing facility (SMF), where together with supplementary terrestrial materials, they will be final processed and fabricated into space communication systems, solar cell blankets, radio frequency generators, and electrical equipment. Satellite Power System (SPS) material requirements and lunar material availability and utilization are detailed, and the SMF processing, refining, fabricating facilities, material flow and manpower requirements are described.

  7. Design and manufacturing tools for laser beam processing

    NASA Astrophysics Data System (ADS)

    Kaierle, Stefan; Fuerst, B.; Kittel, Jochen; Kreutz, Ernst-Wolfgang; Poprawe, Reinhart

    1999-08-01

    Today's situation with increasingly shorter time-to-market limits and growing variant spectra calls for advanced methods in the manufacturing domain. A big potential for gaining faster and better manufacturing results lies in the application of offline programming, especially if processing small lot sizes. Offline programming offers as main advantage a notable reduction of deadlock times of manufacturing systems. Applying this technology there is no time consumptive teach-in on the robots necessary. A technology module based on CAD/CAM technique--mainly for 3D welding applications--is described which permits to carry out offline path and process planning including simulation and visualization of the processing task.

  8. Improved electron injection and transport by use of baking soda as a low-cost, air-stable, n-dopant for solution-processed phosphorescent organic light-emitting diodes

    NASA Astrophysics Data System (ADS)

    Earmme, Taeshik; Jenekhe, Samson A.

    2013-06-01

    Sodium bicarbonate (baking soda, NaHCO3) is found to be an efficient low-cost, air-stable, and environmentally friendly n-dopant for electron-transport layer (ETL) in solution-processed phosphorescent organic light-emitting diodes (PhOLEDs). A 2.0-fold enhancement in power efficiency of blue PhOLEDs is observed by use of NaHCO3-doped 4,7-diphenyl-1,10-phenanthroline (BPhen) ETL. The bulk conductivity of NaHCO3-doped BPhen film is increased by 5 orders of magnitude. Enhanced performance of PhOLEDs is similarly observed by use of NaHCO3-doped 1,3,5-tris(m-pyrid-3-yl-phenyl)benzene ETL. These results demonstrate that sodium bicarbonate is an effective n-dopant in organic electronics.

  9. Process and quality verification controls for solid propellant manufacturing

    NASA Technical Reports Server (NTRS)

    Rogers, C. J.

    1983-01-01

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

  10. Process and quality verification controls for solid propellant manufacturing

    NASA Technical Reports Server (NTRS)

    Rogers, C. J.

    1983-01-01

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

  11. Proposal for a low cost close air support aircraft for the year 2000: The Raptor

    NASA Technical Reports Server (NTRS)

    Brown, Jerome D.; Dewitt, Ward S.; Mcdonald, Mark; Riley, John W.; Roberts, Anthony E.; Watson, Sean; Whelan, Margaret M.

    1991-01-01

    The Raptor is a proposed low cost Close Air Support (CAS) aircraft for the U.S. Military. The Raptor incorporates a 'cranked arrow' wing planform, and uses canards instead of a traditional horizontal tail. The Raptor is designed to be capable of responsive delivery of effective ordnance in close proximity to friendly ground forces during the day, night, and 'under the weather' conditions. Details are presented of the Raptor's mission, configuration, performance, stability and control, ground support, manufacturing, and overall cost to permit engineering evaluation of the proposed design. A description of the design process and analysis methods used is also provided.

  12. Room-Temperature Formation of Highly Crystalline Multication Perovskites for Efficient, Low-Cost Solar Cells.

    PubMed

    Matsui, Taisuke; Seo, Ji-Youn; Saliba, Michael; Zakeeruddin, Shaik M; Grätzel, Michael

    2017-04-01

    A room-temperature perovskite material yielding a power conversion efficiency of 18.1% (stabilized at 17.7%) is demonstrated by judicious selection of cations. Both cesium and methylammonium are necessary for room-temperature formamidinium-based perovskite to obtain the photoactive crystalline perovskite phase and high-quality crystals. This room-temperature-made perovskite material shows great potential for low-cost, large-scale manufacturing such as roll-to-roll processing. © 2017 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

  13. Integration Of Low-Cost Single-Frequency GPS Stations Using 'Spider' Technology Within Existing Dual-Frequency GPS Network at Soufrière Hills Volcano, Montserrat (West Indies): Processing And Results

    NASA Astrophysics Data System (ADS)

    Pascal, K.; Palamartchouk, K.; Lahusen, R. G.; Young, K.; Voight, B.

    2015-12-01

    Twenty years ago, began the eruption of the explosive Soufrière Hills Volcano, dominating the southern part of the island of Montserrat, West Indies. Five phases of effusive activity have now occurred, characterized by dome building and collapse, causing numerous evacuations and the emigration of half of the population. Over the years, the volcano monitoring network has greatly expanded. The GPS network, started from few geodetic markers, now consists of 14 continuous dual frequency GPS stations, distributed on and around the edifice, where topography and vegetation allow. The continuous GPS time series have given invaluable insight into the volcano behavior, notably revealing deflation/inflation cycles corresponding to phases and pauses of effusive activity, respectively. In 2014, collaboration of the CALIPSO Project (Penn State; NSF) with the Montserrat Volcano Observatory enriched the GPS and seismic monitoring networks with six 'spider' stations. The 'spiders', developed by R. Lahusen at Cascades Volcano Observatory, are designed to be deployed easily in rough areas and combine a low cost seismic station and a L1-only GPS station. To date, three 'spiders' have been deployed on Soufrière Hills Volcano, the closest at ~1 km from the volcanic conduit, adjacent to a lava lobe on the dome. Here we present the details of GPS data processing in a network consisting of both dual and single frequency receivers ('spiders') using GAMIT/GLOBK software. Processing together single and dual frequency data allowed their representation in a common reference frame, and a meaningful geophysical interpretation of all the available data. We also present the 'spiders' time series along with the results from the rest of the network and examine if any significant deformation, correlating with other manifestations of volcanic activity, has been recorded by the 'spiders' since deployment. Our results demonstrate that low cost GNSS equipment can serve as valuable components in volcano

  14. Wind turbine generator rotor blade concepts with low cost potential

    NASA Technical Reports Server (NTRS)

    Sullivan, T. L.; Cahill, T. P.; Griffee, D. G., Jr.; Gewehr, H. W.

    1977-01-01

    Four processed for producing blades are examined. Two use filament winding techniques and two involve filling a mold or form to produce all or part of a blade. The processes are described and a comparison is made of cost, material properties, design and free vibration characteristics. Conclusions are made regarding the feasibility of each process to produce low cost, structurally adequate blades.

  15. Improving manufacturability of an rf graded channel CMOS process for wireless applications

    NASA Astrophysics Data System (ADS)

    Lamey, Daniel J.; Mackie, Troy; Liang, Han-Bin; Ma, Jun; Robert, Georges; Jasper, Craig; Ngo, David; Papworth, Ken; Cheng, Sunny; Wilcock, Christy; Gurrola, Rosemary; Spears, Edward; Yeung, Bruce

    1998-09-01

    Motorola's Graded Channel CMOS (GCMOS) provides a low cost and highly integrated solution for mixed-mode and RF applications. The GCMOS transistor has demonstrated performance advantages over standard CMOS processes with the same physical gate length. The graded channel, fabricated using lateral diffusion, provides a deep submicron Leff even with a gate length of 0.6 micrometer. The technology is constructed using a process that is fully compatible with standard CMOS manufacturing. However, in order to assure adequate threshold control, the lateral diffusions must be well-behaved. This means that both the channel implant and the source/drain implant must be truly self-aligned, requiring good control of the implants as well as the gate electrode profile. For aggressively designed GCMOS devices, small deviations of the implant beam from normal incidence can lead to unacceptable shifts in threshold. The sources of such error, and current industry standard machine tolerances for each, are discussed. Strategies for ensuring adequate control include a regimen of in-line process monitors, approximate error cancellation of the channel and source/drain implants, and the use of quadrature implants. By using these strategies a manufacturable process has been achieved.

