Advances in compact manufacturing for shape and performance controllability of large-scale components-a review

Science.gov (United States)

Qin, Fangcheng; Li, Yongtang; Qi, Huiping; Ju, Li

2017-01-01

Research on compact manufacturing technology for shape and performance controllability of metallic components can realize the simplification and high-reliability of manufacturing process on the premise of satisfying the requirement of macro/micro-structure. It is not only the key paths in improving performance, saving material and energy, and green manufacturing of components used in major equipments, but also the challenging subjects in frontiers of advanced plastic forming. To provide a novel horizon for the manufacturing in the critical components is significant. Focused on the high-performance large-scale components such as bearing rings, flanges, railway wheels, thick-walled pipes, etc, the conventional processes and their developing situations are summarized. The existing problems including multi-pass heating, wasting material and energy, high cost and high-emission are discussed, and the present study unable to meet the manufacturing in high-quality components is also pointed out. Thus, the new techniques related to casting-rolling compound precise forming of rings, compact manufacturing for duplex-metal composite rings, compact manufacturing for railway wheels, and casting-extruding continuous forming of thick-walled pipes are introduced in detail, respectively. The corresponding research contents, such as casting ring blank, hot ring rolling, near solid-state pressure forming, hot extruding, are elaborated. Some findings in through-thickness microstructure evolution and mechanical properties are also presented. The components produced by the new techniques are mainly characterized by fine and homogeneous grains. Moreover, the possible directions for further development of those techniques are suggested. Finally, the key scientific problems are first proposed. All of these results and conclusions have reference value and guiding significance for the integrated control of shape and performance in advanced compact manufacturing.

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing Part I: System Analysis, Component Identification, Additive Manufacturing, and Testing of Polymer Composites

Science.gov (United States)

Grady, Joseph E.; Haller, William J.; Poinsatte, Philip E.; Halbig, Michael C.; Schnulo, Sydney L.; Singh, Mrityunjay; Weir, Don; Wali, Natalie; Vinup, Michael; Jones, Michael G.;

Manufacturing technology development of plasma/ion nitriding for improvement of hardness of machine components and tools

International Nuclear Information System (INIS)

Suprapto; Tjipto Sujitno; Saminto

2015-01-01

The manufacturing technology development of plasma/ion nitriding to improve of hardness of machine components and tools has been done. The development of this technology aims to improve device performance plasma nitriding double chamber and conducted with the addition of thermal radiation shield. Testing was done by testing for preheating operation (start-up), test operation for conditions nitriding and test for nitriding process. The results show that: the plasma nitriding device can be operated for nitriding process at the temperature of about 500 °C for 6 hours, using the thermal radiation shield obtained outside wall temperature of about 65 °C and shorten start-up time to about 60 minutes. The use of thermal radiation shield can also improve the efficiency of the electric power supply and increase the operating temperature for nitriding process. Test for nitriding obtained increase of hardness 1.33 times for the original camshaft (genuine parts) and 1.8 times for the imitation camshaft (imitation parts), the results are compared with after the tempering process at a temperature of 600 °C. For sample SS 304 was 2.45 times compared with before nitrided These results indicate that the development of manufacturing technology of plasma/ion nitriding to increase hardness of machine components and tools have been successfully able to increase the hardness, although still need to be optimized. Besides that, these devices can be developed to use for the process of carburizing and carbonitriding. (author)

Additive manufacturing of titanium alloy for aircraft components

OpenAIRE

Uhlmann, E.; Kersting, R.; Klein, T.B.; Cruz, M.F.; Borille, A.V.

2015-01-01

Selective Laser melting (SLM) is an additive manufacturing technology that uses laser as a power source to sinter powdered metals to produce solid structures. The application of SLM permits engineers to develop and implement components with topologically optimized designs and resultant material properties in comparison to conventionally produced casting parts. Current aviation programs as ACARE 2020 (Advisory Council for Aviation Research and Innovation in the EU) and Flightpath 2050 request ...

Manufacturing requirements of reactor assembly components for PFBR (Paper No. 041)

International Nuclear Information System (INIS)

Murty, C.G.K.; Bhoje, S.B.

1987-02-01

This paper enumerates the requirements of 500 MWe Prototype Fast Breeder Reactor (PFBR) components and considering the present state of art of Indian industry an analysis is made on the challenges to be faced in manufacture highlighting the areas needing development. The large sizes and weights of the components coupled with the limitations on shop facilities and ODC transport, demand part of the fabrication to be done at shop and balance assembly work as well as certain assembly machining operations to be done at site work shop. The stringent geometrical tolerances coupled with extensive destructive and non-destructive examinations call for balanced and low heat input welding techniques and special inspection equipment like electronic co-ordinate determination system. The present paper deals with the specific manufacturing problems of the main reactor components. (author)

Computer-controlled ultrasonic equipment for automatic inspection of nuclear reactor components after manufacturing

International Nuclear Information System (INIS)

Moeller, P.; Roehrich, H.

1983-01-01

After foundation of the working team ''Automated US-Manufacture Testing'' in 1976 the realization of an ultrasonic test facility for nuclear reactor components after manufacturing has been started. During a period of about 5 years, an automated prototype facility has been developed, fabricated and successfully tested. The function of this facility is to replace the manual ultrasonic tests, which are carried out autonomically at different stages of the manufacturing process and to fulfil the test specification under improved economic conditions. This prototype facility has been designed as to be transported to the components to be tested at low expenditure. Hereby the reproduceability of a test is entirely guaranteed. (orig.) [de

Manufacture and Erection of SFR Components: Feedback from PFBR Experience

International Nuclear Information System (INIS)

Chellapandi, P.

2013-01-01

Unique Features of SFR Components: • Large diameter thin walled shell and slender structures calling for stringent tolerances posing challenges in manufacturing, handling and erection. • Single side welds are unavoidable at some difficult locations. • In-service inspection is difficult. • Residual stresses should be minimum calling for robust heat treatment strategy. • Minimum number of materials to be used from reliability point of view (but not preferred from economic considerations). • Mainly austenitic stainless steels calling for careful considerations for welding without significant weld repairs and distortions. • Reactor assembly components decide the project time schedule (large manufacturing, assembly and erection time). • Leak tightness is very important in view of resulting sodium leaks. • Limited experience on manufacturing and erection of components. • Design and manufacturing codes still evolvingPFBR Reactor Assembly – Major Lessons: • Grid plate Large number of sleeves, posing difficulty in assembly, hard facing of large diameter plates and heavy flange construction. • Roof slab Large box type structure with many penetrations – complicated manufacturing process, time consuming and difficulty to overcome lamellar tearing problems. • Inclined Fuel Transfer Machine Complex manufacturing processes leading to large time and extensive qualification tests. • Increase of number of primary pipes – essential for enhancing safety. • Integration of components manufactured by different industries took unduly long time

Testing of high heat flux components manufactured by ENEA for ITER divertor

International Nuclear Information System (INIS)

Visca, Eliseo; Escourbiac, F.; Libera, S.; Mancini, A.; Mazzone, G.; Merola, M.; Pizzuto, A.

2009-01-01

ENEA is involved in the International Thermonuclear Experimental Reactor (ITER) R and D activities and in particular in the manufacturing of high heat flux plasma-facing components, such as the divertor targets. During the last years ENEA has manufactured actively cooled mock-ups by using different technologies, namely brazing, diffusion bonding and HIPping. A new manufacturing process that combines two main techniques PBC (Pre-Brazed Casting) and the HRP (Hot Radial Pressing) has been set up and widely tested. A full monoblock medium scale vertical target, having a straight CFC armoured part and a curved W armoured part, was manufactured using this process. The ultrasonic method was used for the non-destructive examinations performed during the manufacturing of the component, from the monoblock preparation up to the final mock-up assembling. The component was also examined by thermography on SATIR facility (CEA, France), afterwards it was thermal fatigue tested at FE200 (200 kW electron beam facility, CEA/AREVA France). The successful results of the thermal fatigue testing performed according the ITER requirements (10 MW/m 2 , 3000 cycles of 10 s on both CFC and W part, then 20/15 MW/m 2 , 2000 cycles of 10 s on CFC/W part, respectively) have confirmed that the developed process can be considerate a candidate for the manufacturing of monoblock divertor components. Furthermore, a 35-MW/m 2 Critical Heat Flux was measured at relevant thermal-hydraulics conditions at the end of the testing campaign. This paper reports the manufacturing route, the thermal fatigue testing results, the pre and post non-destructive examination and the destructive examination performed on the ITER vertical target medium scale mock-up. These activities were performed in the frame of EFDA contracts (04-1218 with CEA, 93-851 JN with AREVA and 03-1054 with ENEA).

Technology development for special nuclear components

International Nuclear Information System (INIS)

Sanatkumar, A.

1994-01-01

One of the attractive features of Candu Pressurised Heavy Water Reactor design which influenced the decision to make it the foundation of our nuclear power programme, is that its main components (calandria, end shields, coolant channel components) are relatively simple - in comparison with reactor pressure vessel and associated components of Boiling Water Reactors or Pressurised Water Reactors - and considered to be within the scope of manufacture of developing countries. Over the last two decades, India has been very successful in technology development in many important and critical areas. We are now about to launch the construction of the first 500 MWe PHWR project at Tarapur. In this context, this paper focuses attention on some of the aspects relating to self-reliance in design, engineering and manufacture of these special components as currently perceived. (author). 3 refs

Fabricating Superior NiAl Bronze Components through Wire Arc Additive Manufacturing

Directory of Open Access Journals (Sweden)

Donghong Ding

2016-08-01

Full Text Available Cast nickel aluminum bronze (NAB alloy is widely used for large engineering components in marine applications due to its excellent mechanical properties and corrosion resistance. Casting porosity, as well as coarse microstructure, however, are accompanied by a decrease in mechanical properties of cast NAB components. Although heat treatment, friction stir processing, and fusion welding were implemented to eliminate porosity, improve mechanical properties, and refine the microstructure of as-cast metal, their applications are limited to either surface modification or component repair. Instead of traditional casting techniques, this study focuses on developing NAB components using recently expanded wire arc additive manufacturing (WAAM. Consumable welding wire is melted and deposited layer-by-layer on substrates producing near-net shaped NAB components. Additively-manufactured NAB components without post-processing are fully dense, and exhibit fine microstructure, as well as comparable mechanical properties, to as-cast NAB alloy. The effects of heat input from the welding process and post-weld-heat-treatment (PWHT are shown to give uniform NAB alloys with superior mechanical properties revealing potential marine applications of the WAAM technique in NAB production.

Review of manufacturing processes for fabrication of SOFC components

International Nuclear Information System (INIS)

Stacey, B.; Badwal, S.P.S.; Foger, K.

1998-01-01

In order for fuel cell technology to be commercial, it must meet stringent criteria of reliability, life-time expectations and cost. While materials play an important role in determining these parameters, engineering design and manufacturing processes for fuel cell stack components are equally important. Manufacturing processes must be low cost and suitable for large volume production for the technology to be viable and competitive in the market place. Several processes suitable for the production of ceramic components used in solid oxide fuel cells as well as ceramic coating techniques required for the protection of some metal components have been described. Copyright (1998) Australasian Ceramic Society

Manufacturing development of low activation vanadium alloys

International Nuclear Information System (INIS)

Smith, J.P.; Johnson, W.R.; Baxi, C.B.

1996-10-01

General Atomics is developing manufacturing methods for vanadium alloys as part of a program to encourage the development of low activation alloys for fusion use. The culmination of the program is the fabrication and installation of a vanadium alloy structure in the DIII-D tokamak as part of the Radiative Divertor modification. Water-cooled vanadium alloy components will comprise a portion of the new upper divertor structure. The first step, procuring the material for this program has been completed. The largest heat of vanadium alloy made to date, 1200 kg of V-4Cr-4Ti, has been produced and is being converted into various product forms. Results of many tests on the material during the manufacturing process are reported. Research into potential fabrication methods has been and continues to be performed along with the assessment of manufacturing processes particularly in the area of joining. Joining of vanadium alloys has been identified as the most critical fabrication issue for their use in the Radiative Divertor Program. Joining processes under evaluation include resistance seam, electrodischarge (stud), friction and electron beam welding. Results of welding tests are reported. Metallography and mechanical tests are used to evaluate the weld samples. The need for a protective atmosphere during different welding processes is also being determined. General Atomics has also designed, manufactured, and will be testing a helium-cooled, high heat flux component to assess the use of helium cooled vanadium alloy components for advanced tokamak systems. The component is made from vanadium alloy tubing, machined to enhance the heat transfer characteristics, and joined to end flanges to allow connection to the helium supply. Results are reported

The manufacturing of depleted uranium biological shield components

International Nuclear Information System (INIS)

Metelkin, J.A.

1998-01-01

The unique combination of the physical and mechanical properties of uranium made it possible to manufacture biological shield components of transport package container (TPC) for transportation nuclear power plant irradiated fuel and radionuclides of radiation diagnostic instruments. Protective properties are substantially dependent on the nature radionuclide composition of uranium, that why I recommended depleted uranium after radiation chemical processing. Depleted uranium biological shield (DUBS) has improved specific mass-size characteristics compared to a shield made of lead, steel or tungsten. Technological achievements in uranium casting and machining made it possible to manufacture DUBS components of TPC up to 3 tons of mass and up to 2 metres of the maximum size. (authors)

Multilayer electronic component systems and methods of manufacture

Science.gov (United States)

Thompson, Dane (Inventor); Wang, Guoan (Inventor); Kingsley, Nickolas D. (Inventor); Papapolymerou, Ioannis (Inventor); Tentzeris, Emmanouil M. (Inventor); Bairavasubramanian, Ramanan (Inventor); DeJean, Gerald (Inventor); Li, RongLin (Inventor)

2010-01-01

Multilayer electronic component systems and methods of manufacture are provided. In this regard, an exemplary system comprises a first layer of liquid crystal polymer (LCP), first electronic components supported by the first layer, and a second layer of LCP. The first layer is attached to the second layer by thermal bonds. Additionally, at least a portion of the first electronic components are located between the first layer and the second layer.

Development of steam generator manufacturing technology

International Nuclear Information System (INIS)

Grant, J.A.

1979-01-01

In 1968 Babcock and Wilcox (Operations) Ltd., received an order from the CEGB to design, manufacture, install and commission 16 Steam Generators for 2 x 660 Mw (e) Advanced Gas Cooled Reactor Power Station at Hartlepool. This order was followed in 1970 by a similar order for the Heysham Power Station. The design and manufacture of the Steam Generators represented a major advance in technology and the paper discusses the methods by which a manufacturing facility was developed, by the Production Division of Babcock, to produce components to a quality, complexity and accuracy unique in the U.K. commercial boilermaking industry. The discussion includes a brief design background, a description of the Steam Generators and a view of the Production Division background. This is followed by a description of the organisation of the technological development and a consideration of the results. (author)

Development of and verification test integral reactor major components - Development of manufacturing process and fabrication of prototype for SG and CEDM

Energy Technology Data Exchange (ETDEWEB)

Lee, Chang Hee; Park, Hwa Kyu; Kim, Yong Kyu; Choi, Yong Soon; Kang, Ki Su; Hyun, Young Min [Korea Heavy Industries and Construction Co., LTD., Changwon (Korea)

1999-03-01

Integral SMART(System integrated Modular Advanced Reactor) type reactor is under conceptual design. Because major components is integrated within in a single pressure vessel, compact design using advanced technology is essential. It means that manufacturing process for these components is more complex and difficult. The objective of this study is to confirm the possibility of manufacture of Steam Generator, Control Element Drive Mechanism(CEDM) and Reactor Assembly which includes Reactor Pressure Vessel, it is important to understand the design requirement and function of the major components. After understanding the design requirement and function, it is concluded that the helical bending and weld qualification of titanium tube for Steam Generator and the applicability of electron beam weld for CEDM step motor parts is the critical to fabricate the components. Therefore, bending mock-up and weld qualification of titanium tube was performed and the results are quite satisfactory. Also, it is concluded that electron beam welding technique can be applicable to the CEDM step motor part. (author). 22 refs., 14 figs., 46 tabs.

Additive Manufacturing of Multifunctional Components Using High Density Carbon Nanotube Yarn Filaments

Science.gov (United States)

Gardner, John M.; Sauti, Godfrey; Kim, Jae-Woo; Cano, Roberto J.; Wincheski, Russell A.; Stelter, Christopher J.; Grimsley, Brian W.; Working, Dennis C.; Siochi, Emilie J.

2016-01-01

Additive manufacturing allows for design freedom and part complexity not currently attainable using traditional manufacturing technologies. Fused Filament Fabrication (FFF), for example, can yield novel component geometries and functionalities because the method provides a high level of control over material placement and processing conditions. This is achievable by extrusion of a preprocessed filament feedstock material along a predetermined path. However if fabrication of a multifunctional part relies only on conventional filament materials, it will require a different material for each unique functionality printed into the part. Carbon nanotubes (CNTs) are an attractive material for many applications due to their high specific strength as well as good electrical and thermal conductivity. The presence of this set of properties in a single material presents an opportunity to use one material to achieve multifunctionality in an additively manufactured part. This paper describes a recently developed method for processing continuous CNT yarn filaments into three-dimensional articles, and summarizes the mechanical, electrical, and sensing performance of the components fabricated in this way.

Design and Manufacturing of Young 3 and 4 NSSS Components

International Nuclear Information System (INIS)

Chung, Chungwoon

1989-01-01

Korea nuclear unit 11 and 12 (Young 3 and 4) project, which is the 6th nuclear construction project in Korea, has been implemented since 1987. The project is scheduled to commence commercial operation by March 1995 and March 1996, respectively. The project is executed in such a manner that local firms play the leading role. In parallel with the project, nationwide technical self-reliance program for nuclear power plant construction is activated. Accordingly, the clear-cut division and achievement of responsibilities assigned to local firms will determine the success of this project and future nuclear projects. The local manufacturer takes responsibility for on-time delivery of safety-assured and reliable equipment and also for achieving technical self-reliance in component design and manufacturing. This paper describes the objectives to be achieved by the local manufacturer in the execution of design and manufacturing of NSSS components for the project and action plans taken and/or to be taken to achieve those objectives

Experience in the application of the IAEA QA code and guides to the manufacture of nuclear reactor components

International Nuclear Information System (INIS)

Dutta, N.G.; Mankame, M.A.; Kulkarni, P.G.; Vijayaraghavan, R.; Balaramamoorthy, K.

1985-01-01

India has made considerable progress in the indigenous manufacture of 'Quality' nuclear reactor components. All activities associated with the development of atomic energy from mining of strategic minerals to the design, construction, and operation of nuclear power plants including supporting research and development efforts are mainly carried out by the Department of Atomic Energy (DAE). Through the sustained efforts of DAE, the major industries, both in public and private sectors supplying nuclear components have now adopted the practice of systematic quality assurance (QA). The stringent QA steps are mandatory for achieving the desired quality in the manufactured nuclear components. Control blades for BWRs are now indigenously manufactured by the Atomic Fuels Division (AFD) of Bhabha Atomic Research Centre (BARC), a constituent unit of DAE. For the Project Dhruva, a 100 MW(th) nuclear reactor, constructed at BARC, Trombay, Bombay, an independent cell was formed to carry out quality audit on the manufactured components. The components were designed, fabricated, inspected and tested to the desired quality level. The QA activities were enforced from the procurement of raw materials to the audit of the completed component for monitoring the manufacturer's continued compliance with the design. The major components of Dhruva, viz. calandria, end-shield, coolant channels, heat exchangers, etc., were covered under these quality audit activities. The paper highlights the QA programme implemented in the manufacture of control blades for BWRs, illustrated with a typical example, the end-shield for Dhruva. The authors consider that the recommendations and guidelines provided in the documents 50-SG-QA3, 50-SG-QA8, 50-SG-QA10, etc., were useful in providing a formal and systematic framework, under which various quality assurance functions have been carried out

Product costing guide for wood dimension and component manufacturers

Science.gov (United States)

Adrienn Andersch; Urs Buehlmann; Jeff Palmer; Janice K. Wiedenbeck; Steve. Lawser

2014-01-01

The North American hardwood dimension and components industry plays a critical role in the hardwood forest products industry as the industry is a user of high-value hardwood lumber. Customer expectations, global markets, and international competition, however, require hardwood dimension and components manufacturers to continuously improve their ability to manage their...

China and the Manufacturing Exports of Other Developing Countries

OpenAIRE

Gordon H. Hanson; Raymond Robertson

2008-01-01

In this paper, we examine the impact of China's growth on developing countries that specialize in manufacturing. Over 2000-2005, manufacturing accounted for 32% of China's GDP and 89% of its merchandise exports, making it more specialized in the sector than any other large developing economy. Using the gravity model of trade, we decompose bilateral trade into components associated with demand conditions in importing countries, supply conditions in exporting countries, and bilateral trade cost...

The scope of additive manufacturing in cryogenics, component design, and applications

Science.gov (United States)

Stautner, W.; Vanapalli, S.; Weiss, K.-P.; Chen, R.; Amm, K.; Budesheim, E.; Ricci, J.

2017-12-01

Additive manufacturing techniques using composites or metals are rapidly gaining momentum in cryogenic applications. Small or large, complex structural components are now no longer limited to mere design studies but can now move into the production stream thanks to new machines on the market that allow for light-weight, cost optimized designs with short turnaround times. The potential for cost reductions from bulk materials machined to tight tolerances has become obvious. Furthermore, additive manufacturing opens doors and design space for cryogenic components that to date did not exist or were not possible in the past, using bulk materials along with elaborate and expensive machining processes, e.g. micromachining. The cryogenic engineer now faces the challenge to design toward those new additive manufacturing capabilities. Additionally, re-thinking designs toward cost optimization and fast implementation also requires detailed knowledge of mechanical and thermal properties at cryogenic temperatures. In the following we compile the information available to date and show a possible roadmap for additive manufacturing applications of parts and components typically used in cryogenic engineering designs.

Additive manufacture (3d printing) of plasma diagnostic components and assemblies for fusion experiments

Science.gov (United States)

Sieck, Paul; Woodruff, Simon; Stuber, James; Romero-Talamas, Carlos; Rivera, William; You, Setthivoine; Card, Alexander

2015-11-01

Additive manufacturing (or 3D printing) is now becoming sufficiently accurate with a large range of materials for use in printing sensors needed universally in fusion energy research. Decreasing production cost and significantly lowering design time of energy subsystems would realize significant cost reduction for standard diagnostics commonly obtained through research grants. There is now a well-established set of plasma diagnostics, but these expensive since they are often highly complex and require customization, sometimes pace the project. Additive manufacturing (3D printing) is developing rapidly, including open source designs. Basic components can be printed for (in some cases) less than 1/100th costs of conventional manufacturing. We have examined the impact that AM can have on plasma diagnostic cost by taking 15 separate diagnostics through an engineering design using Conventional Manufacturing (CM) techniques to determine costs of components and labor costs associated with getting the diagnostic to work as intended. With that information in hand, we set about optimizing the design to exploit the benefits of AM. Work performed under DOE Contract DE-SC0011858.

Development of Probabilistic Structural Analysis Integrated with Manufacturing Processes

Science.gov (United States)

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.

Smart manufacturing of complex shaped pipe components

Science.gov (United States)

Salchak, Y. A.; Kotelnikov, A. A.; Sednev, D. A.; Borikov, V. N.

2018-03-01

Manufacturing industry is constantly improving. Nowadays the most relevant trend is widespread automation and optimization of the production process. This paper represents a novel approach for smart manufacturing of steel pipe valves. The system includes two main parts: mechanical treatment and quality assurance units. Mechanical treatment is performed by application of the milling machine with implementation of computerized numerical control, whilst the quality assurance unit contains three testing modules for different tasks, such as X-ray testing, optical scanning and ultrasound testing modules. The advances of each of them provide reliable results that contain information about any failures of the technological process, any deviations of geometrical parameters of the valves. The system also allows detecting defects on the surface or in the inner structure of the component.

Innovative approaches in the manufacture of zirconium alloy components for PHWRs

International Nuclear Information System (INIS)

Rao, M.N.; Srivastava, R.K.

2005-01-01

Selection of an appropriate route for the fabrication of Zirconium alloy fuel components has a direct bearing on the quality of finished product. Many sophisticated and intricate processes such as vacuum arc melting, extrusion, hot rolling and cold working processes - swaging, drawing and sheet rolling are employed. Many advances were made in eddy current and ultrasonic evaluation to meet the stringent quality control requirement and locate the micro flaws. Emphasis was laid on achieving high recoveries and manufacture the product at minimum cost. Several creative and innovative processes were adopted particularly in the fabrication of end caps and spacers. The spacers were produced through the wire route and subsequently parting them into tiny spacers, which is entirely different from the conventional route of fabricating the sheets followed by blanking and coining. This has improved the material recovery and the lead time has been reduced substantially. The end caps used for the closure of clad tubes have to meet the most stringent quality requirements to avoid micro-flaws. The manufacturing processes adopted have direct influence on the integrity of the finished product. Special defect standards were developed to identify and eliminate micro-flaws and thereby ensure consistent and repetitive quality product. The paper brings out the above innovative approaches made in fabrication and quality control techniques in the manufacture of fuel components for PHWR fuel bundles. (author)

Additive Manufacturing Technology for Biomedical Components: A review

Science.gov (United States)

Aimi Zaharin, Haizum; Rani, Ahmad Majdi Abdul; Lenggo Ginta, Turnad; Azam, Farooq I.

2018-03-01

Over the last decades, additive manufacturing has shown potential application in ranging fields. No longer a prototyping technology, it is now being utilised as a manufacturing technology for giant industries such as the automotive, aircraft and recently in the medical industry. It is a very successful method that provides health-care solution in biomedical sectors by producing patient-specific prosthetics, improve tissues engineering and facilitate pre-operating session. This paper thus presents a brief overview of the most commercially important additive manufacturing technologies, which is currently available for fabricating biomedical components such as Stereolithography (SLA), Selective Laser Sintering (SLS), Selective Laser Melting (SLM), Fused Deposition Modelling (FDM) and Electron Beam Melting (EBM). It introduces the basic principles of the main process, highlights some of the beneficial applications in medical industry and the current limitation of applied technology.

Control of microstructure in soldered, brazed, welded, plated, cast or vapor deposited manufactured components

Science.gov (United States)

Ripley, Edward B.; Hallman, Russell L.

2015-11-10

Disclosed are methods and systems for controlling of the microstructures of a soldered, brazed, welded, plated, cast, or vapor deposited manufactured component. The systems typically use relatively weak magnetic fields of either constant or varying flux to affect material properties within a manufactured component, typically without modifying the alloy, or changing the chemical composition of materials or altering the time, temperature, or transformation parameters of a manufacturing process. Such systems and processes may be used with components consisting of only materials that are conventionally characterized as be uninfluenced by magnetic forces.

Manufacture of heavy reactor components with particular considerations to quality assurance

International Nuclear Information System (INIS)

Kreppel, H.; Clausmeyer, H.

1980-01-01

The use of adequate quality assurance measures is one of the most important prerequisites for the manufacture of reactor components. Nature and extent of the quality assurance system at present adopted in the Federal Republic of Germany are illustrated, using the manufacture of a reactor pressure vessel as an example. The system comprises quality organization, planning of all quality assurance measures, quality surveillance through all stages of manufacture and documentation of quality attained. (orig.)

Manufacture of heavy reactor components with particular consideration to quality assurance

International Nuclear Information System (INIS)

Clausmeyer, H.; Kreppel, H.

1977-01-01

The use of adequate quality assurance measures is one of the most important prerequisites for the manufacture of reactor components. Nature and extent of the quality assurance system at present adopted in the Federal Republic of Germany are illustrated, using the manufacture of a reactor pressure vessel as an example. The system comprises quality organization, planning of all quality assurance measures, quality surveillance through all stages of manufacture and documentation of quality attained. (orig.) [de

Manufacture of heavy reactor components with particular consideration to quality assurance

International Nuclear Information System (INIS)

Kreppel, H.; Clausmeyer, H.

1981-01-01

The use of adequate quality assurance measures is one of the most important prerequisites for the manufacture of reactor components. Nature and extent of the quality assurance system at present adopted in the Federal Republic of Germany are illustrated, using the manufacture of a reactor pressure vessel as an example. The system comprises quality organization, planning of all quality assurance measures, quality surveillance through all stages of manufacture and documentation of quality attained. (orig.)

40 CFR 59.506 - How do I demonstrate compliance if I manufacture multi-component kits?

Science.gov (United States)

2010-07-01

... 40 Protection of Environment 5 2010-07-01 2010-07-01 false How do I demonstrate compliance if I manufacture multi-component kits? 59.506 Section 59.506 Protection of Environment ENVIRONMENTAL PROTECTION... § 59.506 How do I demonstrate compliance if I manufacture multi-component kits? (a) If you manufacture...

[Noise hazard and hearing loss in workers in automotive component manufacturing industry in Guangzhou, China].

Science.gov (United States)

Wang, Zhi; Liang, Jiabin; Rong, Xing; Zhou, Hao; Duan, Chuanwei; Du, Weijia; Liu, Yimin

2015-12-01

To investigate noise hazard and its influence on hearing loss in workers in the automotive component manufacturing industry. Noise level in the workplace of automotive component manufacturing enterprises was measured and hearing examination was performed for workers to analyze the features and exposure levels of noise in each process, as well as the influence on hearing loss in workers. In the manufacturing processes for different products in this industry, the manufacturing processes of automobile hub and suspension and steering systems had the highest degrees of noise hazard, with over-standard rates of 79.8% and 57.1%, respectively. In the different technical processes for automotive component manufacturing, punching and casting had the highest degrees of noise hazard, with over-standard rates of 65.0% and 50%, respectively. The workers engaged in the automotive air conditioning system had the highest rate of abnormal hearing ability (up to 3.1%). In the automotive component manufacturing industry, noise hazard exceeds the standard seriously. Although the rate of abnormal hearing is lower than the average value of the automobile manufacturing industry in China, this rate tends to increase gradually. Enough emphasis should be placed on the noise hazard in this industry.

Impact of Flexibility of Manufacturing System Components on Competitiveness of SMEs in Northern India

Directory of Open Access Journals (Sweden)

Shakun Preet Kaur

2016-01-01

Full Text Available The present manufacturing environment is characterized by a number of changes which poses challenges to a typical manufacturing unit. Time demands a shift from the traditional manufacturing strategies as they do not fit to present market competition. A flexible systems strategy has to be designed for remaining competitive in the market and perform well. For designing strategies and policies it is important to know the factors that influence performance of the system. The aim of this paper is to assess the impact of the flexibility of manufacturing system components on competitiveness of SMEs in northern India. A questionnaire based survey was conducted in the SMEs across northern India analysing three sectors namely automotive, machine tool and light engineering (mechanical components and equipment. The study contributes to the existing literature by empirically investigating the impact of machine, material handling and worker flexibility on competitiveness of manufacturing firms. This paper presents a Structural Equation Model displaying the impact of flexibility of manufacturing system components on competitiveness of SMEs.

Manufacture of disposal canisters

International Nuclear Information System (INIS)

Nolvi, L.

2009-12-01

The report summarizes the development work carried out in the manufacturing of disposal canister components, and present status, in readiness for manufacturing, of the components for use in assembly of spent nuclear fuel disposal canister. The disposal canister consist of two major components: the nodular graphite cast iron insert and overpack of oxygen-free copper. The manufacturing process for copper components begins with a cylindrical cast copper billet. Three different manufacturing processes i.e. pierce and draw, extrusion and forging are being developed, which produce a seamless copper tube or a tube with an integrated bottom. The pierce and draw process, Posiva's reference method, makes an integrated bottom possible and only the lid requires welding. Inserts for BWR-element are cast with 12 square channels and inserts for VVER 440-element with 12 round channels. Inserts for EPR-elements have four square channels. Casting of BWR insert type has been studied so far. Experience of casting inserts for PWR, which is similar to the EPR-type, has been got in co-operation with SKB. The report describes the processes being developed for manufacture of disposal canister components and some results of the manufacturing experiments are presented. Quality assurance and quality control in manufacture of canister component is described. (orig.)