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

    NASA Technical Reports Server (NTRS)

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

    2002-01-01

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

  17. Low-cost process for hydrogen production

    DOEpatents

    Cha, C.H.; Bauer, H.F.; Grimes, R.W.

    1993-03-30

    A method is provided for producing hydrogen and carbon black from hydrocarbon gases comprising mixing the hydrocarbon gases with a source of carbon and applying radiofrequency energy to the mixture. The hydrocarbon gases and the carbon can both be the products of gasification of coal, particularly the mild gasification of coal. A method is also provided for producing hydrogen and carbon monoxide by treating a mixture of hydrocarbon gases and steam with radio-frequency energy.

  18. Low-cost process for hydrogen production

    DOEpatents

    Cha, Chang Y.; Bauer, Hans F.; Grimes, Robert W.

    1993-01-01

    A method is provided for producing hydrogen and carbon black from hydrocarbon gases comprising mixing the hydrocarbon gases with a source of carbon and applying radiofrequency energy to the mixture. The hydrocarbon gases and the carbon can both be the products of gasification of coal, particularly the mild gasification of coal. A method is also provided for producing hydrogen an carbon monoxide by treating a mixture of hydrocarbon gases and steam with radio-frequency energy.

  19. Low cost process heat recovery. Interim report

    SciTech Connect

    Theisen, P.; McCray, J.

    1980-01-01

    The objectives of this project are to analyze waste heat recovery potential, economic analysis, heat exchanger and system design, and computer analysis programs. The heating demand and heat recovery potential at a Madison neighborhood bakery was conducted. The building has steam heat and natural gas is used in the hot water heater, the cooking stoves, and in the baking oven. Heat recovery potential was analyzed based upon fuel consumption in the baking oven, flue gas temperature, mass flow rate, and hours of oven operation. The feasibility of waste heat recovery systems is analyzed using life cycle cost and life cycle savings. For a first approximation, hand calculations were performed for air-to-air flat plate, fin-plate, and liquid-to-air tube type heat exchangers using the temperature and mass flow data from a pizza restaurant in Madison. Then a heat exchanger analysis program was written in interactive BASIC. The analysis indicates that heat recovery using the flat-plate and fin-plate exchanger designs is technically feasible and yields high effectiveness. (MCW)

  20. Low Cost Solar Water Heater

    SciTech Connect

    William Bostic

    2005-12-16

    This project was directed by NREL to pursue development of an all polymer solar thermal collector. The proposed design utilized a dual sheet thermoform process to coincidentally form the absorber as well as the containment structure to support the glazing. It utilized ventilation to overcome stagnation degradation of the polymer materials.

  1. Manufacturing technology

    NASA Astrophysics Data System (ADS)

    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. A selective laser sintering process automates wax casting pattern fabrication. Numerical modeling improves the performance of a photoresist stripper (a simulation on a Cray supercomputer reveals the path of a uniform plasma). Improved mathematical models will help make the dream of low-cost ceramic composites come true.

  2. Circofer -- Low cost approach to DRI production

    SciTech Connect

    Weber, P.; Bresser, W.; Hirsch, M. )

    1994-09-01

    Lurgi's Circofer Process for reducing fine ores with coal in a Circulating Fluidized Bed (CFB) is a direct approach by using a widely applied and proven reactor in commercializing a state of the art technology. The technology is in response to the demand for a direct reduction process of the future by making possible: the use of low cost ore fines and inexpensive primary energy, fine coal; production of a high grade product used as feedstock by mini mills with the additional advantage of dilution of contaminants introduced by scrap; low environmental impact; and low specific investment costs due to the closed energy circuit. With the incorporation of the latest developments in CFB technology, Circofer offers excellent heat and mass transfer conditions and, consequently, improved gas and energy utilization. High gas conversions using recycle gas have a positive influence on the process economics whereby no export gas is produced. Sticking, accretion and reoxidation problems, which have plagued all previous attempts at developing direct reduction processes using fine ore and coal as a reductant, are avoided, essentially by operating with defined amounts of excess carbon and separation of the reduction and gasifying zones.

  3. Enhancing Manufacturing Process Education via Computer Simulation and Visualization

    ERIC Educational Resources Information Center

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

    2014-01-01

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

  4. Engineering aspects of rate-related processes in food manufacturing.

    PubMed

    Adachi, Shuji

    2015-01-01

    Many rate-related phenomena occur in food manufacturing processes. This review addresses four of them, all of which are topics that the author has studied in order to design food manufacturing processes that are favorable from the standpoint of food engineering. They include chromatographic separation through continuous separation with a simulated moving adsorber, lipid oxidation kinetics in emulsions and microencapsulated systems, kinetic analysis and extraction in subcritical water, and water migration in pasta.

  5. Development of metamaterial based low cost passive wireless temperature sensor

    NASA Astrophysics Data System (ADS)

    Karim, Hasanul; Shuvo, Mohammad Arif Ishtiaq; Delfin, Diego; Lin, Yirong; Choudhuri, Ahsan; Rumpf, R. C.

    2014-03-01

    Wireless passive temperature sensors are gaining increasing attention due to the ever-growing need of precise monitoring of temperature in high temperature energy conversion systems such as gas turbines and coal-based power plants. Unfortunately, the harsh environment such as high temperature and corrosive atmosphere present in these systems limits current solutions. In order to alleviate these issues, this paper presents the design, simulation, and manufacturing process of a low cost, passive, and wireless temperature sensor that can withstand high temperature and harsh environment. The temperature sensor was designed following the principle of metamaterials by utilizing Closed Ring Resonators (CRR) embedded in a dielectric matrix. The proposed wireless, passive temperature sensor behaves like an LC circuit that has a resonance frequency that depends on temperature. A full wave electromagnetic solver Ansys Ansoft HFSS was used to perform simulations to determine the optimum dimensions and geometry of the sensor unit. The sensor unit was prepared by conventional powder-binder compression method. Commercially available metal washers were used as CRR structures and Barium Titanate (BTO) was used as the dielectric materials. Response of the fabricated sensor at room temperature was analyzed using a pair of horn antenna connected with a network analyzer.

  6. Defective Reduction in Frozen Pie Manufacturing Process

    NASA Astrophysics Data System (ADS)

    Nooted, Oranuch; Tangjitsitcharoen, Somkiat

    2017-06-01

    The frozen pie production has a lot of defects resulting in high production cost. Failure mode and effect analysis (FMEA) technique has been applied to improve the frozen pie process. Pareto chart is also used to determine the major defects of frozen pie. There are 3 main processes that cause the defects which are the 1st freezing to glazing process, the forming process, and the folding process. The Risk Priority Number (RPN) obtained from FMEA is analyzed to reduce the defects. If RPN of each cause exceeds 45, the process will be considered to be improved and selected for the corrective and preventive actions. The results showed that RPN values decreased after the correction. Therefore, the implementation of FMEA technique can help to improve the performance of frozen pie process and reduce the defects approximately 51.9%.

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

    NASA Astrophysics Data System (ADS)

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

    2016-05-01

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

  8. 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.

  9. MAQVIS: a low-cost flexible industrial-inspection-system

    NASA Astrophysics Data System (ADS)

    Davies, Roger; Carvalho, Fernando D.; Freitas, Jose C. A.; Rodrigues, Fernando C.