Additive manufacturing method for SRF components of various geometries

Science.gov (United States)

Rimmer, Robert; Frigola, Pedro E; Murokh, Alex Y

2015-05-05

An additive manufacturing method for forming nearly monolithic SRF niobium cavities and end group components of arbitrary shape with features such as optimized wall thickness and integral stiffeners, greatly reducing the cost and technical variability of conventional cavity construction. The additive manufacturing method for forming an SRF cavity, includes atomizing niobium to form a niobium powder, feeding the niobium powder into an electron beam melter under a vacuum, melting the niobium powder under a vacuum in the electron beam melter to form an SRF cavity; and polishing the inside surface of the SRF cavity.

Development of an ergonomics guideline for the furniture manufacturing industry.

Science.gov (United States)

Mirka, Gary A

2005-03-01

Industry-specific ergonomics guidelines are an important component in the four-pronged approach to workplace ergonomics currently pursued by the United States Occupational Safety and Health Administration. The American Furniture Manufacturers Association has taken the initiative of developing such a guideline for its members. The result of this effort is the "AFMA Voluntary Ergonomics Guideline for the Furniture Manufacturing Industry", a document that includes basic information about ergonomics program components as well as a compilation of work-proven, ergonomics best practices as submitted by members of the furniture manufacturing community. This guideline was developed through an industry-research-government partnership and made strategic use of the unique attributes that each sector brought to this effort. Outlined in this paper are some of the characteristics of this partnership including, the roles played by each, the different motivations for pursuing the guideline, the challenges faced during the development of the document, the successes experienced in this process, as well as a proposed outline for measuring the effectiveness of this effort. The hope is that this summary, and some of the lessons learned contained herein, would be helpful to others considering the prospect of developing such a guideline for their industry.

Development of a virtual manufacturing assembly simulation system

Directory of Open Access Journals (Sweden)

Abdulrahman M Al-Ahmari

2016-03-01

Full Text Available Assembly operations are a key component of modern manufacturing systems. Designing, planning, and conducting assembly operations represent an important part of the cost of a product. Virtual reality provides an efficient and cost-effective solution to manufacturing design, planning, and prototyping. Still there are certain issues (such as data translation, integration of various hardware and software systems, and real-time collision detection faced while applying this advanced technology to the assembly domain. For example, existing works focus on using virtual reality systems and environments mainly to design new products and to plan for assembly. Little focus has been given to develop virtual reality environments that contribute to train operators on assembly operations and to bridge the gap between design and implementation/execution of assembly. Therefore, the research work presented in this article focuses on developing a fully functional virtual manufacturing assembly simulation system that solves the issues related to virtual reality environments. The proposed system uses a virtual environment to create an interactive workbench that can be used for evaluating assembly decisions and training assembly operations. It is a comprehensive system that provides visual, auditory, tactile, as well as force feedback. The system works successfully even with large components.

Additively Manufactured Ceramic Rocket Engine Components

Data.gov (United States)

National Aeronautics and Space Administration — HRL Laboratories, LLC, with Vector Space Systems (VSS) as subcontractor, has a 24-month effort to develop additive manufacturing technology for reinforced ceramic...

Knowledge Assisted Integrated Design of a Component and Its Manufacturing Process

Science.gov (United States)

Gautham, B. P.; Kulkarni, Nagesh; Khan, Danish; Zagade, Pramod; Reddy, Sreedhar; Uppaluri, Rohith

Integrated design of a product and its manufacturing processes would significantly reduce the total cost of the products as well as the cost of its development. However this would only be possible if we have a platform that allows us to link together simulations tools used for product design, performance evaluation and its manufacturing processes in a closed loop. In addition to that having a comprehensive knowledgebase that provides systematic knowledge guided assistance to product or process designers who may not possess in-depth design knowledge or in-depth knowledge of the simulation tools, would significantly speed up the end-to-end design process. In this paper, we propose a process and illustrate a case for achieving an integrated product and manufacturing process design assisted by knowledge support for the user to make decisions at various stages. We take transmission component design as an example. The example illustrates the design of a gear for its geometry, material selection and its manufacturing processes, particularly, carburizing-quenching and tempering, and feeding the material properties predicted during heat treatment into performance estimation in a closed loop. It also identifies and illustrates various decision stages in the integrated life cycle and discusses the use of knowledge engineering tools such as rule-based guidance, to assist the designer make informed decisions. Simulation tools developed on various commercial, open-source platforms as well as in-house tools along with knowledge engineering tools are linked to build a framework with appropriate navigation through user-friendly interfaces. This is illustrated through examples in this paper.

Challenges faced in selection, manufacture, quality assurance and qualification of the components for FBTR CRDM applications

International Nuclear Information System (INIS)

Ramesh, E.; Krovvidi, S.C.S.P. Kumar; Sarangarajan, S.; Kasinathan, N.; Srinivasan, G.

2015-01-01

Fast Breeder Test Reactor (FBTR) is a sodium cooled type experimental reactor. Six numbers of Control Rod Drive Mechanisms (CRDM) along with their B4C control rods perform reactor start up, controlled shutdown, reactivity control for power changing and burn-up compensation and to shut down the reactor by SCRAM action during abnormal conditions. Lower part of the CRDM which consists of translation tube, outer sheath and gripper is partially immersed in sodium. Nested Ripple type Welded Disc Bellows (NRWDB) called translation bellows prevents entry of sodium in the space between the translation tube and outer sheath and acts as primary leak tight barrier. Silicone bellows which is near ground level elevation acts as secondary leak tight barrier. Non standard Aluminium bronze rod was used as raw material for various drive components in CRDM. These components were imported earlier from FRANCE. Indigenous development of these items and bellows was taken up due to difficulties in procurement. Extensive studies were carried out on selection of materials, establishment of manufacturing procedures and stringent Quality Assurance Program (QAP) to ensure defect free component during indigenous development. Suitable methodology was arrived for qualification of these components. Successful development of silicone bellows and Aluminium bronze rods were completed as per our requirements and selection, establishment of manufacturing procedure and QAP were completed for (NRWDB). Prototype development of NRWDB is in progress. (author)

Methods for microwave heat treatment of manufactured components

Science.gov (United States)

Ripley, Edward B.

2010-08-03

An apparatus for heat treating manufactured components using microwave energy and microwave susceptor material. Heat treating medium such as eutectic salts may be employed. A fluidized bed introduces process gases which may include carburizing or nitriding gases. The process may be operated in a batch mode or continuous process mode. A microwave heating probe may be used to restart a frozen eutectic salt bath.

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

Energy Technology Data Exchange (ETDEWEB)

Saifee, T.; Konnerth, A. III [Solar Kinetics, Inc., Dallas, TX (United States)

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.

U.S. Offshore Wind Manufacturing and Supply Chain Development

Energy Technology Data Exchange (ETDEWEB)

Hamilton, Bruce Duncan [Navigant Consulting, Inc.

2013-02-22

The objective of the report is to provide an assessment of the domestic supply chain and manufacturing infrastructure supporting the U.S. offshore wind market. The report provides baseline information and develops a strategy for future development of the supply chain required to support projected offshore wind deployment levels. A brief description of each of the key chapters includes: » Chapter 1: Offshore Wind Plant Costs and Anticipated Technology Advancements. Determines the cost breakdown of offshore wind plants and identifies technical trends and anticipated advancements in offshore wind manufacturing and construction. » Chapter 2: Potential Supply Chain Requirements and Opportunities. Provides an organized, analytical approach to identifying and bounding the uncertainties associated with a future U.S. offshore wind market. It projects potential component-level supply chain needs under three demand scenarios and identifies key supply chain challenges and opportunities facing the future U.S. market as well as current suppliers of the nation’s land-based wind market. » Chapter 3: Strategy for Future Development. Evaluates the gap or competitive advantage of adding manufacturing capacity in the U.S. vs. overseas, and evaluates examples of policies that have been successful . » Chapter 4: Pathways for Market Entry. Identifies technical and business pathways for market entry by potential suppliers of large-scale offshore turbine components and technical services. The report is intended for use by the following industry stakeholder groups: (a) Industry participants who seek baseline cost and supplier information for key component segments and the overall U.S. offshore wind market (Chapters 1 and 2). The component-level requirements and opportunities presented in Section 2.3 will be particularly useful in identifying market sizes, competition, and risks for the various component segments. (b) Federal, state, and local policymakers and economic development

Lightweight custom composite prosthetic components using an additive manufacturing-based molding technique.

Science.gov (United States)

Leddy, Michael T; Belter, Joseph T; Gemmell, Kevin D; Dollar, Aaron M

2015-01-01

Additive manufacturing techniques are becoming more prominent and cost-effective as 3D printing becomes higher quality and more inexpensive. The idea of 3D printed prosthetics components promises affordable, customizable devices, but these systems currently have major shortcomings in durability and function. In this paper, we propose a fabrication method for custom composite prostheses utilizing additive manufacturing, allowing for customizability, as well the durability of professional prosthetics. The manufacturing process is completed using 3D printed molds in a multi-stage molding system, which creates a custom finger or palm with a lightweight epoxy foam core, a durable composite outer shell, and soft urethane gripping surfaces. The composite material was compared to 3D printed and aluminum materials using a three-point bending test to compare stiffness, as well as gravimetric measurements to compare weight. The composite finger demonstrates the largest stiffness with the lowest weight compared to other tested fingers, as well as having customizability and lower cost, proving to potentially be a substantial benefit to the development of upper-limb prostheses.

Neutron Characterization of Additively Manufactured Components. Workshop Report

Energy Technology Data Exchange (ETDEWEB)

Watkins, Thomas R. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Payzant, E. Andrew [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Babu, Sudarsanam Suresh [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

2015-09-01

Additive manufacturing (AM) is a collection of promising manufacturing methods that industry is beginning to explore and adopt. Macroscopically complicated and near net shape components are being built using AM, but how the material behaves in service is a big question for industry. Consequently, AM components/materials need further research into exactly what is made and how it will behave in service. This one and a half day workshop included a series of invited presentations from academia, industry and national laboratories (see Appendix A for the workshop agenda and list of talks). The workshop was welcomed by Alan Tennant, Chief Scientist, Neutron Sciences Directorate, ORNL, and opened remotely by Rob Ivestor, Deputy Director, Advanced Manufacturing Office-DOE, who declared AM adoptees as titans who will be able to create customized 3-D structures with 1 million to 1 billion micro welds with locally tailored microstructures. Further he stated that characterization with neutrons is key to be able to bring critical insight/information into the AM process/property/behavior relationship. Subsequently, the presentations spanned a slice of the current state of the art AM techniques and many of the most relevant characterization techniques using neutrons. After the talks, a panel discussion was held; workshop participants (see Appendix B for a list of attendees) providing questions and the panel answers. The main purpose of the panel discussion was to build consensus regarding the critical research needs in AM that can be addressed with neutrons. These needs were placed into three categories: modes of access for neutrons, new capabilities needed, new AM material issues and neutrons. Recommendations from the workshop were determined based on the panel discussion.

Computer Simulation of Robotic Device Components in 3D Printer Manufacturing

Directory of Open Access Journals (Sweden)

M. A. Kiselev

2016-01-01

Full Text Available The paper considers a relevant problem "Computer simulation of robotic device components in manufacturing on a 3D printer" and highlights the problem of computer simulation based on the cognitive programming technology of robotic device components. The paper subject is urgent because computer simulation of force-torque and accuracy characteristics of robot components in terms of their manufacturing properties and conditions from polymeric and metallic materials is of paramount importance for programming and manufacturing on the 3D printers. Two types of additive manufacturing technologies were used:1. FDM (Fused deposition modeling - layered growth of products from molten plastic strands;2. SLM (Selective laser melting - selective laser sintering of metal powders, which, in turn, create:• conditions for reducing the use of expensive equipment;• reducing weight and increasing strength through optimization of  the lattice structures when using a bionic design;• a capability to implement mathematical modeling of individual components of robotic and other devices in terms of appropriate characteristics;• a 3D printing capability to create unique items, which cannot be made by other known methods.The paper aim was to confirm the possibility of ensuring the strength and accuracy characteristics of cases when printing from polymeric and metallic materials on a 3D printer. The investigation emphasis is on mathematical modeling based on the cognitive programming technology using the additive technologies in their studies since it is, generally, impossible to make the obtained optimized structures on the modern CNC machines.The latter allows us to create a program code to be clear to other developers without cost, additional time for development, adaptation and implementation.Year by year Russian companies increasingly use a 3D-print system in mechanical engineering, aerospace industry, and for scientific purposes. Machines for the additive

Influence of Powder Characteristics on Formation of Porosity in Additive Manufacturing of Ti-6Al-4V Components

Science.gov (United States)

Iebba, Maurizio; Astarita, Antonello; Mistretta, Daniela; Colonna, Ivano; Liberini, Mariacira; Scherillo, Fabio; Pirozzi, Carmine; Borrelli, Rosario; Franchitti, Stefania; Squillace, Antonino

2017-08-01

This paper aims to study the genesis of defects in titanium components made through two different additive manufacturing technologies: selective laser melting and electron beam melting. In particular, we focussed on the influence of the powders used on the formation of porosities and cavities in the manufactured components. A detailed experimental campaign was carried out to characterize the components made through the two additive manufacturing techniques aforementioned and the powders used in the process. It was found that some defects of the final components can be attributed to internal porosities of the powders used in the manufacturing process. These internal porosities are a consequence of the gas atomization process used for the production of the powders themselves. Therefore, the importance of using tailored powders, free from porosities, in order to manufacture components with high mechanical properties is highlighted.

Additively Manufactured IN718 Components with Wirelessly Powered and Interrogated Embedded Sensing

Energy Technology Data Exchange (ETDEWEB)

Attridge, Paul [United Technologies Research Center, East Hartford, CT (United States); Bajekal, Sanjay [United Technologies Research Center, East Hartford, CT (United States); Klecka, Michael [United Technologies Research Center, East Hartford, CT (United States); Wu, Xin [United Technologies Research Center, East Hartford, CT (United States); Savulak, Steve [United Technologies Research Center, East Hartford, CT (United States); Viens, Dan [United Technologies Research Center, East Hartford, CT (United States); Carey, Michael [United Technologies Research Center, East Hartford, CT (United States); Miano, John [United Technologies Research Center, East Hartford, CT (United States); Rioux, William [United Technologies Research Center, East Hartford, CT (United States); Zacchio, Joseph [United Technologies Research Center, East Hartford, CT (United States); Dunst, Richard [National Energy Technology Lab. (NETL), Pittsburgh, PA, (United States); Straub, Doug [National Energy Technology Lab. (NETL), Pittsburgh, PA, (United States); Mantese, Joseph [United Technologies Research Center, East Hartford, CT (United States)

2017-07-14

A methodology is described for embedding commercial-off-the-shelf sensors together with wireless communication and power circuit elements using direct laser metal sintered additively manufactured components. Physics based models of the additive manufacturing processes and sensor/wireless level performance models guided the design and embedment processes. A combination of cold spray deposition and laser engineered net shaping was used to fashion the transmitter/receiving elements and embed the sensors, thereby providing environmental protection and component robustness/survivability for harsh conditions. By design, this complement of analog and digital sensors were wirelessly powered and interrogated using a health and utilization monitoring system; enabling real-time, in situ prognostics and diagnostics.

Powder Injection Molding - An innovative manufacturing method for He-cooled DEMO divertor components

International Nuclear Information System (INIS)

Antusch, Steffen; Norajitra, Prachai; Piotter, Volker; Ritzhaupt-Kleissl, Hans-Joachim; Spatafora, Luigi

2011-01-01

At Karlsruhe Institute of Technology (KIT), a He-cooled divertor design for future fusion power plants has been developed. This concept is based on the use of modular cooling fingers made from tungsten and tungsten alloy, which are presently considered the most promising divertor materials to withstand the specific heat load of 10 MW/m 2 . Since a large number of the finger modules (n > 250,000) are needed for the whole reactor, developing a mass-oriented manufacturing method is indispensable. In this regard, an innovative manufacturing technology, Powder Injection Molding (PIM), has been adapted to W processing at KIT since a couple of years. This production method is deemed promising in view of large-scale production of tungsten parts with high near-net-shape precision, hence, offering an advantage of cost-saving process compared to conventional machining. The complete technological PIM process for tungsten materials and its application on manufacturing of real divertor components, including the design of a new PIM tool is outlined and, results of the examination of the finished product after heat-treatment are discussed. A binary tungsten powder feedstock with a solid load of 50 vol.% was developed and successfully tested in molding experiments. After design, simulation and manufacturing of a new PIM tool, real divertor parts are produced. After heat-treatment (pre-sintering and HIP) the successful finished samples showed a sintered density of approximately 99%, a hardness of 457 HV0.1, a grain size of approximately 5 μm and a microstructure without cracks and porosity.

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

Science.gov (United States)

Ku, Robert T.

2004-05-01

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

Design, Manufacturing and Integration of LHC Cryostat Components an Example of Collaboration between CERN and Industry

CERN Document Server

Slits, Ivo; Canetti, Marco; Colombet, Thierry; Gangini, Fabrizio; Parma, Vittorio; Tock, Jean-Philippe

2006-01-01

The components for the LHC cryostats and interconnections are supplied by European industry. The manufacturing, assembly and testing of these components in accordance with CERN technical specifications require a close collaboration and dedicated approach from the suppliers. This paper presents the different phases of design, manufacturing, testing and integration of four LHC cryostat components supplied by RIAL Vacuum (Parma, Italy), including 112 Insulation Vacuum Barriers (IVB), 482 Cold-mass Extension Tubes (CET), 121 cryostat vacuum vessel Jumper Elbows (JE) and 10800 Interconnection Sleeves (IS). The Quality Assurance Plan, which the four projects have in common, is outlined. The components are all leak-tight thin stainless steel assemblies (<10-8 mbar l/s), most of them operating at cryogenic temperature (2 K), however each having specific requirements. The particularities of each component are presented with respect to manufacturing, assembly and testing. These components are being integrated ...

Size effects in manufacturing of metallic components

DEFF Research Database (Denmark)

Vollertsen, F; Biermann, D; Hansen, Hans Nørgaard

2009-01-01

In manufacturing of metallic components, the size of the part plays an important role for the process behaviour. This is due to so called size effects, which lead to changes in the process behaviour even if the relationship between the main geometrical features is kept constant. The aim...... of this paper is to give a systematic review on Such effects and their potential use or remedy. First, the typology of size effects will be explained, followed by a description of size effects on strength and tribology. The last three sections describe size effects on formability, forming processes and cutting...... processes. (C) 2009 CIRP....

Component Manufacturing Development for the National Compact Stellarator Experiment (NCSX)

International Nuclear Information System (INIS)

Heitzenroeder, P.J.; Brown, T.G.; Chrzanowski, J.H.; Cole, M.J.; Goranson, P.L.; Neilson, G.H.; Nelson, B.E.; Reiersen, W.T.; Sutton, L.L.; Williamson, D.E.; Viola, M.E.

2004-11-01

NCSX [National Compact Stellarator Experiment] is the first of a new class of stellarators called compact stellarators which hold the promise of retaining the steady state feature of the stellarator but at a much lower aspect ratio and using a quasi-axisymmetric magnetic field to obtain tokamak-like performance. Although much of NCSX is conventional in design and construction, the vacuum vessel and modular coils provide significant engineering challenges due to their complex shapes, need for high dimensional accuracy, and the high current density required in the modular coils due space constraints. Consequently, a three-phase development program has been undertaken. In the first phase, laboratory/industrial studies were performed during the development of the conceptual design to permit advances in manufacturing technology to be incorporated into NCSX's plans. In the second phase, full-scale prototype modular coil winding forms, compacted cable conductors, and 20 degree sectors of the vacuum vessel were fabricated in industry. In parallel, the NCSX project team undertook RandD studies that focused on the windings. The third (production) phase began in September 2004. First plasma is scheduled for January 2008

Component manufacturing development for the National Compact Stellarator Experiment (NCSX)

International Nuclear Information System (INIS)

Heitzenroeder, P.J.; Brown, T.G.; Chrzanowski, J.H.; Neilson, G.H.; Reiersen, W.T.; Sutton, L.L.; Viola, M.E.; Cole, M.J.; Goranson, P.L.; Nelson, B.E.; Williamson, D.E.

2005-01-01

NCSX is the first of a new class of stellarators called compact stellarators which hold the promise of retaining the steady state feature of the stellarator but at a much lower aspect ratio and using a quasi-axisymmetric magnetic field to obtain tokamak-like performance. Although much of NCSX is conventional in design and construction, the vacuum vessel and modular coils provide significant engineering challenges due to their complex shapes, need for high dimensional accuracy, and the need for high current density in the modular coils due space constraints. Consequently, a three-phase development program has been undertaken. In the first phase, laboratory / industrial studies were performed during the development of the conceptual design to permit advances in manufacturing technology to be incorporated into NCSX's plans. In the second phase, full-scale prototype modular coil winding forms, compacted cable conductors, and 20-degree sectors of the vacuum vessel were fabricated in industry. In parallel, the NCSX project team undertook R and D studies that focused on the windings. The third (production) phase began in September 2004. First plasma is scheduled for January 2008. (author)

Rheo-processing of semi-solid metal alloys: a new technology for manufacturing Automotive and aerospace components - Conference paper

CSIR Research Space (South Africa)

Ivanchev, L

2006-02-01

Full Text Available -solid forming processes. The CSIR in SA, developed and patented a rheocasting process and equipment for semi solid casting, which is in the commercialization stage and an automotive component will be manufactured soon....

Development of materials and manufacturing technologies for Indian fast reactor programme

International Nuclear Information System (INIS)

Raj, Baldev; Jayakumar, T.; Bhaduri, A.K.; Mandal, Sumantra

2010-01-01

Fast Breeder Reactors (FBRs) are vital towards meeting security and sustainability of energy for the growing economy of India. The development of FBRs necessitates extensive research and development in domains of materials and manufacturing technologies in association with a wide spectrum of disciplines and their inter-twining to meet the challenging technology. The paper highlight the work and the approaches adopted for the successful deployment of materials, manufacturing and inspection technologies for the in-core and structural components of current and future Indian Fast Breeder Reactor Programme. Indigenous development of in-core materials viz. Titanium modified austenitic stainless steel (Alloy D9) and its variants, ferritic/martensitic oxide-dispersion strengthened (ODS) steels as well as structural materials viz. 316L(N) stainless steel and modified 9Cr-1Mo have been achieved through synergistic interactions between Indira Gandhi Centre for Atomic Research (IGCAR), education and research institutes and industries. Robust manufacturing technology has been established for forming and joining of various components of 500 MWe Prototype Fast Breeder Reactor (PFBR) through 'science-based technology' approach. To achieve the strict quality standards of formed parts in terms of geometrical tolerances, residual stresses and microstructural defects, FEM-based modelling and experimental validation was carried out for estimation of spring-back during forming of multiple curvature thick plantes. Optimization of grain boundary character distribution in Alloy D9 was carried out by adopting the grain boundary engineering approach to reduce radiation induced segregation. Extensive welding is involved in the fabrication of reactor vessels, piping, steam generators, fuel sub-assemblies etc. Activated Tungsten Inert Gas Welding process along with activated flux developed at IGCAR has been successfully used in fabrication of dummy fuel subassemblies (DFSA) required for testing

Development of materials and manufacturing technologies for Indian fast reactor programme

Energy Technology Data Exchange (ETDEWEB)

Raj, Baldev; Jayakumar, T.; Bhaduri, A.K.; Mandal, Sumantra [Indira Gandhi Centre for Atomic Research, Kalpakkam (India)

2010-07-01

Fast Breeder Reactors (FBRs) are vital towards meeting security and sustainability of energy for the growing economy of India. The development of FBRs necessitates extensive research and development in domains of materials and manufacturing technologies in association with a wide spectrum of disciplines and their inter-twining to meet the challenging technology. The paper highlight the work and the approaches adopted for the successful deployment of materials, manufacturing and inspection technologies for the in-core and structural components of current and future Indian Fast Breeder Reactor Programme. Indigenous development of in-core materials viz. Titanium modified austenitic stainless steel (Alloy D9) and its variants, ferritic/martensitic oxide-dispersion strengthened (ODS) steels as well as structural materials viz. 316L(N) stainless steel and modified 9Cr-1Mo have been achieved through synergistic interactions between Indira Gandhi Centre for Atomic Research (IGCAR), education and research institutes and industries. Robust manufacturing technology has been established for forming and joining of various components of 500 MWe Prototype Fast Breeder Reactor (PFBR) through 'science-based technology' approach. To achieve the strict quality standards of formed parts in terms of geometrical tolerances, residual stresses and microstructural defects, FEM-based modelling and experimental validation was carried out for estimation of spring-back during forming of multiple curvature thick plantes. Optimization of grain boundary character distribution in Alloy D9 was carried out by adopting the grain boundary engineering approach to reduce radiation induced segregation. Extensive welding is involved in the fabrication of reactor vessels, piping, steam generators, fuel sub-assemblies etc. Activated Tungsten Inert Gas Welding process along with activated flux developed at IGCAR has been successfully used in fabrication of dummy fuel subassemblies (DFSA) required

Design and development of R.F. LINAC accelerator components

International Nuclear Information System (INIS)

Abhay Kumar; Guha, S.; Balasubramaniam, R.; Jawale, S.B.

2003-01-01

Full text: Radio frequency linear accelerator, a high power electron LINAC technology, is being developed at BARC. These accelerators are considered to be the most compact and effective for a given power capacity. Important application areas of this LINAC include medical sterilization, food preservation, pollution control, semiconductor industries, radiation therapy and material science. Center for Design and Manufacture (CDM), BARC has been entrusted with the design, development and manufacturing of various mechanical components of the accelerator. Most critical and precision components out of them are Diagnostic chamber, Faraday cup, Drift tube and R.F. cavities. This paper deals with the design aspects in respect of Ultra high vacuum compatibility and the mechanism of operation. Also this paper discusses the state-of-art technology for machining of intricate contour using specially designed poly crystalline diamond tool and the inspection methodology developed to minimize the measurement errors on the machined contour. Silver brazing technique employed to join the LINAC cavities is also described in detail

Experience feedback from high heat flux component manufacturing for Tore Supra

International Nuclear Information System (INIS)

Schlosser, J.; Durocher, A.; Huber, T.; Garin, P.; Schedler, B.; Agarici, G.

2001-01-01

Tore Supra is involved in flat tile carbon armoured plasma facing components (PFCs) since 1985. In 1997, a third generation of components, based on the original concept developed with Plansee Company, called active metal casting (AMC[reg]), has been launched. Since 1998, 660 elementary components for the toroidal pump limiter (TPL) are in production. The route of the manufacture is rather complex and many controls were requested all along the fabrication to insure a high reliability of the elements. One of the main controls is the final infrared (IR) test allowing to determine the quality of the bonding between the carbon fibre composite (CFC) tiles and the heat sink made of copper-chromium-zirconium alloy (CuCrZr). Although results for the first batch of elements were as expected (less than 5% rejected at the final test), unexpected defects appeared with the followings batches. Investigations on the fabrication processes underlined the importance of having a better heat treatment of the pieces in copper alloy (CuCrZr), however this was not sufficient to completely explain the observed defects

Additive Manufacturing Thermal Performance Testing of Single Channel GRCop-84 SLM Components

Science.gov (United States)

Garcia, Chance P.; Cross, Matthew

2014-01-01

The surface finish found on components manufactured by sinter laser manufacturing (SLM) is rougher (0.013 - 0.0006 inches) than parts made using traditional fabrication methods. Internal features and passages built into SLM components do not readily allow for roughness reduction processes. Alternatively, engineering literature suggests that the roughness of a surface can enhance thermal performance within a pressure drop regime. To further investigate the thermal performance of SLM fabricated pieces, several GRCop-84 SLM single channel components were tested using a thermal conduction rig at MSFC. A 20 kW power source running at 25% duty cycle and 25% power level applied heat to each component while varying water flow rates between 2.1 - 6.2 gallons/min (GPM) at a supply pressure of 550 to 700 psi. Each test was allowed to reach quasi-steady state conditions where pressure, temperature, and thermal imaging data were recorded. Presented in this work are the heat transfer responses compared to a traditional machined OHFC Copper test section. An analytical thermal model was constructed to anchor theoretical models with the empirical data.

Advanced optical manufacturing digital integrated system

Science.gov (United States)

Tao, Yizheng; Li, Xinglan; Li, Wei; Tang, Dingyong

2012-10-01

It is necessarily to adapt development of advanced optical manufacturing technology with modern science technology development. To solved these problems which low of ration, ratio of finished product, repetition, consistent in big size and high precision in advanced optical component manufacturing. Applied business driven and method of Rational Unified Process, this paper has researched advanced optical manufacturing process flow, requirement of Advanced Optical Manufacturing integrated System, and put forward architecture and key technology of it. Designed Optical component core and Manufacturing process driven of Advanced Optical Manufacturing Digital Integrated System. the result displayed effective well, realized dynamic planning Manufacturing process, information integration improved ratio of production manufactory.

Numerical and Experimental Study of Ti6Al4V Components Manufactured Using Powder Bed Fusion Additive Manufacturing

Science.gov (United States)

Zielinski, Jonas; Mindt, Hans-Wilfried; Düchting, Jan; Schleifenbaum, Johannes Henrich; Megahed, Mustafa

2017-12-01

Powder bed fusion additive manufacturing of titanium alloys is an interesting manufacturing route for many applications requiring high material strength combined with geometric complexity. Managing powder bed fusion challenges, including porosity, surface finish, distortions and residual stresses of as-built material, is the key to bringing the advantages of this process to production main stream. This paper discusses the application of experimental and numerical analysis towards optimizing the manufacturing process of a demonstration component. Powder characterization including assessment of the reusability, assessment of material consolidation and process window optimization is pursued prior to applying the identified optima to study the distortion and residual stresses of the demonstrator. Comparisons of numerical predictions with measurements show good correlations along the complete numerical chain.

Manufacturing of reliable actively cooled fusion components - a challenge for non-destructive inspections

International Nuclear Information System (INIS)

Reheis, N.; Zabernig, A.; Ploechl, L.

1994-01-01

Actively cooled in-vessel components like divertors or limiters require high quality and reliability to ensure safe operation during long term use. Such components are subjected to very severe thermal and mechanical cyclic loads and high power densities. Key requirements for materials in question are e.g. high melting point and thermal conductivity and low atomic mass number. Since no single material can simultaneously meet all of these requirements the selection of materials to be combined in composite components as well as of manufacturing and non-destructive inspection (NDI) methods is a particularly challenging task. Armour materials like graphite intended to face the plasma and help to maintain its desired properties, are bonded to metallic substrates like copper, molybdenum or stainless steel providing cooling and mechanical support. Several techniques such as brazing and active metal casting have been developed and successfully applied for joining materials with different thermophysical properties, pursuing the objective of sufficient heat dissipation from the hot, plasma facing surface to the coolant. NDI methods are an integral part of the manufacturing schedule of these components, starting in the design phase and ending in the final inspection. They apply all kinds of divertor types (monobloc and flat-tile concept). Particular focus is put on the feasibility of detecting small flaws and defects in complex interfaces and on the limits of these techniques. Special test pieces with defined defects acting as standards were inspected. Accompanying metallographic investigations were carried out to compare actual defects with results recorded during NDI

DEVELOPMENT OF LOW-COST MANUFACTURING PROCESSES FOR PLANAR, MULTILAYER SOLID OXIDE FUEL CELL ELEMENTS

Energy Technology Data Exchange (ETDEWEB)

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.