    1995-08-01

    The paper describes a low-cost industrial inspection system (MAQVIS) developed by the authors and based on a personal computer equipped with a simple frame grabber and a digital input/output controller. Originally developed under a contract with an industrial partner for inspecting text and symbols printed on electronic components, MAQVIS can be applied to many inspection tasks since it is based on a generic template matching algorithm. The task of inspection is broken down into two steps; first, location of the symbols that must be verified in the image and second, verification of the symbols using criteria previously defined by the operator during the set-up phase. The first step is important in many applications where it is impossible, due to lack of mechanical precision, to guarantee that the object being inspected (or the symbols printed upon it) will always appear in the same position relative to the camera. The second step produces a pass/fail result for each symbol and finally for the component itself. MAQVIS can be programmed to display failed symbols on-screen and indicate the reason for the failure, or simply divert the offending component to the reject bin. Both the location and the verification steps are performed on gray-level images using algorithms specifically developed for this application. Statistical information about the number of failed components and the failure rate of individual symbols is generated and can be used to trace problems in the manufacturing process. The paper describes the system in general, and specifically the template matching algorithm used to locate symbols in the image and also the verification algorithm that validates each symbol as it is found. Results of tests performed using the system on the production line of an electronic components manufacturer are also presented.

  10. Industrial web inspection for manufacturing process understanding and control

    NASA Astrophysics Data System (ADS)

    Xu, Wenyuan; Floeder, Steven P.

    1999-03-01

    Many industrial manufacturing processes are not well understood and are treated as `black art' with few experts able to control the process and ensure product quality. However, modern manufacturing companies are finding it increasingly difficult to compete in the global marketplace without better process understanding and control. Automated inspection systems for general manufacturing have become more feasible through technical advances, primarily in sensor and computing technology. However, these systems have been used almost exclusively for the detection and subsequent removal of well defined, discrete defects from the product; thus guaranteeing high quality for the customer. This paper describes a larger opportunity to affect operations by employing web inspection techniques to dynamically analyze manufacturing conditions rather than just detecting the presence of defective material. One can then keep the process under better control, thereby eliminating defects, ensuring product quality, and optimizing manufacturing time on the production line. Specific image and data processing techniques will be illustrated including product uniformity metrics, automatic determination of thresholds for blob analysis, and localization of repeating defects within production data. The benefit of these techniques will be demonstrated through `real-world' examples of web-based manufactured products.

  11. Electric poling-assisted additive manufacturing process for PVDF polymer-based piezoelectric device applications

    NASA Astrophysics Data System (ADS)

    Lee, ChaBum; Tarbutton, Joshua A.

    2014-09-01

    This paper presents a new additive manufacturing (AM) process to directly and continuously print piezoelectric devices from polyvinylidene fluoride (PVDF) polymeric filament rods under a strong electric field. This process, called ‘electric poling-assisted additive manufacturing or EPAM, combines AM and electric poling processes and is able to fabricate free-form shape piezoelectric devices continuously. In this process, the PVDF polymer dipoles remain well-aligned and uniform over a large area in a single design, production and fabrication step. During EPAM process, molten PVDF polymer is simultaneously mechanically stresses in-situ by the leading nozzle and electrically poled by applying high electric field under high temperature. The EPAM system was constructed to directly print piezoelectric structures from PVDF polymeric filament while applying high electric field between nozzle tip and printing bed in AM machine. Piezoelectric devices were successfully fabricated using the EPAM process. The crystalline phase transitions that occurred from the process were identified by using the Fourier transform infrared spectroscope. The results indicate that devices printed under a strong electric field become piezoelectric during the EPAM process and that stronger electric fields result in greater piezoelectricity as marked by the electrical response and the formation of sharper peaks at the polar β crystalline wavenumber of the PVDF polymer. Performing this process in the absence of an electric field does not result in dipole alignment of PVDF polymer. The EPAM process is expected to lead to the widespread use of AM to fabricate a variety of piezoelectric PVDF polymer-based devices for sensing, actuation and energy harvesting applications with simple, low cost, single processing and fabrication step.

  12. Thermoplastic rubberlike material produced at low cost

    NASA Technical Reports Server (NTRS)

    Hendel, F. J.

    1966-01-01

    Thermoplastic rubberlike material is prepared by blending a copolymer of ethylene and vinyl acetate with asphalt and a petroleum distillate. This low cost material is easily molded or extruded and is compatible with a variety of fillers.

  13. A Low Cost TDRSS Compatible Transmitter Option

    NASA Technical Reports Server (NTRS)

    Whiteman, Don

    2005-01-01

    The NASA Space-based Telemetry and Range Safety (STARS) program has developed and tested a low cost Ku-Band transmitter alternative for TDRSS applications based on an existing IRIG shaped offset quaternary phase shift keying (SOQPSK) transmitter. This paper presents information related to the implementation of this low cost system, as well as performance measurements of the alternative TDRSS transmitter system compared with an existing QPSK TDRSS transmitter.

  14. Integrated study of sustainability technological-economic in manufacturing processes

    NASA Astrophysics Data System (ADS)

    Peinado, B.; Sevilla, L.; Sebastián, M. A.

    2012-04-01

    Nowadays, some of the key aspects to consider during a manufacturing process are the ones related to its energy study. Choosing the most appropriate process allows to optimize not only technological and economic, but also it influence in sustainability and suitability of the process. In the current work a comparative technological-economic analysis between forming processes and machining processes is developed. We can find that drawing (forming process) has more advantages in most cases.

  15. Cleaning Process Development for Metallic Additively Manufactured Parts

    NASA Technical Reports Server (NTRS)

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

    2014-01-01

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

  16. Real time intelligent process control system for thin film solar cell manufacturing

    SciTech Connect

    George Atanasoff

    2010-10-29

    This project addresses the problem of lower solar conversion efficiency and waste in the typical solar cell manufacturing process. The work from the proposed development will lead toward developing a system which should be able to increase solar panel conversion efficiency by an additional 12-15% resulting in lower cost panels, increased solar technology adoption, reduced carbon emissions and reduced dependency on foreign oil. All solar cell manufacturing processes today suffer from manufacturing inefficiencies that currently lead to lower product quality and lower conversion efficiency, increased product cost and greater material and energy consumption. This results in slower solar energy adoption and extends the time solar cells will reach grid parity with traditional energy sources. The thin film solar panel manufacturers struggle on a daily basis with the problem of thin film thickness non-uniformity and other parameters variances over the deposited substrates, which significantly degrade their manufacturing yield and quality. Optical monitoring of the thin films during the process of the film deposition is widely perceived as a necessary step towards resolving the non-uniformity and non-homogeneity problem. In order to enable the development of an optical control system for solar cell manufacturing, a new type of low cost optical sensor is needed, able to acquire local information about the panel under deposition and measure its local characteristics, including the light scattering in very close proximity to the surface of the film. This information cannot be obtained by monitoring from outside the deposition chamber (as traditional monitoring systems do) due to the significant signal attenuation and loss of its scattering component before the reflected beam reaches the detector. In addition, it would be too costly to install traditional external in-situ monitoring systems to perform any real-time monitoring over large solar panels, since it would require

  17. Laser processing for manufacturing nanocarbon materials

    NASA Astrophysics Data System (ADS)

    Van, Hai Hoang

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

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

    PubMed

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

    2016-05-01

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

  19. Encapsulation Processing and Manufacturing Yield Analysis

    NASA Technical Reports Server (NTRS)

    Willis, P.

    1985-01-01

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

  20. Fast Paced, Low Cost Projects at MSFC

    NASA Technical Reports Server (NTRS)

    Watson-Morgan, Lisa; Clinton, Raymond

    2012-01-01

    What does an orbiting microsatellite, a robotic lander and a ruggedized camera and telescope have in common? They are all fast paced, low cost projects managed by Marshall Space Flight Center (MSFC) teamed with successful industry partners. MSFC has long been synonymous with human space flight large propulsion programs, engineering acumen and risk intolerance. However, there is a growing portfolio/product line within MSFC that focuses on these smaller, fast paced projects. While launching anything into space is expensive, using a managed risk posture, holding to schedule and keeping costs low by stopping at egood enough f were key elements to their success. Risk is defined as the possibility of loss or failure per Merriam Webster. The National Aeronautics and Space Administration (NASA) defines risk using procedural requirement 8705.4 and establishes eclasses f to discern the acceptable risk per a project. It states a Class D risk has a medium to significant risk of not achieving mission success. MSFC, along with industry partners, has created a niche in Class D efforts. How did the big, cautious MSFC succeed on these projects that embodied the antithesis of its heritage in human space flight? A key factor toward these successful projects was innovative industry partners such as Dynetics Corporation, University of Alabama in Huntsville (UAHuntsville), Johns Hopkins Applied Physics Laboratory (JHU APL), Teledyne Brown Engineering (TBE), Von Braun Center for Science and Innovation (VCSI), SAIC, and Jacobs. Fast Affordable Satellite Technology (FastSat HSV01) is a low earth orbit microsatellite that houses six instruments with the primary scientific objective of earth observation and technology demonstration. The team was comprised of Dynetics, UAHuntsvile, SAIC, Goddard Space Flight Center (GSFC) and VCSI with the United States Air Force Space Test Program as the customer. The team completed design, development, manufacturing, environmental test and integration in

  1. Modeling of additive manufacturing processes for metals: Challenges and opportunities

    DOE PAGES

    Francois, Marianne M.; Sun, Amy; King, Wayne E.; ...

    2017-01-09

    Here, with the technology being developed to manufacture metallic parts using increasingly advanced additive manufacturing processes, a new era has opened up for designing novel structural materials, from designing shapes and complex geometries to controlling the microstructure (alloy composition and morphology). The material properties used within specific structural components are also designable in order to meet specific performance requirements that are not imaginable with traditional metal forming and machining (subtractive) techniques.

  2. Ramp Technology and Intelligent Processing in Small Manufacturing

    NASA Technical Reports Server (NTRS)

    Rentz, Richard E.

    1992-01-01

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

  3. Ramp Technology and Intelligent Processing in Small Manufacturing

    NASA Technical Reports Server (NTRS)

    Rentz, Richard E.

    1992-01-01

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

  4. Framework for Sustainability Performance Assessment for Manufacturing Processes- A Review

    NASA Astrophysics Data System (ADS)

    Singh, K.; Sultan, I.

    2017-07-01

    Manufacturing industries are facing tough competition due to increasing raw material cost and depleting natural resources. There is great pressure on the industry to produce environmental friendly products using environmental friendly processes. To address these issues modern manufacturing industries are focusing on sustainable manufacturing. To develop more sustainable societies, industries need to better understand how to respond to environmental, economic and social challenges. This paper proposed some framework and tools that accelerate the transition towards a sustainable system. The developed framework will be beneficial for sustainability assessment comparing different plans alongside material properties, ultimately helping the manufacturing industries to reduce the carbon emissions and material waste, besides improving energy efficiency. It is expected that this would be highly beneficial for determination of environmental impact of a process at early design stages. Therefore, it would greatly help the manufacturing industries for selection of process plan based on sustainable indices. Overall objective of this paper would have good impact on reducing air emissions and protecting environment. We expect this work to contribute to the development of a standard reference methodology to help further sustainability in the manufacturing sector.

  5. NASA's In-Space Manufacturing Project: Materials and Manufacturing Process Development Update

    NASA Technical Reports Server (NTRS)

    Prater, Tracie; Bean, Quincy; Werkheiser, Niki; Ledbetter, Frank

    2017-01-01

    The mission of NASA's In-Space Manufacturing (ISM) project is to identify, design, and implement on-demand, sustainable manufacturing solutions for fabrication, maintenance and repair during exploration missions. ISM has undertaken a phased strategy of incrementally increasing manufacturing capabilities to achieve this goal. The ISM project began with the development of the first 3D printer for the International Space Station. To date, the printer has completed two phases of flight operations. Results from phase I specimens indicated some differences in material properties between ground-processed and ISS-processed specimens, but results of follow-on analyses of these parts and a ground-based study with an equivalent printer strongly indicate that this variability is likely attributable to differences in manufacturing process settings between the ground and flight prints rather than microgravity effects on the fused deposition modeling (FDM) process. Analysis of phase II specimens from the 3D Printing in Zero G tech demo, which shed further light on the sources of material variability, will be presented. The ISM project has also developed a materials characterization plan for the Additive Manufacturing Facility, the follow-on commercial multimaterial 3D printing facility developed for ISS by Made in Space. This work will yield a suite of characteristic property values that can inform use of AMF by space system designers. Other project activities include development of an integrated 3D printer and recycler, known as the Refabricator, by Tethers Unlimited, which will be operational on ISS in 2018. The project also recently issued a broad area announcement for a multimaterial fabrication laboratory, which may include in-space manufacturing capabilities for metals, electronics, and polymeric materials, to be deployed on ISS in the 2022 timeframe.

  6. Post Processing Methods used to Improve Surface Finish of Products which are Manufactured by Additive Manufacturing Technologies: A Review

    NASA Astrophysics Data System (ADS)

    Kumbhar, N. N.; Mulay, A. V.

    2016-08-01

    The Additive Manufacturing (AM) processes open the possibility to go directly from Computer-Aided Design (CAD) to a physical prototype. These prototypes are used as test models before it is finalized as well as sometimes as a final product. Additive Manufacturing has many advantages over the traditional process used to develop a product such as allowing early customer involvement in product development, complex shape generation and also save time as well as money. Additive manufacturing also possess some special challenges that are usually worth overcoming such as Poor Surface quality, Physical Properties and use of specific raw material for manufacturing. To improve the surface quality several attempts had been made by controlling various process parameters of Additive manufacturing and also applying different post processing techniques on components manufactured by Additive manufacturing. The main objective of this work is to document an extensive literature review in the general area of post processing techniques which are used in Additive manufacturing.

  7. Low Cost Ozone Generation in Corona Streamer

    NASA Astrophysics Data System (ADS)

    Potapkin, B.; Knijnik, A.; Korobtsev, S.; Medvedev, D.; Shiryaevsky, V.

    1998-10-01

    There is an interesting experimental result (S. Korobtsev, D. Medvedev et al , ISPC 13,1997, vol.2, p. 755. ) for low cost ozone generation (7-8 eV/molec in air) in streamer with dominant energy consumption in streamer channel (where molecular vibrations are excited). For explanation we considered the effect of vibrational pumping saturation, when vibrational energy was increased (due to the super-elastic processes) and the change of electron cross-sections due to vibrational excitation, which could also lead to efficiency growth. Boltzmann equation solution showed that both effects required too large energy consumption in discharge (>0.7 eV/mole). Thus we went to conclusion, that some direct energy transfer from vibrational degrees of freedom to electronic degrees should take place. One of the possible new mechanisms is the reaction: N2 (v)+N2 (v)=N2 (A)+N_2. Our numerical model of vibrational kinetic in air with this reaction showed that dependence of ozone generation cost upon energy consumption in streamer channel had a minimum with the value of the cost about 8-10 eV/molec.

  8. Modeling Manufacturing Processes to Mitigate Technological Risk

    SciTech Connect

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

    1999-10-24

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

  9. A novel process for manufacture of methanol

    SciTech Connect

    Tierney, J.W.; Wender, I.

    1990-01-01

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

  10. Mining manufacturing data for discovery of high productivity process characteristics.

    PubMed

    Charaniya, Salim; Le, Huong; Rangwala, Huzefa; Mills, Keri; Johnson, Kevin; Karypis, George; Hu, Wei-Shou

    2010-06-01

    Modern manufacturing facilities for bioproducts are highly automated with advanced process monitoring and data archiving systems. The time dynamics of hundreds of process parameters and outcome variables over a large number of production runs are archived in the data warehouse. This vast amount of data is a vital resource to comprehend the complex characteristics of bioprocesses and enhance production robustness. Cell culture process data from 108 'trains' comprising production as well as inoculum bioreactors from Genentech's manufacturing facility were investigated. Each run constitutes over one-hundred on-line and off-line temporal parameters. A kernel-based approach combined with a maximum margin-based support vector regression algorithm was used to integrate all the process parameters and develop predictive models for a key cell culture performance parameter. The model was also used to identify and rank process parameters according to their relevance in predicting process outcome. Evaluation of cell culture stage-specific models indicates that production performance can be reliably predicted days prior to harvest. Strong associations between several temporal parameters at various manufacturing stages and final process outcome were uncovered. This model-based data mining represents an important step forward in establishing a process data-driven knowledge discovery in bioprocesses. Implementation of this methodology on the manufacturing floor can facilitate a real-time decision making process and thereby improve the robustness of large scale bioprocesses. 2010 Elsevier B.V. All rights reserved.