Manufacturing and testing experience for FFTF major safety related components

International Nuclear Information System (INIS)

Peckinpaugh, C.L.

1976-01-01

Experience with FFTF Heat Transport System components during design, manufacturing, and prototype testing is dscussed. Specifically the special design features and the results of the testing performed to assure that the designs provide for safe operation are outlined. Particular emphasis is placed on the full size prototype testing programs and the valuable experience gained

The scope of additive manufacturing in cryogenics, component design, and applications

NARCIS (Netherlands)

Stautner, W.; Vanapalli, S.; Weiss, K.-P.; Chen, R.; Amm, K.; Budesheim, E.; Ricci, J.

2017-01-01

Additive manufacturing techniques using composites or metals are rapidly gaining momentum in cryogenic applications. Small or large, complex structural components are now no longer limited to mere design studies but can now move into the production stream thanks to new machines on the market that

Roadmap for Lean implementation in Indian automotive component manufacturing industry: comparative study of UNIDO Model and ISM Model

Science.gov (United States)

Jadhav, J. R.; Mantha, S. S.; Rane, S. B.

2015-06-01

The demands for automobiles increased drastically in last two and half decades in India. Many global automobile manufacturers and Tier-1 suppliers have already set up research, development and manufacturing facilities in India. The Indian automotive component industry started implementing Lean practices to fulfill the demand of these customers. United Nations Industrial Development Organization (UNIDO) has taken proactive approach in association with Automotive Component Manufacturers Association of India (ACMA) and the Government of India to assist Indian SMEs in various clusters since 1999 to make them globally competitive. The primary objectives of this research are to study the UNIDO-ACMA Model as well as ISM Model of Lean implementation and validate the ISM Model by comparing with UNIDO-ACMA Model. It also aims at presenting a roadmap for Lean implementation in Indian automotive component industry. This paper is based on secondary data which include the research articles, web articles, doctoral thesis, survey reports and books on automotive industry in the field of Lean, JIT and ISM. ISM Model for Lean practice bundles was developed by authors in consultation with Lean practitioners. The UNIDO-ACMA Model has six stages whereas ISM Model has eight phases for Lean implementation. The ISM-based Lean implementation model is validated through high degree of similarity with UNIDO-ACMA Model. The major contribution of this paper is the proposed ISM Model for sustainable Lean implementation. The ISM-based Lean implementation framework presents greater insight of implementation process at more microlevel as compared to UNIDO-ACMA Model.

Application of microCT to the non-destructive testing of an additive manufactured titanium component

Directory of Open Access Journals (Sweden)

Anton du Plessis

2015-11-01

Full Text Available In this paper the application of X-ray microCT to the non-destructive testing of an additive manufactured titanium alloy component of complex geometry is demonstrated. Additive manufacturing of metal components is fast growing and shows great promise, yet these parts may contain defects which affect mechanical properties of the components. In this work a layered form of defect is found by microCT, which would have been very difficult or impossible to detect by other non-destructive testing methods due to the object complexity, defect size and shape and because the pores are entirely contained inside the object and not connected to the surface. Additionally, this test part was subjected to hot isostatic pressing (HIPPING and subsequently scanned. Comparing before and after scans by alignment of the volumes allows visualization and quantification of the pore size changes. The application of X-ray microCT to additive manufacturing is thus demonstrated in this example to be an ideal combination, especially for process improvements and for high value components.

Integrated Manufacturing of Aerospace Components by Superplastic Forming Technology

Directory of Open Access Journals (Sweden)

Ju Min Kyung

2015-01-01

Full Text Available Aerospace vehicle requires lightweight structures to obtain weight saving and fuel efficiency. It is known that superplastic characteristics of some materials provide significant opportunity for forming complicated, lightweight components of aerospace structure. One of the most important advantages of using superplastic forming process is its simplicity to form integral parts and economy in tooling[1]. For instance, it can be applied to blow-forming, in which a metal sheet is deformed due to the pressure difference of hydrostatic gas on both sides of the sheet. Since the loading medium is gas pressure difference, this forming is different from conventional sheet metal forming technique in that this is stress-controlled rather than strain and strain rate controlled. This method is especially advantageous when several sheet metals are formed into complex shapes. In this study, it is demonstrated that superplastic forming process with titanium and steel alloy can be applied to manufacturing lightweight integral structures of aerospace structural parts and rocket propulsion components. The result shows that the technology to design and develop the forming process of superplastic forming can be applied for near net shape forming of a complex contour of a thrust chamber and a toroidal fuel tank.

Estimation of cellular manufacturing cost components using simulation and activity-based costing

OpenAIRE

Paul Savory; Robert Williams

2010-01-01

It can be difficult estimating all of the cost components that are attributed to a machined part.  This problem is more pronounced when a factory uses group technology manufacturing cells as opposed to a functional or process layout of a job shop.  This paper describes how activity-based costing (ABC) concepts can be integrated into a discrete-event simulation model of a U-shaped manufacturing cell producing a part family with four members.  The simulation model generates detai...

Estimation of cellular manufacturing cost components using simulation and activity-based costing

OpenAIRE

Savory, Paul

2010-01-01

It can be difficult estimating all of the cost components that are attributed to a machined part. This problem is more pronounced when a factory uses group technology manufacturing cells as opposed to a functional or process layout of a job shop. This paper describes how activity-based costing (ABC) concepts can be integrated into a discrete-event simulation model of a U-shaped manufacturing cell producing a part family with four members. The simulation model generates detailed Bills of Ac...

The influence of cellular structures on flow stress of high strength components manufactured using SLM

DEFF Research Database (Denmark)

Mahshid, Rasoul; Hansen, Hans Nørgaard; Loft Højbjerre, Klaus

2016-01-01

Additive manufacturing has shown significant improvement in material and machines for high-quality solid freeform fabrication processes such as selective laser melting (SLM). In particular, manufacturing lattice structures using the SLM procedure is of interest. This research examines the effect...... of cellular materials on compression strength. The specimens are manufactured additively using industrial 3D printing systems from high-strength alloy. The material has the right mechanical properties for manufacturing tool components. This includes samples with solid and lattice structures. The Compression...

Advances in the manufacture of clad tubes and components for PHWR fuel bundle

International Nuclear Information System (INIS)

Saibaba, N.; Jha, S.K.; Chandrasekha, B.; Tonpe, S.; Jayaraj, R.N.

2010-01-01

Fuel bundles for Pressurized Heavy Water Reactors (PHWRs) consists of Uranium di-oxide pellets encapsulated into thin wall Zircaloy clad tubes. Other components such as end caps, bearing pads and spacer pads are the integral elements of the fuel bundle. As the fuel assembly is subjected to severe operating conditions of high temperature and pressure in addition to continual irradiation exposure, all the components are manufactured conforming to stringent specifications with respect to chemical composition, mechanical & metallurgical properties and dimensional tolerances. The integrity of each component is ensured by NDE at different stages of manufacture. The manufacturing route for fuel tubes and components comprise of a combination of thermomechanical processing and each process step has marked effect on the final properties. The fuel tubes are manufactured by processing the extruded blanks in four stage cold pilgering with intermediate annealing and final stress relieving operation. The bar material is produced by hot extrusion followed by multi-pass swaging and intermediate annealing. Spacer pads and bearing pads are manufactured by blanking and coining of Zircaloy sheet which is made by a combination of hot and cold rolling operations. Due to the small size and stringent dimensional requirements of these appendages, selection of production route and optimization of process parameters are important. This paper discusses about various measures taken for improving the recoveries and mechanical and corrosion properties of the tube, sheet and bar materials being manufactured at Nuclear Fuel Complex, Hyderabad For the production of clad tubes, modifications at extrusion stage to reduce the wall thickness variation, introduction of ultrasonic testing of extruded blanks, optimization of cold working and heat treatment parameters at various stages of production etc. were done. The finished bar material is subjected to 100% Ultrasonic and eddy current testing to ensure

Phase 1 Development Testing of the Advanced Manufacturing Demonstrator Engine

Science.gov (United States)

Case, Nicholas L.; Eddleman, David E.; Calvert, Marty R.; Bullard, David B.; Martin, Michael A.; Wall, Thomas R.

2016-01-01

The Additive Manufacturing Development Breadboard Engine (BBE) is a pressure-fed liquid oxygen/pump-fed liquid hydrogen (LOX/LH2) expander cycle engine that was built and operated by NASA at Marshall Space Flight Center's East Test Area. The breadboard engine was conceived as a technology demonstrator for the additive manufacturing technologies for an advanced upper stage prototype engine. The components tested on the breadboard engine included an ablative chamber, injector, main fuel valve, turbine bypass valve, a main oxidizer valve, a mixer and the fuel turbopump. All parts minus the ablative chamber were additively manufactured. The BBE was successfully hot fire tested seven times. Data collected from the test series will be used for follow on demonstration tests with a liquid oxygen turbopump and a regeneratively cooled chamber and nozzle.

The study and design of a national supply chain for the aerospace titanium components manufacturing industry

Directory of Open Access Journals (Sweden)

Lene van der Merwe

2012-11-01

Full Text Available Titanium’s strength-to-density ratio, corrosion resistance and high thermal compatibility makes it the perfect metal for aerospace. Titanium is for instance used for the structural airframe, seat tracks, engine components and landing gear of aircraft. The Boeing 787 that had its test flight in 2009 is one of the latest aircraft designs that incorporates a substantially higher percentage of parts manufactured from titanium due to the weight benefit. Titanium’s extensive use in aerospace applications ensures that the aerospace market is the main driver of titanium metal demand. South Africa is the second largest titanium producer in the world after Australia. The abundance of titanium in South Africa together with the growing demand has led it to be identified as a beneficiation priority in a collaborative government initiative, called Titanium Beneficiation Initiative (TBI. The purpose of this paper is to develop a supply chain model for the anticipated South African titanium component manufacturing industry.

Development of Manufacturing Technology to Accelerate Cost Reduction of Low Concentration and

Energy Technology Data Exchange (ETDEWEB)

Detrick, Adam [The Solaria Corporation, Fremont, CA (United States)

2017-09-27

The purpose of this project was to accelerate deployment of cost-effective US-based manufacturing of Solaria’s unique c-Si module technology. This effort successfully resulted in the development of US-based manufacturing technology to support two highly-differentiated, market leading product platforms. The project was initially predicated on developing Solaria’s low-concentration PV (LCPV) module technology which at the time of the award was uniquely positioned to exceed the SunShot price goal of $0.50/Wp for standard c-Si modules. The Solaria LCPV module is a 2.5x concentrator that leverages proven, high-reliability PV module materials and low silicon cell usage into a technology package that already had the lowest direct material cost and leading Levelized Cost of Electricity (LCOE). With over 25 MW commercially deployed globally, the Solaria module was well positioned to continue to lead in PV module cost reduction. Throughout the term of the contract, market conditions changed dramatically and so to did Solaria’s product offerings to support this. However, the manufacturing technology developed for the LCPV module was successfully leveraged and optimized to support two new and different product platforms. BIPV “PowerVision” and High-efficiency “PowerXT” modules. The primary barrier to enabling high-volume PV module manufacturing in the US is the high manual labor component in certain unique aspects of our manufacturing process. The funding was used to develop unique manufacturing automation which makes the manual labor components of these key processes more efficient and increase throughput. At the core of Solaria’s product offerings are its unique and proprietary techniques for dicing and re-arranging solar cells into modules with highly-differentiated characteristics that address key gaps in the c-Si market. It is these techniques that were successfully evolved and deployed into US-based manufacturing site with SunShot funding. Today, Solaria

Fiber Laser Component Testing for Space Qualification Protocol Development

Science.gov (United States)

Falvey, S.; Buelow, M.; Nelson, B.; Starcher, Y.; Thienel, L.; Rhodes, C.; Tull, Jackson; Drape, T.; Westfall, C.

A test protocol for the space qualifying of Ytterbium-doped diode-pumped fiber laser (DPFL) components was developed under the Bright Light effort, sponsored by AFRL/VSE. A literature search was performed and summarized in an AMOS 2005 conference paper that formed the building blocks for the development of the test protocol. The test protocol was developed from the experience of the Bright Light team, the information in the literature search, and the results of a study of the Telcordia standards. Based on this protocol developed, test procedures and acceptance criteria for a series of vibration, thermal/vacuum, and radiation exposure tests were developed for selected fiber laser components. Northrop Grumman led the effort in vibration and thermal testing of these components at the Aerospace Engineering Facility on Kirtland Air Force Base, NM. The results of the tests conducted have been evaluated. This paper discusses the vibration and thermal testing that was executed to validate the test protocol. The lessons learned will aid in future assessments and definition of space qualification protocols. Components representative of major items within a Ytterbium-doped diode-pumped fiber laser were selected for testing; including fibers, isolators, combiners, fiber Bragg gratings, and laser diodes. Selection of the components was based on guidelines to test multiple models of typical fiber laser components. A goal of the effort was to test two models (i.e. different manufacturers) of each type of article selected, representing different technologies for the same type of device. The test articles did not include subsystems or systems. These components and parts may not be available commercial-off-the-shelf (COTS), and, in fact, many are custom articles, or newly developed by the manufacturer. The primary goal for this effort is a completed taxonomy that lists all relevant laser components, modules, subsystems, and interfaces, and cites the documentation for space

A study of internal structure in components made by additive manufacturing process using 3 D X-ray tomography

Energy Technology Data Exchange (ETDEWEB)

Raguvarun, K., E-mail: prajagopal@iitm.ac.in; Balasubramaniam, Krishnan, E-mail: prajagopal@iitm.ac.in; Rajagopal, Prabhu, E-mail: prajagopal@iitm.ac.in [Centre for NDE, Indian Institute of Technology Madras, Chennai 600036, Tamilnadu (India); Palanisamy, Suresh [Swinburne University of Technology, Faculty of Engineering, Science and Technology, Hawthorn, Victoria 3122 Australia and Defence Materials Technology Centre, Hawthorn, Victoria 3122 (Australia); Nagarajah, Romesh; Kapoor, Ajay [Swinburne University of Technology, Faculty of Engineering, Science and Technology, Hawthorn, Victoria 3122 (Australia); Hoye, Nicholas; Curiri, Dominic [University of Wollongong, Faculty of Engineering, New South Wales 2522, Australia and Defence Materials Technology Centre, Hawthorn, Victoria 3122 (Australia)

2015-03-31

Additive manufacturing methods are gaining increasing popularity for rapidly and efficiently manufacturing parts and components in the industrial context, as well as for domestic applications. However, except when used for prototyping or rapid visualization of components, industries are concerned with the load carrying capacity and strength achievable by additive manufactured parts. In this paper, the wire-arc additive manufacturing (AM) process based on gas tungsten arc welding (GTAW) has been examined for the internal structure and constitution of components generated by the process. High-resolution 3D X-ray tomography is used to gain cut-views through wedge-shaped parts created using this GTAW additive manufacturing process with titanium alloy materials. In this work, two different control conditions for the GTAW process are considered. The studies reveal clusters of porosities, located in periodic spatial intervals along the sample cross-section. Such internal defects can have a detrimental effect on the strength of the resulting AM components, as shown in destructive testing studies. Closer examination of this phenomenon shows that defect clusters are preferentially located at GTAW traversal path intervals. These results highlight the strong need for enhanced control of process parameters in ensuring components with minimal defects and higher strength.