  11. Nitrogen removal from pharmaceutical manufacturing wastewater via nitrite and the process optimization with on-line control.

    PubMed

    Li, Y Z; Peng, C Y; Peng, Y Z; Wang, P

    2004-01-01

    In this study, laboratory scale experiments were conducted to investigate the nitrogen removal from pharmaceutical manufacturing wastewater. The results indicate that by selective inhibition of free ammonia on oxidizers, nitrogen removal can be achieved by nitritation and denitritation process. The nitrite ratio was above 98% in the aerobic stage and the nitrogen removal efficiency was about 99%. The complete ammonia removal corresponded exactly to the "Ammonia Valley" in the pH versus time graphic and the anoxic reaction was completed when the "Nitrite Knee" appeared in the ORP versus time graphic. Optimization of the SBR cycle by step-feed and on-line control with pH and ORP strategy allowed the carbon and energy saving. The easy operation and the low cost make the SBR system an interesting option for the biological nitrogen removal from the pharmaceutical manufacturing wastewater.

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

    SciTech Connect

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

    1998-02-01

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

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

    SciTech Connect

    E.A. Eastwood

    2009-11-01

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

  14. Recovery Act: Low Cost Integrated Substrate for OLED Lighting Development

    SciTech Connect

    Benton, Scott; Bhandari, Abhinav

    2012-12-26

    PPG pursued the development of an integrated substrate, including the anode, external, and internal extraction layers. The objective of PPG's program was to achieve cost reductions by displacing the existing expensive borosilicate or double-side polished float glass substrates and developing alternative electrodes and scalable light extraction layer technologies through focused and short-term applied research. One of the key highlights of the project was proving the feasibility of using PPG's high transmission Solarphire® float glass as a substrate to consistently achieve organic lightemitting diode (OLED) devices with good performance and high yields. Under this program, four low-cost alternatives to the Indium Tin Oxide (ITO) anode were investigated using pilot-scale magnetron sputtered vacuum deposition (MSVD) and chemical vapor deposition (CVD) technologies. The anodes were evaluated by fabricating small and large phosphorescent organic lightemitting diode (PHOLED) devices at Universal Display Corporation (UDC). The device performance and life-times comparable to commercially available ITO anodes were demonstrated. A cost-benefit analysis was performed to down-select two anodes for further low-cost process development. Additionally, PPG developed and evaluated a number of scalable and compatible internal and external extraction layer concepts such as scattering layers on the outside of the glass substrate or between the transparent anode and the glass interface. In one external extraction layer (EEL) approach, sol-gel sprayed pyrolytic coatings were deposited using lab scale equipment by hand or automated spraying of sol-gel solutions on hot glass, followed by optimizing of scattering with minimal absorption. In another EEL approach, PPG tested large-area glass texturing by scratching a glass surface with an abrasive roller and acid etching. Efficacy enhancements of 1.27x were demonstrated using white PHOLED devices for 2.0mm substrates which are at par with

  15. Final Air Toxics Standards for Clay Ceramics Manufacturing, Glass Manufacturing, and Secondary Nonferrous Metals Processing Area Sources Fact Sheet

    EPA Pesticide Factsheets

    This page contains a December 2007 fact sheet with information regarding the National Emissions Standards for Hazardous Air Pollutants (NESHAP) for Clay Ceramics Manufacturing, Glass Manufacturing, and Secondary Nonferrous Metals Processing Area Sources

  16. Manufacturing Squares: An Integrative Statistical Process Control Exercise

    ERIC Educational Resources Information Center

    Coy, Steven P.

    2016-01-01

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

  17. Manufacturing Squares: An Integrative Statistical Process Control Exercise

    ERIC Educational Resources Information Center

    Coy, Steven P.

    2016-01-01

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

  18. Manufacturing Processes for Various Shaped Consumable Ordnance Products

    DTIC Science & Technology

    1982-10-01

    Spacers Spiral wrapping Felting...manufacture of a variety of different shaped combustible ordnance products. Matched metal molding and spiral wrapping processes were utilized...higher product off-press weight and slick feeling of the product’s outer surface. The process of spiral wrapping with nitro- cellulose paper was

  19. Continuous Flow in Labour-Intensive Manufacturing Process

    NASA Astrophysics Data System (ADS)

    Pacheco Eng., Jhonny; Carbajal MSc., Eduardo; Stoll-Ing., Cesar, Dr.

    2017-06-01

    A continuous-flow manufacturing represents the peak of standard production, and usually it means high production in a strict line production. Furthermore, low-tech industry demands high labour-intensive, in this context the efficient of the line production is tied at the job shop organization. Labour-intensive manufacturing processes are a common characteristic for developing countries. This research aims to propose a methodology for production planning in order to fulfilment a variable monthly production quota. The main idea is to use a clock as orchestra director in order to synchronize the rate time (takt time) of customer demand with the manufacturing time. In this way, the study is able to propose a stark reduction of stock in process, over-processing, and unnecessary variability.

  20. Application of Contact Mode AFM to Manufacturing Processes

    NASA Astrophysics Data System (ADS)

    Giordano, Michael A.; Schmid, Steven R.

    A review of the application of contact mode atomic force microscopy (AFM) to manufacturing processes is presented. A brief introduction to common experimental techniques including hardness, scratch, and wear testing is presented, with a discussion of challenges in the extension of manufacturing scale investigations to the AFM. Differences between the macro- and nanoscales tests are discussed, including indentation size effects and their importance in the simulation of processes such as grinding. The basics of lubrication theory are presented and friction force microscopy is introduced as a method of investigating metal forming lubrication on the nano- and microscales that directly simulates tooling/workpiece asperity interactions. These concepts are followed by a discussion of their application to macroscale industrial manufacturing processes and direct correlations are made.

  1. A novel passivation process of silicon nanowires by a low-cost PECVD technique for deposition of hydrogenated silicon nitride using SiH4 and N2 as precursor gases

    NASA Astrophysics Data System (ADS)

    Bouaziz, Lamia; Dridi, Donia; Karyaoui, Mokhtar; Angelova, Todora; Sanchez Plaza, Guillermo; Chtourou, Radhouane

    2017-03-01

    In this work, a different SiNx passivation process of silicon nanowires has been opted for the deposition of a hydrogenated silicon nitride (SiNx:H) by a low-cost plasma enhanced chemical vapor deposition (PECVD) using silane ( SiH4 and nitrogen ( N2 as reactive gases. This study is focused on the effect of the gas flow ratio on chemical composition, morphological, optical and optoelectronic properties of silicon nanowires. The existence of Si-N and Si-H bonds was proven by the Fourier transmission infrared (FTIR) spectrum. Morphological structures were shown by scanning electron microscopy (SEM), and the roughness was investigated by atomic force microscopy (AFM). A low reflectivity less than 6% in the wavelength range 250-1200nm has been shown by UV-visible spectroscopy. Furthermore, the thickness and the refractive index of the passivation layer is determined by ellipsometry measurements. As a result, an improvement in minority carrier lifetime has been obtained by reducing surface recombination of silicon nanowires.

  2. Low-cost robotic arm control

    NASA Astrophysics Data System (ADS)

    Rogers, John R.

    2008-04-01

    A low-cost robotic arm and controller system is presented. The controller is a desktop model of the robotic arm with the same degrees of freedom whose joints are equipped with sensors. Manipulating the controller by hand causes the robotic arm to mimic the movement in maser-slave fashion. The system takes advantage of the low cost and wide availability of hobby radio control components and uses a low-cost, easy-to-program microprocessor. The system is implemented with a video camera on the robotic arm, and the arm is mounted on an unmanned omnidirectional vehicle inspection robot. With a camera on the end of a robot arm, the vehicle inspection system can reach difficult to-access regions of the vehicle underbody. Learning to manipulate the robot arm with this controller is faster than learning with a traditional joystick. Limitations of the microcontroller are discussed, and suggestions for further development of the robot arm and control are made.

  3. Ultrasonic-assisted manufacturing processes: variational model and numerical simulations.

    PubMed

    Siddiq, Amir; El Sayed, Tamer

    2012-04-01

    We present a computational study of ultrasonic assisted manufacturing processes including sheet metal forming, upsetting, and wire drawing. A fully variational porous plasticity model is modified to include ultrasonic softening effects and then utilized to account for instantaneous softening when ultrasonic energy is applied during deformation. Material model parameters are identified via inverse modeling, i.e. by using experimental data. The versatility and predictive ability of the model are demonstrated and the effect of ultrasonic intensity on the manufacturing process at hand is investigated and compared qualitatively with experimental results reported in the literature.

  4. Process development status report for advanced manufacturing projects

    SciTech Connect

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

    1990-03-30

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

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

    NASA Technical Reports Server (NTRS)

    Driggers, G. W.

    1977-01-01

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

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

    NASA Technical Reports Server (NTRS)

    Driggers, G. W.

    1977-01-01

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

  7. Increasing component functionality via multi-process additive manufacturing

    NASA Astrophysics Data System (ADS)

    Coronel, Jose L.; Fehr, Katherine H.; Kelly, Dominic D.; Espalin, David; Wicker, Ryan B.

    2017-05-01

    Additively manufactured components, although extensively customizable, are often limited in functionality. Multi-process additive manufacturing (AM) grants the ability to increase the functionality of components via subtractive manufacturing, wire embedding, foil embedding and pick and place. These processes are scalable to include several platforms ranging from desktop to large area printers. The Multi3D System is highlighted, possessing the capability to perform the above mentioned processes, all while transferring a fabricated component with a robotic arm. Work was conducted to fabricate a patent inspired, printed missile seeker. The seeker demonstrated the advantage of multi-process AM via introduction of the pick and place process. Wire embedding was also explored, with the successful interconnect of two layers of embedded wires in different planes. A final demonstration of a printed contour bracket, served to show the reduction of surface roughness on a printed part is 87.5% when subtractive manufacturing is implemented in tandem with AM. Functionality of the components on all the cases was improved. Results included optical components embedded within the printed housing, wires embedded with interconnection, and reduced surface roughness. These results highlight the improved functionality of components through multi-process AM, specifically through work conducted with the Multi3D System.

  8. Low Cost, Advanced, Integrated Microcontroller Training Kit

    NASA Astrophysics Data System (ADS)

    Somantri, Y.; Fushshilat, I.

    2017-03-01

    This paper describes the design of an AVR microcontroller training kit with a low cost and the additional feature of an integrated downloader. The main components of this device include: Microcontroller, terminal, I/O keypad, push button, LED, seven segment display, LCD, motor stepper, and sensors. The device configuration results in low cost and ease of use; this device is suitable for laboratories with limited funding. The device can also be used as a training kit for the teaching and learning of microcontrollers.

  9. Low cost microfluidic device based on cotton threads for electroanalytical application.

    PubMed

    Agustini, Deonir; Bergamini, Márcio F; Marcolino-Junior, Luiz Humberto

    2016-01-21

    Microfluidic devices are an interesting alternative for performing analytical assays, due to the speed of analyses, reduced sample, reagent and solvent consumption and less waste generation. However, the high manufacturing costs still prevent the massive use of these devices worldwide. Here, we present the construction of a low cost microfluidic thread-based electroanalytical device (μTED), employing extremely cheap materials and a manufacturing process free of equipment. The microfluidic channels were built with cotton threads and the estimated cost per device was only $0.39. The flow of solutions (1.12 μL s(-1)) is generated spontaneously due to the capillary forces, eliminating the use of any pumping system. To demonstrate the analytical performance of the μTED, a simultaneous determination of acetaminophen (ACT) and diclofenac (DCF) was performed by multiple pulse amperometry (MPA). A linear dynamic range (LDR) of 10 to 320 μmol L(-1) for both species, a limit of detection (LOD) and a limit of quantitation (LOQ) of 1.4 and 4.7 μmol L(-1) and 2.5 and 8.3 μmol L(-1) for ACT and DCF, respectively, as well as an analytical frequency of 45 injections per hour were reached. Thus, the proposed device has shown potential to extend the use of microfluidic analytical devices, due to its simplicity, low cost and good analytical performance.

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

    NASA Astrophysics Data System (ADS)

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

    2013-12-01

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

  11. Monitoring of manufacturing processes in the automotive industry using indoor location system

    NASA Astrophysics Data System (ADS)

    Ionescu, LM; Belu, N.; Rachieru, N.; Mazăre, AG; Anghel, D.-C.

    2016-08-01

    This paper presents a method for locating the operators, equipment and parts using radio communications systems. Specifically there will be radio transceiver arranged in a network of active and passive radio receivers placed on personnel, equipment or parts. Based on a radio triangulation method, it is determined the location of the all resources and parts involved in manufacturing process. The transceivers communicate with each other via “routers” - also components of the network. Such a structure may extend over large distances even in indoor spaces where there are obstacles (walls between rooms). The location is done by determining the power of transmission signal for at least three end points. The receiver position is then transmitted over the network through routers, to a central server where all positions of the resources are centralized. Our solution is a non-invasive and low cost method for determining resource position in the factory. The system can be used for both resource planning production for current process more efficient and for further analysis of the movement of resources during previous processes with possible adjustments to the workspace and re-planning of resources for future processes.

  12. Monitoring Chlorfenapyr in Green Tea during the Manufacturing Process

    NASA Astrophysics Data System (ADS)

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

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-05-01

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

  14. Development of Probabilistic Structural Analysis Integrated with Manufacturing Processes

    NASA Technical Reports Server (NTRS)

    Pai, Shantaram S.; Nagpal, Vinod K.

    2007-01-01

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

  15. Enery Efficient Press and Sinter of Titanium Powder for Low-Cost Components in Vehicle Applications

    SciTech Connect

    Thomas Zwitter; Phillip Nash; Xiaoyan Xu; Chadwick Johnson

    2011-03-31

    This is the final technical report for the Department of Energy NETL project NT01931 Energy Efficient Press and Sinter of Titanium Powder for Low-Cost Components in Vehicle Applications. Titanium has been identified as one of the key materials with the required strength that can reduce the weight of automotive components and thereby reduce fuel consumption. Working with newly developed sources of titanium powder, Webster-Hoff will develop the processing technology to manufacture low cost vehicle components using the single press/single sinter techniques developed for iron based powder metallurgy today. Working with an automotive or truck manufacturer, Webster-Hoff will demonstrate the feasibility of manufacturing a press and sinter titanium component for a vehicle application. The project objective is two-fold, to develop the technology for manufacturing press and sinter titanium components, and to demonstrate the feasibility of producing a titanium component for a vehicle application. The lowest cost method for converting metal powder into a net shape part is the Powder Metallurgy Press and Sinter Process. The method involves compaction of the metal powder in a tool (usually a die and punches, upper and lower) at a high pressure (up to 60 TSI or 827 MPa) to form a green compact with the net shape of the final component. The powder in the green compact is held together by the compression bonds between the powder particles. The sinter process then converts the green compact to a metallurgically bonded net shape part through the process of solid state diffusion. The goal of this project is to expand the understanding and application of press and sinter technology to Titanium Powder applications, developing techniques to manufacture net shape Titanium components via the press and sinter process. In addition, working with a vehicle manufacturer, demonstrate the feasibility of producing a titanium component for a vehicle. This is not a research program, but rather a