A study of internal structure in components made by additive manufacturing process using 3 D X-ray tomography

International Nuclear Information System (INIS)

Raguvarun, K.; Balasubramaniam, Krishnan; Rajagopal, Prabhu; Palanisamy, Suresh; Nagarajah, Romesh; Kapoor, Ajay; Hoye, Nicholas; Curiri, Dominic

2015-01-01

Additive manufacturing methods are gaining increasing popularity for rapidly and efficiently manufacturing parts and components in the industrial context, as well as for domestic applications. However, except when used for prototyping or rapid visualization of components, industries are concerned with the load carrying capacity and strength achievable by additive manufactured parts. In this paper, the wire-arc additive manufacturing (AM) process based on gas tungsten arc welding (GTAW) has been examined for the internal structure and constitution of components generated by the process. High-resolution 3D X-ray tomography is used to gain cut-views through wedge-shaped parts created using this GTAW additive manufacturing process with titanium alloy materials. In this work, two different control conditions for the GTAW process are considered. The studies reveal clusters of porosities, located in periodic spatial intervals along the sample cross-section. Such internal defects can have a detrimental effect on the strength of the resulting AM components, as shown in destructive testing studies. Closer examination of this phenomenon shows that defect clusters are preferentially located at GTAW traversal path intervals. These results highlight the strong need for enhanced control of process parameters in ensuring components with minimal defects and higher strength

Manufacturing development for the SAFE 100 kW core

International Nuclear Information System (INIS)

Carter, Robert; Roman, Jose; Salvail, Pat

2002-01-01

In stark contrast to what is sometimes considered the norm in traditional manufacturing processes, engineers at the Marshall Space Flight Center (MSFC) arc in the practice of altering the standard in an effort to realize other potential methods in core manufacturing. While remaining within the bounds of the materials database, we are researching into core manufacturing techniques that may have been overlooked in the past due to funding and/or time constraints. To augment proven core fabrication capabilities we are pursuing plating processes as another possible method for core build-up and assembly. Although brazing and a proprietary HIP cycle are used for module assembly (proven track record for stability and endurance), it is prudent to pursue secondary or backup methods of module and core assembly. For this reason heat tube manufacture and module assembly by means of plating is being investigated. Potentially, the plating processes will give engineers the ability to manufacture replacement modules for any module that might fail to perform nominally, and to assemble/disassemble a complete core in much less time than would be required for the conventional Braze-HIP process. Another area of improvement in core manufacturing capabilities is the installation of a sodium and lithium liquid metal heat pipe fill machine. This, along with the ability to Electron Beam Weld heat pipe seals and wet-in the pipes in the necessary vacuum atmosphere, will eliminate the need to ship potentially hazardous components outside for processing. In addition to developing core manufacturing techniques, the SAFE manufacturing team has been evaluating the thermal heat transfer characteristics, and manufacturability of several heat exchanger design concepts

Development of a novel cold forging process to manufacture eccentric shafts

Science.gov (United States)

Pasler, Lukas; Liewald, Mathias

2018-05-01

Since the commercial usage of compact combustion engines, eccentric shafts have been used to transform translational into rotational motion. Over the years, several processes to manufacture these eccentric shafts or crankshafts have been developed. Especially for single-cylinder engines manufactured in small quantities, built crankshafts disclose advantages regarding tooling costs and performance. Those manufacturing processes do have one thing in common: They are all executed at elevated temperatures to enable the material to be formed to high forming degree. In this paper, a newly developed cold forging process is presented, which combines lateral extrusion and shifting for manufacturing a crank in one forming operation at room temperature. In comparison to the established upsetting and shifting methods to manufacture such components, the tool cavity or crank web thickness remains constant. Therefore, the developed new process presented in this paper consists of a combination of shifting and extrusion of the billet, which allows pushing material into the forming zone during shifting. In order to reduce the tensile stresses induced by the shifting process, compressive stresses are superimposed. It is expected that the process limits will be expanded regarding the horizontal displacement and form filling. In the following report, the simulation and design of the tooling concept are presented. Experiments were conducted and compared with corresponding simulation results afterwards.

Design and development of progressive tool for manufacturing washer

Science.gov (United States)

Annigeri, Ulhas K.; Raghavendra Ravi Kiran, K.; Deepthi, Y. P.

2017-07-01

In a progressive tool the raw material is worked at different station to finally fabricate the component. A progressive tool is a lucrative tool for mass production of components. A lot of automobile and other transport industries develop progressive tool for the production of components. The design of tool involves lot of planning and the same amount of skill of process planning is required in the fabrication of the tool. The design also involves use of thumb rules and standard elements as per experience gained in practice. Manufacturing the press tool is a laborious task as special jigs and fixtures have to be designed for the purpose. Assembly of all the press tool elements is another task where use of accurate measuring instruments for alignment of various tool elements is important. In the present study, design and fabrication of progressive press tool for production of washer has been developed and the press tool has been tried out on a mechanical type of press. The components produced are to dimensions.

An example of RCCM application to exportation. Manufacture of components for 900 MW nuclear power plants in Korea

International Nuclear Information System (INIS)

Bitouzet, P.

1983-03-01

The National Korean Electricy society KEPCO ordered the KNU9 and 10 power plants from FRAMATOME. This contract involve an important fabrication of components. The KHIC society has been indicated to manufacture the main components. This paper gives some precisions about the organization of the Technical Assistance for the Korean realization of five big components (pressure vessel, steam generator, pressurizer, accumulator and injection reservoir of boron), components manufactured according to French standard, including RCC (design and construction rules). Finally, it is shown how this Technical Assistance is carried out [fr

Method of Manufacturing A Porous Polymer Component Involving Use of A Dissolvable, Sacrificial Material

DEFF Research Database (Denmark)

2015-01-01

and thereby the resulting inner structure of the component 1 is arranged in a controlled and reproducible manner. The sacrificial material 2 and possibly also the component material 3 may e.g. be arranged by use of a 3D-printer or manually. The method may e.g. be used to manufacture a three...

Sustainable Manufacturing via Multi-Scale, Physics-Based Process Modeling and Manufacturing-Informed Design

Energy Technology Data Exchange (ETDEWEB)

None

2017-04-01

This factsheet describes a project that developed and demonstrated a new manufacturing-informed design framework that utilizes advanced multi-scale, physics-based process modeling to dramatically improve manufacturing productivity and quality in machining operations while reducing the cost of machined components.

Mechanized inspection of steam generator components during manufacture

International Nuclear Information System (INIS)

Otte, H.-J.; Leupoldt, K.; Meister, W.

2009-01-01

Steam Generator (SG) parts are intensively inspected by UT in the course of the manufacturing process. These inspections - mostly performed manually using different codes - are time consuming and call for a sophisticated documentation, figuring part of the life time documentation package. In order to reduce time and costs mechanized inspection equipment is introduced, combining short inspection times, avoiding influence of the human factor and providing proper electronic storage of all inspection results prepared for comparison with data generated during in-service inspection. Since 2001 Cegelec delivered various UT systems for gas turbine disks and rotor ends called SIRO-MAN. Within only a few years the majority of important providers of such components successfully switched from manual inspection to mechanized inspection following the requirements of manufacturers like ALSTOM, GE and Siemens. The SIRO-MAN is now adapted to the needs of mechanized inspection of SG components. The inspection is performed on the products during rotation around the vertical axis. The multi - probe assemblies are manoeuvred on the products by a manipulator system backed by a NC control unit. Acoustic coupling of UT probes to the product surface is performed with oil or water in a closed circuit. UT and - if requested ET - data along with position information of the probe assembly provided by the control unit are acquired, processed and evaluated by an UT / ET electronic system delivered by either Olympus or ZETEC. As performed already on rotor ends a sequence of inspections using different parameter settings can be programmed with simple means (Teach In) so that such inspection sequence can be executed without operating personnel. Probe assemblies allow for individual operation of probes out of the probe assembly according to the individual needs. Conventional UT and phased array applications or combination of both techniques can be provided. The UT / ET electronic equipment offers

Apparatus with moderating material for microwave heat treatment of manufactured components

Science.gov (United States)

Ripley, Edward B [Knoxville, TN

2011-05-10

An apparatus for heat treating manufactured components using microwave energy and microwave susceptor material. Heat treating medium such as eutectic salts may be employed. A fluidized bed introduces process gases which may include carburizing or nitriding gases The process may be operated in a batch mode or continuous process mode. A microwave heating probe may be used to restart a frozen eutectic salt bath.

In-Space Manufacturing Baseline Property Development

Science.gov (United States)

Stockman, Tom; Schneider, Judith; Prater, Tracie; Bean, Quincy; Werkheiser, Nicki

2016-01-01

The In-Space Manufacturing (ISM) project at NASA Marshall Space Flight Center currently operates a 3D FDM (fused deposition modeling) printer onboard the International Space Station. In order to enable utilization of this capability by designer, the project needs to establish characteristic material properties for materials produced using the process. This is difficult for additive manufacturing since standards and specifications do not yet exist for these technologies. Due to availability of crew time, there are limitations to the sample size which in turn limits the application of the traditional design allowables approaches to develop a materials property database for designers. In this study, various approaches to development of material databases were evaluated for use by designers of space systems who wish to leverage in-space manufacturing capabilities. This study focuses on alternative statistical techniques for baseline property development to support in-space manufacturing.

Manufacture of piping components for nuclear power plants

International Nuclear Information System (INIS)

Bartecek, R.

1983-01-01

Hammer forging of hollow forging ingots, extrusion and elestroslag remelting may be used for the manufacture of large pipes. Technologies have been developed for the manufacture of elbows based on various types of forming. These procedures mainly include the hydraulic pressing of elbows from tubes and the pressing of symmetrical halves of elbows with subsequent welding. The hammer forging of valves, cross pieces, etc., has been replaced by forging and pressing. In order to prevent failures from occurring in the pipes during operation of nuclear power plants, pipes are being made of larger forgings, which reduces the number of welds. This improves the quality of the pipes, reduces production and assembly costs and is metal-saving. (E.S.)

In-Space Manufacturing Project (prior to FY15: Additive Manufacturing Technology Development)

Data.gov (United States)

National Aeronautics and Space Administration — The In-Space Manufacturing (ISM) project is responsible for developing the manufacturing capabilities that will provide on-demand, sustainable operations during NASA...

Process development for the manufacturing of state-of-the-art spacer grids

Energy Technology Data Exchange (ETDEWEB)

Schebitz, Florian; Dietrich, Matthias [Advanced Nuclear Fuels GmbH, Karlstein (Germany)

2013-07-01

At the beginning it was questioned if 'time to market' is really important for the nuclear industry. The clear answer is YES. Even if the development times might be longer compared to projects in other industries it is still beneficial to use concurrent engineering. In the world wide network of manufacturing sites, Advanced Nuclear Fuels GmbH in Karlstein is quite often involved when the development of new processes is necessary. As ANF Karlstein is delivering products around the world the experience with different customer requirements supports an optimized solution in order to fulfill these principle requirements and to deliver state-of-the-art products like spacer grids. Continues feedback from process development already improves the first prototypes. In the meantime ANF Karlstein manufactured the components for both new fuel assembly designs which are introduced as a first set of Lead Fuel Assemblies. For the manufacturing of the next sets of spacer grids (for tests and next series of Lead Fuel Assemblies) the described processes will be used and further improved, so that an industrialized solution is available. (orig.)

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

Science.gov (United States)

Vickers, John; Fikes, John

2015-01-01

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

System and method for manufacture of airfoil components

Science.gov (United States)

Moors, Thomas Michael

2016-11-29

Embodiments of the present disclosure relate generally to systems and methods for manufacturing an airfoil component. The system can include: a geometrical mold; an elongated flexible sleeve having a closed-off interior and positioned within the geometrical mold, wherein the elongated flexible sleeve is further positioned to have a desired geometry; an infusing channel in fluid communication with the closed-off interior of the elongated flexible sleeve and configured to communicate a resinous material thereto; a vacuum channel in fluid communication with the closed-off interior of the elongated flexible sleeve and configured to vacuum seal the closed-off interior of the elongated flexible sleeve; and a glass fiber layer positioned within the closed-off interior of the elongated flexible sleeve.

Development of software for computing forming information using a component based approach

Directory of Open Access Journals (Sweden)

Kwang Hee Ko

2009-12-01

Full Text Available In shipbuilding industry, the manufacturing technology has advanced at an unprecedented pace for the last decade. As a result, many automatic systems for cutting, welding, etc. have been developed and employed in the manufacturing process and accordingly the productivity has been increased drastically. Despite such improvement in the manufacturing technology, however, development of an automatic system for fabricating a curved hull plate remains at the beginning stage since hardware and software for the automation of the curved hull fabrication process should be developed differently depending on the dimensions of plates, forming methods and manufacturing processes of each shipyard. To deal with this problem, it is necessary to create a “plug-in” framework, which can adopt various kinds of hardware and software to construct a full automatic fabrication system. In this paper, a framework for automatic fabrication of curved hull plates is proposed, which consists of four components and related software. In particular the software module for computing fabrication information is developed by using the ooCBD development methodology, which can interface with other hardware and software with minimum effort. Examples of the proposed framework applied to medium and large shipyards are presented.

Manufacturing studies of double wall components for the ITER EC H and CD upper launcher

International Nuclear Information System (INIS)

Spaeh, P.; Aiello, G.; Goldmann, A.; Kleefeldt, K.; Kroiss, A.; Meier, A.; Obermeier, C.; Scherer, T.; Schreck, S.; Serikov, A.; Strauss, D.; Vaccaro, A.

2012-01-01

Highlights: ► Double wall manufacturing technologies for ITER In-vessel components. ► Rigid and safe accommodation of ECRH heating and current drive systems. ► Thermo hydraulic analysis of coolant flow in double-wall structures. - Abstract: To counteract plasma instabilities, Electron Cyclotron Launchers will be installed in four of the ITER Upper Ports. The structural system of an EC Upper Launcher accommodates the MM-wave-components and has to meet strong demands on alignment, removal of nuclear heat loads, mechanical strength and nuclear shielding. The EC Upper Launcher has successfully undergone the Preliminary Design Review in 2009 and is now in the final design phase. Nuclear heat loads from 0.1 W/cm 3 up to 0.8 W/cm 3 will affect the front area of the launcher main frame. To guarantee save and homogenous removal of those heat loads, the front part of the launcher main frame is designed as a double wall steel-casing with cooling channels inside the shell structure. To finalize the design of this double wall component, the main emphasis is now to define the cooling channels geometry and to identify the optimum manufacturing route to assure adequate flow of coolant and sufficient mechanical strength in compliance with required dimension tolerances and quality of the welds. Several manufacturing options have been investigated and were evaluated by computational analysis and fabrication of pre-prototypes. To come to a final design, the most promising route will be chosen to manufacture a full-size mock-up of the double wall main frame. It will be tested at the KIT Launcher Handling Test facility to check the compliance with the design goals related to geometrical accuracy and thermo-hydraulic characteristics. This paper describes the design and the manufacturing routes of the prototypic double wall main frame.