  16. Thermodynamic analysis of resources used in manufacturing processes.

    PubMed

    Gutowski, Timothy G; Branham, Matthew S; Dahmus, Jeffrey B; Jones, Alissa J; Thiriez, Alexandre

    2009-03-01

    In this study we use a thermodynamic framework to characterize the material and energy resources used in manufacturing processes. The analysis and data span a wide range of processes from "conventional" processes such as machining, casting, and injection molding, to the so-called "advanced machining" processes such as electrical discharge machining and abrasive waterjet machining, and to the vapor-phase processes used in semiconductor and nanomaterials fabrication. In all, 20 processes are analyzed. The results show that the intensity of materials and energy used per unit of mass of material processed (measured either as specific energy or exergy) has increased by at least 6 orders of magnitude over the past several decades. The increase of material/energy intensity use has been primarily a consequence of the introduction of new manufacturing processes, rather than changes in traditional technologies. This phenomenon has been driven by the desire for precise small-scale devices and product features and enabled by stable and declining material and energy prices over this period. We illustrate the relevance of thermodynamics (including exergy analysis) for all processes in spite of the fact that long-lasting focus in manufacturing has been on product quality--not necessarily energy/material conversion efficiency. We promote the use of thermodynamics tools for analysis of manufacturing processes within the context of rapidly increasing relevance of sustainable human enterprises. We confirm that exergy analysis can be used to identify where resources are lost in these processes, which is the first step in proposing and/or redesigning new more efficient processes.

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

    SciTech Connect

    Geisz, J. F.

    2012-11-01

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

  18. Porosity of additive manufacturing parts for process monitoring

    SciTech Connect

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

    2014-02-18

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

  19. Porosity of additive manufacturing parts for process monitoring

    NASA Astrophysics Data System (ADS)

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

    2014-02-01

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

  20. Testing low cost anaerobic digestion (AD) systems

    USDA-ARS?s Scientific Manuscript database

    To evaluate the potential for low technology and low cost digesters for small dairies, BARC and researchers from the University of Maryland installed six modified Taiwanese-model field-scale (FS) digesters near the original dairy manure digester. The FS units receive the same post-separated liquid ...

  1. Simplified, low cost below-knee prosthesis.

    PubMed

    Kijkusol, D

    1986-08-01

    Problems are encountered in using standard prostheses in developing countries, especially when the prostheses need repair and the amputees cannot come back to the workshop. Very simple, low cost and durable prostheses can solve this problem. The solution described has worked well with villagers in some rural areas of Thailand, where the inexpensive prosthesis permits walking bare-foot and through water and mud.

  2. Construction of a low-cost luximeter

    NASA Astrophysics Data System (ADS)

    Pedroso, L. S.; de Macedo, J. A.; de Araújo, M. S. T.; Voelzke, M. R.

    2016-04-01

    This paper proposes the construction of an electronic instrument called digital luximeter, combining simplicity and low cost, making it simpler and cheaper than those on the market. Its construction tends to facilitate dissemination and access to this type of measuring instrument between high school teachers and educational institutions, making it ideal to be a science lab.

  3. Low-cost inertial measurement unit.

    SciTech Connect

    Deyle, Travis Jay

    2005-03-01

    Sandia National Laboratories performs many expensive tests using inertial measurement units (IMUs)--systems that use accelerometers, gyroscopes, and other sensors to measure flight dynamics in three dimensions. For the purpose of this report, the metrics used to evaluate an IMU are cost, size, performance, resolution, upgradeability and testing. The cost of a precision IMU is very high and can cost hundreds of thousands of dollars. Thus the goals and results of this project are as follows: (1) Examine the data flow in an IMU and determine a generic IMU design. (2) Discuss a high cost IMU implementation and its theoretically achievable results. (3) Discuss design modifications that would save money for suited applications. (4) Design and implement a low cost IMU and discuss its theoretically achievable results. (5) Test the low cost IMU and compare theoretical results with empirical results. (6) Construct a more streamlined printed circuit board design reducing noise, increasing capabilities, and constructing a self-contained unit. Using these results, we can compare a high cost IMU versus a low cost IMU using the metrics from above. Further, we can examine and suggest situations where a low cost IMU could be used instead of a high cost IMU for saving cost, size, or both.

  4. Low Cost Constellations to Assist the Warfighter

    DTIC Science & Technology

    2006-08-01

    Low Cost Constellations to Assist the Warfighter Stuart Eves (SSTL), David Carter (EADS- Astrium ), David Beard (Dstl) Email: s.eves@sstl.co.uk Tel... Astrium Ltd Earth Observation & Science Anchorage Road Portsmouth, Hampshire PO3 5PU UK davidj.carter@astrium.eads.net David Beard DSTL

  5. Sport for All. Low Cost Sports Halls.

    ERIC Educational Resources Information Center

    Council of Europe, Strasbourg (France).

    This report of the conference on low-cost sports halls, sponsored by the Council of Europe, is divided into two sections: technical studies and conclusions. The introduction to the report provides an overview of the long-term program of the Council of Europe with regard to sport for all and a discussion of multipurpose sports halls. Sociocultural,…

  6. Low cost silicon solar cell array

    NASA Technical Reports Server (NTRS)

    Bartels, F. T. C.

    1974-01-01

    The technological options available for producing low cost silicon solar cell arrays were examined. A project value of approximately $250/sq m and $2/watt is projected, based on mass production capacity demand. Recommendations are included for the most promising cost reduction options.

  7. Strategies to fight low-cost rivals.

    PubMed

    Kumar, Nirmalya

    2006-12-01

    Companies find it challenging and yet strangely reassuring to take on opponents whose strategies, strengths, and weaknesses resemble their own. Their obsession with familiar rivals, however, has blinded them to threats from disruptive, low-cost competitors. Successful price warriors, such as the German retailer Aldi, are changing the nature of competition by employing several tactics: focusing on just one or a few consumer segments, delivering the basic product or providing one benefit better than rivals do, and backing low prices with superefficient operations. Ignoring cutprice rivals is a mistake because they eventually force companies to vacate entire market segments. Price wars are not the answer, either: Slashing prices usually lowers profits for incumbents without driving the low-cost entrants out of business. Companies take various approaches to competing against cut-price players. Some differentiate their products--a strategy that works only in certain circumstances. Others launch low-cost businesses of their own, as many airlines did in the 1990s--a so-called dual strategy that succeeds only if companies can generate synergies between the existing businesses and the new ventures, as the financial service providers HSBC and ING did. Without synergies, corporations are better off trying to transform themselves into low-cost players, a difficult feat that Ryanair accomplished in the 1990s, or into solution providers. There will always be room for both low-cost and value-added players. How much room each will have depends not only on the industry and customers' preferences, but also on the strategies traditional businesses deploy.