Manufacturing studies of double wall components for the ITER EC H and CD upper launcher

Energy Technology Data Exchange (ETDEWEB)

Spaeh, P., E-mail: peter.spaeh@kit.edu [Institute for Applied Materials, Karlsruhe Institute of Technology, P.O. Box 3640, D-76021 Karlsruhe (Germany); Aiello, G. [Institute for Applied Materials, Karlsruhe Institute of Technology, P.O. Box 3640, D-76021 Karlsruhe (Germany); Goldmann, A. [MAN Diesel and Turbo, D-94452 Deggendorf, P.O. Box 3640, D-76021 Karlsruhe (Germany); Kleefeldt, K. [Institute for Applied Materials, Karlsruhe Institute of Technology, P.O. Box 3640, D-76021 Karlsruhe (Germany); Kroiss, A. [MAN Diesel and Turbo, D-94452 Deggendorf, P.O. Box 3640, D-76021 Karlsruhe (Germany); Meier, A. [Institute for Applied Materials, Karlsruhe Institute of Technology, P.O. Box 3640, D-76021 Karlsruhe (Germany); Obermeier, C. [MAN Diesel and Turbo, D-94452 Deggendorf, P.O. Box 3640, D-76021 Karlsruhe (Germany); Scherer, T.; Schreck, S. [Institute for Applied Materials, Karlsruhe Institute of Technology, P.O. Box 3640, D-76021 Karlsruhe (Germany); Serikov, A. [Institute for Neutron Physics and Reactor Technology, Karlsruhe Institute of Technology, P.O. Box 3640, D-76021 Karlsruhe (Germany); Strauss, D.; Vaccaro, A. [Institute for Applied Materials, Karlsruhe Institute of Technology, P.O. Box 3640, D-76021 Karlsruhe (Germany)

2012-08-15

Highlights: Black-Right-Pointing-Pointer Double wall manufacturing technologies for ITER In-vessel components. Black-Right-Pointing-Pointer Rigid and safe accommodation of ECRH heating and current drive systems. Black-Right-Pointing-Pointer Thermo hydraulic analysis of coolant flow in double-wall structures. - Abstract: To counteract plasma instabilities, Electron Cyclotron Launchers will be installed in four of the ITER Upper Ports. The structural system of an EC Upper Launcher accommodates the MM-wave-components and has to meet strong demands on alignment, removal of nuclear heat loads, mechanical strength and nuclear shielding. The EC Upper Launcher has successfully undergone the Preliminary Design Review in 2009 and is now in the final design phase. Nuclear heat loads from 0.1 W/cm{sup 3} up to 0.8 W/cm{sup 3} will affect the front area of the launcher main frame. To guarantee save and homogenous removal of those heat loads, the front part of the launcher main frame is designed as a double wall steel-casing with cooling channels inside the shell structure. To finalize the design of this double wall component, the main emphasis is now to define the cooling channels geometry and to identify the optimum manufacturing route to assure adequate flow of coolant and sufficient mechanical strength in compliance with required dimension tolerances and quality of the welds. Several manufacturing options have been investigated and were evaluated by computational analysis and fabrication of pre-prototypes. To come to a final design, the most promising route will be chosen to manufacture a full-size mock-up of the double wall main frame. It will be tested at the KIT Launcher Handling Test facility to check the compliance with the design goals related to geometrical accuracy and thermo-hydraulic characteristics. This paper describes the design and the manufacturing routes of the prototypic double wall main frame.

[Epidemiology of contact hypersensitivity to rubber components in manufacturers of automobile tires at the Stomil plant].

Science.gov (United States)

Rubisz-Brzezińska, J; Bogdanowski, T; Brzezińska-Wcisło, L; Mozdzanowska, K; Bajcar, S

1990-01-01

Dermatological examination and patch tests with 34 rubber components were carried out in 114 tire manufacturers, 78 women and 36 men aged 29 years on average, with a mean duration of work in the plant 7 years. For correct interpretation of the obtained results patch tests with the same components were done in two control groups that is in 120 healthy subjects and 120 patients with contact dermatitis. Patch tests with proper concentrations of the studied components were evaluated after 48, 72 and 96 hours. Positive patch tests were found most frequently with antioxidants--16.6% (including IPPD--8.6%), followed by vulcanization accelerators--10.6%, and other rubber components--11.4% in all. During about 3 years of follow-up in 4 manufacturers contact allergic eczema was noted and polyvalent hypersensitivity to antioxidants and vulcanization accelerators without clinical manifestations of this hypersensitivity was diagnosed in 3 other subjects.

First wall and shield components manufacturing by hot isostatic pressing

International Nuclear Information System (INIS)

Lind, Anders; Tegman, R.

1994-01-01

At a meeting in Garching in June 1994 Hot Isostatic Pressing (HIP) was presented as a possible route to manufacture ITER first wall and shield components. The main advantages of the HIP concept include excellent and uniform mechanical properties of the produced materials and joints, high reliability and robustness of the HIP process, double containment of coolant, good flexibility concerning general design as well as size and location for inner cooling tubes, low cost and short delivery times, and a good near net shape capability for components in size up to 15 tons. To assess the applicability of HIP for the manufacturing of ITER first wall and shield components, it was agreed * to choose possible production parameters based in the present know-how, * to produce a compound mock-up in one shot from available solid steel/powder copper/steel tubes to demonstrate the joinability of the materials, * to examine the produced mock-up/materials by multi array ultrasonic testing, limited mechanical testing, metallography, scanning electron microscopy and energy dispersive spectroscopy, and * to compile data on Type 316L steels produced by HIP. Preliminary results and the mock-up were presented at a meeting in Garching in mid July 1994. This study clearly shows the excellent joinability of a copper alloy (Cu-0.5%Zr) and stainless steels (Type 304, 316 L) by HIP at temperatures close to the melting temperature of copper, with only limited influence on the microstructures, which makes it possible to HIP the first wall and shield structure in one step. Excellent mechanical properties of the compound are obtained with the copper alloy and not the joint being the weakest part. 7 refs, 21 figs, 1 tab

A Component-based Software Development and Execution Framework for CAx Applications

Directory of Open Access Journals (Sweden)

N. Matsuki

2004-01-01

Full Text Available Digitalization of the manufacturing process and technologies is regarded as the key to increased competitive ability. The MZ-Platform infrastructure is a component-based software development framework, designed for supporting enterprises to enhance digitalized technologies using software tools and CAx components in a self-innovative way. In the paper we show the algorithm, system architecture, and a CAx application example on MZ-Platform. We also propose a new parametric data structure based on MZ-Platform.

Development of composite aircraft components in INCDT COMOTI, Bucharest

Directory of Open Access Journals (Sweden)

Raluca VOICU

2012-12-01

Full Text Available This paper presents the recent research activities within INCDT COMOTI, in the composite materials field. The author makes a short introduction of this field and presents an example of application developed within the composite materials laboratory from INCDT COMOTI, targeting the aeronautic field. The aircraft component is a stator blade made of CFRP composites, integrating new active noise reduction technologies and manufactured by means of the autoclave technology.

Development of zirconium alloy tube manufacturing technology

International Nuclear Information System (INIS)

Kim, In Kyu; Park, Chan Hyun; Lee, Seung Hwan; Chung, Sun Kyo

2009-01-01

In late 2004, Korea Nuclear Fuel Company (KNF) launched a government funded joint development program with Westinghouse Electric Co. (WEC) to establish zirconium alloy tube manufacturing technology in Korea. Through this program, KNF and WEC have developed a state of the art facility to manufacture high quality nuclear tubes. KNF performed equipment qualification tests for each manufacturing machine with the support of WEC, and independently carried out product qualification tests for each tube product to be commercially produced. Apart from those tests, characterization test program consisting of specification test and characterization test was developed by KNF and WEC to demonstrate to customers of KNF the quality equivalency of products manufactured by KNF and WEC plants respectively. As part of establishment of performance evaluation technology for zirconium alloy tube in Korea, KNF carried out analyses of materials produced for the characterization test program using the most advanced techniques. Thanks to the accomplishment of the development of zirconium alloy tube manufacturing technology, KNF is expected to acquire positive spin off benefits in terms of technology and economy in the near future

Features of the Manufacturing Vision Development Process

DEFF Research Database (Denmark)

Dukovska-Popovska, Iskra; Riis, Jens Ove; Boer, Harry

2005-01-01

of action research. The methodology recommends wide participation of people from different hierarchical and functional positions, who engage in a relatively short, playful and creative process and come up with a vision (concept) for the future manufacturing system in the company. Based on three case studies......This paper discusses the key features of the process of Manufacturing Vision Development, a process that enables companies to develop their future manufacturing concept. The basis for the process is a generic five-phase methodology (Riis and Johansen, 2003) developed as a result of ten years...... of companies going through the initial phases of the methodology, this research identified the key features of the Manufacturing Vision Development process. The paper elaborates the key features by defining them, discussing how and when they can appear, and how they influence the process....

Design and R&D for manufacturing the beamline components of MITICA and ITER HNBs

Energy Technology Data Exchange (ETDEWEB)

Dalla Palma, M., E-mail: mauro.dallapalma@igi.cnr.it [Consorzio RFX, Padova (Italy); Sartori, E. [Consorzio RFX, Padova (Italy); Blatchford, P.; Chuilon, B. [CCFE, Culham Science Centre, Oxfordshire (United Kingdom); Graceffa, J. [ITER Organization, St Paul Lez Durance (France); Hanke, S. [KIT, Institute for Technical Physics, Eggenstein-Leopoldshafen (Germany); Hardie, C. [CCFE, Culham Science Centre, Oxfordshire (United Kingdom); Masiello, A. [F4E, Barcelona (Spain); Muraro, A. [Consorzio RFX, Padova (Italy); Ochoa, S. [KIT, Institute for Technical Physics, Eggenstein-Leopoldshafen (Germany); Shah, D. [ITER Organization, St Paul Lez Durance (France); Veltri, P.; Zaccaria, P.; Zaupa, M. [Consorzio RFX, Padova (Italy)

2015-10-15

Highlights: • Particle beam-component interaction was analysed developing and applying numerical codes. • Gas density distribution was calculated with AVOCADO code and applied for electrical analyses. • High heat flux components were designed, analysed with subcooled boiling, verified for fatigue. • Fracture behaviour of ceramics was analysed by finite element modelling and was verified. • R&D supports the design of the beamline components, especially for water-vacuum barriers. - Abstract: The design of the beamline components of MITICA, the full prototype of the ITER heating neutral beam injectors, is almost finalised and technical specifications for the procurement are under preparation. These components are the gas neutraliser, the electrostatic residual ion dump, and the calorimeter. Electron dump panels are foreseen each side of the upstream end of the neutraliser to protect the cryo-panels from electrons, created by stripping and other processes, that exit the 1 MeV accelerator. As the design of the components must fulfil requirements on the beam physics, insight on physical processes is required to identify performance trade-offs and constraints. The spatial gas distribution was simulated to verify the pumping requirements with electron dump panels and local conditions for breakdown voltage. Electrostatic analyses were carried out for the insulating elements of the RID to verify the limits of the electric field intensity. Different criteria were approached to investigate the fracture behaviour of ceramics considering the manufacturing implications and extrapolating the conditions for proof testing. Severe heating conditions will be applied steadily, as the maximum pulse duration is 1 h, and cyclically so requiring to fulfil fatigue and ratcheting verifications. High heat fluxes, up to 13 MW/m{sup 2} on the calorimeter, with enhanced heat transfer in subcooled boiling conditions will occur in the actively cooled CuCr1Zr panel elements provided with

Industrial based volume manufacturing of lightweight aluminium alloy panel components with high-strength and complex-shape for car body and chassis structures

Science.gov (United States)

Anyasodor, Gerald; Koroschetz, Christian

2017-09-01

To achieve the high volume manufacture of lightweight passenger cars at economic cost as required in the automotive industry, low density materials and new process route will be needed. While high strength aluminium alloy grades: AA7075 and AA6082 may provide the alternative material solution, hot stamping process used for high-strength and ultrahigh strength steels such as boron steel 22mnb5 can enable the volume manufacture of panel components with high-strength and complex-shape for car body and chassis structures. These aluminium alloy grades can be used to manufacture panel components with possible yield strengths ≥ 500 MPa. Due to the differences in material behaviors, hot stamping process of 22mnb5 cannot be directly applied to high strength aluminium alloy grades. Despite recorded successes in laboratories, researches and niche hot forming processes of high strength aluminium alloy grades, not much have been achieved for adequate and efficient volume manufacturing system applicable in the automotive industry. Due to lack of such system and based on expert knowledge in hot stamping production-line, AP&T presents in this paper a hot stamping processing route for high strength aluminium alloys been suitable for production-line development and volume manufacturing.

A Multi-Component Automated Laser-Origami System for Cyber-Manufacturing

Science.gov (United States)

Ko, Woo-Hyun; Srinivasa, Arun; Kumar, P. R.

2017-12-01

Cyber-manufacturing systems can be enhanced by an integrated network architecture that is easily configurable, reliable, and scalable. We consider a cyber-physical system for use in an origami-type laser-based custom manufacturing machine employing folding and cutting of sheet material to manufacture 3D objects. We have developed such a system for use in a laser-based autonomous custom manufacturing machine equipped with real-time sensing and control. The basic elements in the architecture are built around the laser processing machine. They include a sensing system to estimate the state of the workpiece, a control system determining control inputs for a laser system based on the estimated data and user’s job requests, a robotic arm manipulating the workpiece in the work space, and middleware, named Etherware, supporting the communication among the systems. We demonstrate automated 3D laser cutting and bending to fabricate a 3D product as an experimental result.

Developments in fuel manufacturing

International Nuclear Information System (INIS)

Williams, T.

1997-01-01

BNFL has a long tradition of willingness to embrace technological challenge and a dedication to quality. This paper describes advances in the overall manufacturing philosophy at BNFL's Fuel Business Group and then covers how some new technologies are currently being employed in BNFL Fuel Business Group's flagship oxide complex (OFC), which is currently in its final stages of commissioning. This plant represents a total investment of some Pound 200 million. This paper also describes how these technologies are also being deployed in BNFL's MOX plant now being built at Sellafield and, finally, covers some new processes being developed for advanced fuel manufacture. (author)

Design, Development and Hotfire Testing of Monolithic Copper and Bimetallic Additively Manufactured Combustion Chambers

Science.gov (United States)

Gradl, Paul; Barnett, Greg; Brandsmeier, Will; Greene, Sandy Elam; Protz, Chris

2016-01-01

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM) otherwise commonly referred to as additive manufacturing. The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for the GRCop-84 copper-alloy commensurate with powder bed additive manufacturing, evaluate bimetallic deposition and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. As a direct spin off of this program, NASA is working with industry partners to further develop the printing process for the GRCop-84 material in addition to the C-18150 (CuCrZr) material. To advance the process further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic additively manufactured chambers. A 1.2k sized thrust-chamber was designed and developed to compare the printing process of the GRCop-84 and C-18150 SLM materials. A series of similar MCC liners also completed development with an Inconel 625 jacket bonded to the GRcop-84 liner evaluating direct metal deposition (DMD) laser and arc-based techniques. This paper describes the design, development, manufacturing and testing of these combustion chambers and associated lessons learned throughout the design and development process.

The Development Of A Theoretical Lean Culture Causal Framework To Support The Effective Implementation Of Lean In Automotive Component Manufacturers

Directory of Open Access Journals (Sweden)

Van der Merwe, Karl Robert

2014-05-01

Full Text Available Although it is generally accepted that lean manufacturing improves operational performance, many organisations are struggling to adapt to the lean philosophy. The purpose of this study is to contribute to a more effective strategy for implementing the lean manufacturing improvement philosophy. The study sets out both to integrate well-researched findings and theories related to generic organisational culture with more recent research and experience related to lean culture, and to examine the role that culture plays in the effective implementation of lean manufacturing principles and techniques. The ultimate aim of this exercise is to develop a theoretical lean culture causal framework.

Manufacture of steam generator units and components for the AGR power stations at Heysham II and Torness

International Nuclear Information System (INIS)

Glasgow, J.R.; Parkin, K.

1984-01-01

The current AGR Steam Generator is a development of the successful once-through units supplied for the Oldbury Magnox and Hinkley B/Hunterston B AGR power stations. In this paper a brief outline of the evolution of the steam generator design from the earlier gas cooled reactor stations is presented. A description of the main items of fabrication development is given. The production facilities for the manufacture of the units are described. Reference is also made to some of the work on associated components. The early experience on the construction site of installation of the steam generators is briefly outlined. (author)

Manufacture of steam generator units and components for the AGR power stations at Heysham II and Torness

Energy Technology Data Exchange (ETDEWEB)

Glasgow, J R; Parkin, K [N.E.I. Nuclear Systems Ltd., Gateshead, Tyne and Wear (United Kingdom)

1984-07-01

The current AGR Steam Generator is a development of the successful once-through units supplied for the Oldbury Magnox and Hinkley B/Hunterston B AGR power stations. In this paper a brief outline of the evolution of the steam generator design from the earlier gas cooled reactor stations is presented. A description of the main items of fabrication development is given. The production facilities for the manufacture of the units are described. Reference is also made to some of the work on associated components. The early experience on the construction site of installation of the steam generators is briefly outlined. (author)

New developments in coordinate measuring machines for manufacturing industries

Directory of Open Access Journals (Sweden)

Hammad Mian S.