  8. The Colloidal Stabilization of Quantum Dots: Towards Manufacturable, Efficient Solution-Processed Solar Cells

    NASA Astrophysics Data System (ADS)

    Rollny, Lisa

    Understanding colloidal stabilization can influence the design of optoelectronic devices and enable improvements to their performance and stability. For photovoltaics, important characteristics of the active layer material are high conductivity along with a minimum of recombination centers. In order to capitalize on the benefits of solution-processed materials, it is important to minimize the number of processing steps: ideally, to achieve a low-cost solution, materials would be deposited using a single process step compatible with roll-to-roll manufacturing. Prior to this work, the highest-performing colloidal quantum dots (CQD) solar cells have relied on several deposition steps that are repeated in a layer-by-layer (LBL) fashion. The purpose of these process steps has been to remove the long insulating ligands used in synthesis and replace them with short ligands that allow electrical conduction. The large number of steps combined, typically implemented via spin coating, leads to inefficient materials utilization and fails to show a path to a manufacturable solution. In this work, the first CQD solar cells were designed, built, and characterized combining state-of-art performance with scalable manufacture. Firstly, I report the first automated CQD synthesis to result in CQDs that form high-performance CQD solar cells. I analyze the CQD synthesis and by separating it into two phases---nucleation and growth phase---my insights are used to create higher-quality CQDs exhibiting enhanced monodispersity. I then proceed to develop a CQD ink: a CQD solution ready for direct deposition to form a semiconducting film exhibiting low trap state density. In early trials the CQD ink showed only limited power conversion efficiencies of 2%. I designed a new ink strategy, which I term cleavable hemiketal ligands. This novel two-component ligand strategy enables the combination of colloidal stabilization (via this longer two-component ligand) and cleavability (enabling excellent

  9. Development of High Rate Coating Technology for Low Cost Electrochromic Dynamic Windows

    SciTech Connect

    Kwak, B.; Joshi, Ajey

    2013-03-31

    Objectives of the Project: The objective of this project was to develop and demonstrate the feasibility of depositing critical electrochromic layers at high rate using new novel vacuum coating sources, to develop a full electrochromic process flow by combining conventional processes with new deposition sources, to characterize, test, evaluate, and optimize the resulting coatings and devices, and, to demonstrate an electrochromic device using the new process flow and sources. As addendum objectives, this project was to develop and demonstrate direct patterning methods with novel integration schemes. The long term objective, beyond this program, is to integrate these innovations to enable production of low-cost, high-performance electrochromic windows produced on highly reliable and high yielding manufacturing equipment and systems.

  10. The metallurgy and processing science of metal additive manufacturing

    DOE PAGES

    Sames, William J.; List, III, Frederick Alyious; Pannala, Sreekanth; ...

    2016-03-07

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

  11. The metallurgy and processing science of metal additive manufacturing

    SciTech Connect

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

    2016-03-07

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

  12. Evaluation of options for process sequences. [in solar cell manufacturing

    NASA Technical Reports Server (NTRS)

    Wolf, M.; Goldman, H. M.; Lawson, A. C.

    1978-01-01

    A methodology is being developed to ease the comparative evaluation of competing options in the process sequence for the manufacture of photovoltaic solar energy utilization systems. This evaluation will largely involve process economic analyses but will place equal emphasis on other characteristics, including energy consumption and environmental effects of the process options. Early analyses have been performed for the energy consumption in the arc furnace reduction of SiO2, for the costs and energy consumption in CZ crystal pulling and various slicing processes, and for the total energy consumption of process sequence through the completed module.

  13. Documentation of a heroin manufacturing process in Afghanistan.

    PubMed

    Zerell, U; Ahrens, B; Gerz, P

    2005-01-01

    The present article documents an authentic process of heroin manufacturing in Afghanistan: white heroin hydrochloride produced using simple equipment and a small quantity of chemicals. The quantities of chemicals actually used corresponded to the minimum needed for manufacturing heroin. The only organic solvent used was acetone, and only a very small quantity of it was used. Because the chemicals used in the demonstration were from actual seizures in Afghanistan, some of the chemicals had been disguised or repackaged by smugglers. Others had been put into labelled containers that proved to be counterfeit, and some glass containers used were not the original containers of the manufacturer displayed on the label. The brown heroin base prepared as an intermediate step in the process shares some of the characteristics of the South-West Asia type of heroin preparations often seized in Germany. The final product of the documented heroin manufacturing process was white heroin hydrochloride, which shares the key characteristics of the white heroin occasionally seized in Germany and other countries in Western Europe since 2000. The present article demonstrates that this kind of heroin can be produced in Afghanistan.

  14. Low-Cost Inkjet Printing Technology for the Rapid Prototyping of Transducers

    PubMed Central

    Andò, Bruno; Baglio, Salvatore; Bulsara, Adi R.; Emery, Teresa; Marletta, Vincenzo; Pistorio, Antonio

    2017-01-01

    Recently, there has been an upsurge in efforts dedicated to developing low-cost flexible electronics by exploiting innovative materials and direct printing technologies. This interest is motivated by the need for low-cost mass-production, shapeable, and disposable devices, and the rapid prototyping of electronics and sensors. This review, following a short overview of main printing processes, reports examples of the development of flexible transducers through low-cost inkjet printing technology. PMID:28368318

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

    SciTech Connect

    Traub, Richard J.

    2008-10-01

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

  16. Cost-Effective Cable Insulation: Nanoclay Reinforced Ethylene-Propylene-Rubber for Low-Cost HVDC Cabling

    SciTech Connect

    2012-02-24

    GENI Project: GE is developing new, low-cost insulation for high-voltage direct current (HVDC) electricity transmission cables. The current material used to insulate HVDC transmission cables is very expensive and can account for as much as 1/3 of the total cost of a high-voltage transmission system. GE is embedding nanomaterials into specialty rubber to create its insulation. Not only are these materials less expensive than those used in conventional HVDC insulation, but also they will help suppress excess charge accumulation. The excess charge left behind on a cable poses a major challenge for high-voltage insulation—if it’s not kept to a low level, it could ultimately lead the insulation to fail. GE’s low-cost insulation is compatible with existing U.S. cable manufacturing processes, further enhancing its cost effectiveness.

  17. Hacking for astronomy: can 3D printers and open-hardware enable low-cost sub-/millimeter instrumentation?

    NASA Astrophysics Data System (ADS)

    Ferkinhoff, Carl

    2014-07-01

    There have been several exciting developments in the technologies commonly used n in the hardware hacking community. Advances in low cost additive-manufacturing processes (i.e. 3D-printers) and the development of openhardware projects, which have produced inexpensive and easily programmable micro-controllers and micro-computers (i.e. Arduino and Raspberry Pi) have opened a new door for individuals seeking to make their own devices. Here we describe the potential for these technologies to reduce costs in construction and development of submillimeter/millimeter astronomical instrumentation. Specifically we have begun a program to measure the optical properties of the custom plastics used in 3D-printers as well as the printer accuracy and resolution to assess the feasibility of directly printing sub- /millimeter transmissive optics. We will also discuss low cost designs for cryogenic temperature measurement and control utilizing Arduino and Raspberry Pi.

  18. Biodiesel production from low cost and renewable feedstock

    NASA Astrophysics Data System (ADS)

    Gude, Veera; Grant, Georgene; Patil, Prafulla; Deng, Shuguang

    2013-12-01

    Sustainable biodiesel production should: a) utilize low cost renewable feedstock; b) utilize energy-efficient, nonconventional heating and mixing techniques; c) increase net energy benefit of the process; and d) utilize renewable feedstock/energy sources where possible. In this paper, we discuss the merits of biodiesel production following these criteria supported by the experimental results obtained from the process optimization studies. Waste cooking oil, non-edible (low-cost) oils (Jatropha curcas and Camelina Sativa) and algae were used as feedstock for biodiesel process optimization. A comparison between conventional and non-conventional methods such as microwaves and ultrasound was reported. Finally, net energy scenarios for different biodiesel feedstock options and algae are presented.

  19. Biodiesel production from low cost and renewable feedstock

    NASA Astrophysics Data System (ADS)

    Gude, Veera G.; Grant, Georgene E.; Patil, Prafulla D.; Deng, Shuguang

    2013-12-01

    Sustainable biodiesel production should: a) utilize low cost renewable feedstock; b) utilize energy-efficient, nonconventional heating and mixing techniques; c) increase net energy benefit of the process; and d) utilize renewable feedstock/energy sources where possible. In this paper, we discuss the merits of biodiesel production following these criteria supported by the experimental results obtained from the process optimization studies. Waste cooking oil, non-edible (low-cost) oils (Jatropha curcas and Camelina Sativa) and algae were used as feedstock for biodiesel process optimization. A comparison between conventional and non-conventional methods such as microwaves and ultrasound was reported. Finally, net energy scenarios for different biodiesel feedstock options and algae are presented.

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

    PubMed

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

    2000-12-01

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