2014-01-01

Full Text Available There have been substantial improvements in measurement systems in order to meet fluctuating market demands. This rapid change and development in measurement technology has primarily been governed by demands of accuracy and precision from aerospace, automotive and other manufacturing industries. Coordinate measuring machines (CMMs available with different technologies and configurations has efficiently been fulfilling customer demands for more than a decade. Though, current CMMs can meet needs of rapid and increased demands of customers to a greater extent but still there is lot of scope for improvement and development in CMMs. The globalization of manufacturing has resulted in development of variety of complex products and miniaturization of mechanical components. The technology of micro/nano-scale 3D measurement is still a bottleneck for industries. Therefore, precise and accurate system which is flexible enough to deal with complexities of parts and micro & nano range products has to be investigated. In this paper, comprehensive review concerning CMMs with capabilities to measure micro/nano features has been presented. This work has also discussed different methods to estimate measurement uncertainty, as well as performance evaluation of CMMs. Moreover, novel concepts such as intelligent CMM, multi-sensor CMM, virtual CMM have been presented.

Development and Manufacture of the Nuclear Laboratory Equipment

International Nuclear Information System (INIS)

Youm, Ki Un; Kim, J. K.; Kim, K. S.; Lee, I. B.; Youm, J. H.; Park, I. W.

2008-12-01

This report on development and manufacture of the nuclear laboratory equipment contains the work scope and contents performed for supporting the researches and the developments projects efficiently. And also, the records for the principal production design, the manufacture contents, the working drawings and the CNC program are described in it. Most of works are to support the successful and convenient performance of the R and D projects by development and manufacturing the requested laboratory equipment

Development and Manufacture of the Nuclear Laboratory Equipment

International Nuclear Information System (INIS)

Youm, Ki Un; Moon, J. S.; Lee, I. B.; Youn, J. H.

2010-12-01

This report on development and manufacture of the nuclear laboratory equipment contains the work scope and contents performed for supporting the researches and the developments projects efficiently. And also, the records for the principal production design, the manufacture contents, the working drawings and the CNC program are described in it. Most of works are to support the successful and convenient performance of the R and D projects by development and manufacturing the requested laboratory equipment

Development and Manufacture of the Nuclear laboratory equipment

International Nuclear Information System (INIS)

Youm, Ki Un; Lee, I. B.; Youm, J. H.

2009-12-01

This report on development and manufacture of the nuclear laboratory equipment contains the work scope and contents performed for supporting the researches and the developments projects efficiently. And also, the records for the principal production design, the manufacture contents, the working drawings and the CNC program are described in it. Most of works are to support the successful and convenient performance of the R and D projects by development and manufacturing the requested laboratory equipment

Laser additive manufacturing of high-performance materials

CERN Document Server

Gu, Dongdong

2015-01-01

This book entitled “Laser Additive Manufacturing of High-Performance Materials” covers the specific aspects of laser additive manufacturing of high-performance new materials components based on an unconventional materials incremental manufacturing philosophy, in terms of materials design and preparation, process control and optimization, and theories of physical and chemical metallurgy. This book describes the capabilities and characteristics of the development of new metallic materials components by laser additive manufacturing process, including nanostructured materials, in situ composite materials, particle reinforced metal matrix composites, etc. The topics presented in this book, similar as laser additive manufacturing technology itself, show a significant interdisciplinary feature, integrating laser technology, materials science, metallurgical engineering, and mechanical engineering. This is a book for researchers, students, practicing engineers, and manufacturing industry professionals interested i...

Manufacturing study of Be, W and CFC bonded structures for plasma-facing components

Science.gov (United States)

Onozuka, M.; Hirai, S.; Kikuchi, K.; Oda, Y.; Shimizu, K.

2004-08-01

A manufacturing study has been conducted for Be, W, and CFC bonded structures employed in plasma-facing components for the ITER. For Be tiles bonded to the Cu-Cr-Zr alloy heat sink with stainless-steel cooling pipes, a one-axis hot press with two heating processes has been used to bond the three materials. An Al-Si base interlayer has been used to bond Be to the Cu-alloy. The heating processes have been selected to match the required heat treatment conditions for the Cu-alloy. Because of the limited heat processes using a conventional hot press, the manufacturing cost can be minimized. For both the W and CFC tiles, the materials have been brazed at the same time to the Cu-alloy. Ni-Cu-Mn and Cu-Ti brazing materials have been used for the W and CFC tiles, respectively. Using the above bonding techniques, partial mockups of a blanket first-wall panel and divertor target have been successfully manufactured.

Manufacturing study of Be, W and CFC bonded structures for plasma-facing components

International Nuclear Information System (INIS)

Onozuka, M.; Hirai, S.; Kikuchi, K.; Oda, Y.; Shimizu, K.

2004-01-01

A manufacturing study has been conducted for Be, W, and CFC bonded structures employed in plasma-facing components for the ITER. For Be tiles bonded to the Cu-Cr-Zr alloy heat sink with stainless-steel cooling pipes, a one-axis hot press with two heating processes has been used to bond the three materials. An Al-Si base interlayer has been used to bond Be to the Cu-alloy. The heating processes have been selected to match the required heat treatment conditions for the Cu-alloy. Because of the limited heat processes using a conventional hot press, the manufacturing cost can be minimized. For both the W and CFC tiles, the materials have been brazed at the same time to the Cu-alloy. Ni-Cu-Mn and Cu-Ti brazing materials have been used for the W and CFC tiles, respectively. Using the above bonding techniques, partial mockups of a blanket first-wall panel and divertor target have been successfully manufactured

Composites Manufacturing Education and Technology Facility Expedites Manufacturing Innovation

Energy Technology Data Exchange (ETDEWEB)

2017-01-01

The Composites Manufacturing Education and Technology facility (CoMET) at the National Wind Technology Center at the National Renewable Energy Laboratory (NREL) paves the way for innovative wind turbine components and accelerated manufacturing. Available for use by industry partners and university researchers, the 10,000-square-foot facility expands NREL's composite manufacturing research capabilities by enabling researchers to design, prototype, and test composite wind turbine blades and other components -- and then manufacture them onsite. Designed to work in conjunction with NREL's design, analysis, and structural testing capabilities, the CoMET facility expedites manufacturing innovation.

Component database development for the CBM experiment

International Nuclear Information System (INIS)

Akishina, E.P.; Alexandrov, E.I.; Alexandrov, I.N.; Filozova, I.A.; Ivanov, V.V.; Friese, V.

2015-01-01

This paper presents the implementation of the component database for the CBM experiment. The considered database is designed to effectively manage a large number of components for different CBM detectors during their manufacture, installation and operation. This database contains information about the production company, quality indicators, including test results, information on the whereabouts of the component and its status. A functional model, a design of the database schema, a description of tables and catalogs as well as a graphical user interface system are shown. [ru

NASA Game Changing Development Program Manufacturing Innovation Project

Science.gov (United States)

Tolbert, Carol; Vickers, John

2011-01-01

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

Utility of Big Area Additive Manufacturing (BAAM) For The Rapid Manufacture of Customized Electric Vehicles

Energy Technology Data Exchange (ETDEWEB)

Love, Lonnie J [ORNL

2015-08-01

This Oak Ridge National Laboratory (ORNL) Manufacturing Development Facility (MDF) technical collaboration project was conducted in two phases as a CRADA with Local Motors Inc. Phase 1 was previously reported as Advanced Manufacturing of Complex Cyber Mechanical Devices through Community Engagement and Micro-manufacturing and demonstrated the integration of components onto a prototype body part for a vehicle. Phase 2 was reported as Utility of Big Area Additive Manufacturing (BAAM) for the Rapid Manufacture of Customized Electric Vehicles and demonstrated the high profile live printing of an all-electric vehicle using ONRL s Big Area Additive Manufacturing (BAAM) technology. This demonstration generated considerable national attention and successfully demonstrated the capabilities of the BAAM system as developed by ORNL and Cincinnati, Inc. and the feasibility of additive manufacturing of a full scale electric vehicle as envisioned by the CRADA partner Local Motors, Inc.

A product-process approach for development of the manufacturing footprint

DEFF Research Database (Denmark)

Farooq, Sami; Yang, Cheng; Johansen, John

2009-01-01

to ever changing global business environment there are certain other external factors that act as drivers for the manufacturing facility development process and therefore should be given considerable importance as they play a major role in defining the future footprint of a manufacturing organisation....... elaborating the development and establishment of various manufacturing facilities of a Danish pump manufacturer is then described. The discussion from the case leads to the conclusion that developing new manufacturing facilities can be explained using existing theories of manufacturing strategy. However due...

Participation and dialogue in strategic manufacturing development

DEFF Research Database (Denmark)

Riis, Jens Ove; Dukovska-Popovska, Iskra; Johansen, John

2006-01-01

Increased competition and the dynamics of technological and market developments have made operations in industrial enterprises very complex, with many stakeholders in and around the enterprise. At the same time, it has become important to address strategic issues of manufacturing. To plan...... dialogues during a workshop, part of which is a dialogue-monitoring instrument. Empirical studies will draw out process elements of participation and dialogue and demonstrate the applicability of the model. Finally, implications are spelled out for planning and managing workshops in different phases...... and manage an appropriate degree of participation in strategy development has become a key issue, especially to ensure ideas and ownership from those who will be involved in the implementation of a manufacturing strategy. We have developed and implemented a five-phased process for developing a manufacturing...

Effect of ITER components manufacturing cycle on the irradiation behaviour of 316L(N)-IG steel

International Nuclear Information System (INIS)

Rodchenkov, B.S.; Prokhorov, V.I.; Makarov, O.Yu.; Shamardin, V.K.; Kalinin, G.M.; Strebkov, Yu.S.; Golosov, O.A.

2000-01-01

The main options for the manufacturing of high heat flux (HHF) components is hot isostatic pressing (HIP) using either solid pieces or powder. There was no database on the radiation behaviour of these materials, and in particular stainless steel (SS) 316L(N)-IG with ITER components manufacturing thermal cycle. Irradiation of wrought steel, powder-HIP, solid-HIP and HIPed joints has been performed within the framework of an ITER task. Specimens cut from 316L(N)-IG plate, HIP products, and solid-HIP joints were irradiated in the SM-3 reactor in Dimitrovgrad up to 4 and 10 dpa at 175 deg. C and 265 deg. C. The paper describes the results of post-irradiation tensile and fracture toughness tests

Fuel Cell Manufacturing Research and Development | Hydrogen and Fuel Cells

Science.gov (United States)

| NREL Fuel Cell Manufacturing Research and Development Fuel Cell Manufacturing Research and Development NREL's fuel cell manufacturing R&D focuses on improving quality-inspection practices for high costs. A researcher monitoring web-line equipment in the Manufacturing Laboratory Many fuel cell

The development of zirconium alloy and its manufacturing

International Nuclear Information System (INIS)

Yuan Gaihuan; Yue Qiang

2015-01-01

Nuclear power which acts as one of low-carbon energy resources is the most realistic in large-scale application. It is also the preferred choice for many countries to develop energy resources and optimize its structure. Zirconium alloy is a key structural material for nuclear power plant fuel assemblies and cladding tubes of zirconium alloy are often referred as the first safeguard to nuclear power safety. With the development of nuclear power, three kinds of zirconium alloys Zr-Sn, Zr-Nb, Zr-Sn-Nb and with the representative products of Zr-4, M5, Zirlo respectively are developed and widely applied. Because of its severe operating environment and influence to nuclear safety, the requirements to zirconium alloys for physical and chemical properties, nuclear capability, tolerance and surface quality are very strict. The in-depth research and its manufacture capability become one of the main barriers for many countries who are developing the nuclear energy. In recent years, a stated-owned company, State Nuclear Bao Ti Zirconium Industry Company ('SNZ' for short) as well as National R and D Center for Nuclear Grade Zirconium material, is founded to meet the requirement of the rapid development of China's nuclear power industry. SNZ is dedicated for the fabrication and the research of nuclear grade zirconium products. After the successful completion of technology transfer of manufacturing for production chain and fully grasped of the manufacturing technology for the nuclear grade zirconium sponge through zirconium alloy tube, rod and strip products. National R and D Center for Nuclear Grade Zirconium material is cooperating with universities, nuclear energy research and design institutes and the owners of nuclear power plant to develop new zirconium alloy of self-owned brand. Through the selection of components, in-process testing and product inspection, four kinds of new zirconium alloys owns better performance than currently commercialized M5, Zirlo etc

Additive Manufacturing of IN100 Superalloy Through Scanning Laser Epitaxy for Turbine Engine Hot-Section Component Repair: Process Development, Modeling, Microstructural Characterization, and Process Control

Science.gov (United States)

Acharya, Ranadip; Das, Suman

2015-09-01

This article describes additive manufacturing (AM) of IN100, a high gamma-prime nickel-based superalloy, through scanning laser epitaxy (SLE), aimed at the creation of thick deposits onto like-chemistry substrates for enabling repair of turbine engine hot-section components. SLE is a metal powder bed-based laser AM technology developed for nickel-base superalloys with equiaxed, directionally solidified, and single-crystal microstructural morphologies. Here, we combine process modeling, statistical design-of-experiments (DoE), and microstructural characterization to demonstrate fully metallurgically bonded, crack-free and dense deposits exceeding 1000 μm of SLE-processed IN100 powder onto IN100 cast substrates produced in a single pass. A combined thermal-fluid flow-solidification model of the SLE process compliments DoE-based process development. A customized quantitative metallography technique analyzes digital cross-sectional micrographs and extracts various microstructural parameters, enabling process model validation and process parameter optimization. Microindentation measurements show an increase in the hardness by 10 pct in the deposit region compared to the cast substrate due to microstructural refinement. The results illustrate one of the very few successes reported for the crack-free deposition of IN100, a notoriously "non-weldable" hot-section alloy, thus establishing the potential of SLE as an AM method suitable for hot-section component repair and for future new-make components in high gamma-prime containing crack-prone nickel-based superalloys.

Component-based development process and component lifecycle

NARCIS (Netherlands)

Crnkovic, I.; Chaudron, M.R.V.; Larsson, S.

2006-01-01

The process of component- and component-based system development differs in many significant ways from the "classical" development process of software systems. The main difference is in the separation of the development process of components from the development process of systems. This fact has a

Key Features of the Manufacturing Vision Development Process

DEFF Research Database (Denmark)

Dukovska-Popovska, Iskra; Riis, Jens Ove; Boer, Harry

2005-01-01

of action research. The methodology recommends wide participation of people from different hierarchical and functional positions, who engage in a relatively short, playful and creative process and come up with a vision (concept) for the future manufacturing system in the company. Based on three case studies......This paper discusses the key features of the process of Manufacturing Vision Development, a process that enables companies to develop their future manufacturing concept. The basis for the process is a generic five-phase methodology (Riis and Johansen 2003) developed as a result of ten years...... of companies going through the initial phases of the methodology, this research identified the key features of the Manufacturing Vision Development process. The paper elaborates the key features by defining them, discussing how and when they can appear, and how they influence the process....

Manufacturing of curd products of increased biological value for the elderly from dried components.

Science.gov (United States)

Zabodalova, Ludmila A; Belozerova, Maria S; Evstigneeva, Tatiana N

2018-01-01

In recent years, the number of elderly people has increased, and the diseases that arise in old age are associated, amongst other factors, with malnutrition. In the elderly, the need for primary nutrients and energy changes, so the development of food products intended for this particular group of people is becom- ing increasingly important. The purpose of this research is to work out the composition of and technology for producing low-fat curd products from raw milk and vegetable components. The developed products can be used for their gerodietetic properties, because nutritional and energy needs in the elderly were taken into account when designing the product. The curd product was manufactured from skimmed dried milk (SDM), soy isolate protein (SIP) and spelt grain. Optimal conditions for the recombination of SIP were determined. The influence of mass fraction of SIP on the properties of the clot and the end product was studied. The degree of dispersion of the grain component was determined, from the organoleptic evaluation of samples of the mixture, and the optimum method of addition was chosen. The method of adding cooked spelt into the clot after pressing was chosen. Harrington’s generalized desirability function was used for the calculation of the optimum mass frac- tion of the grain component in the end product. The formulation and technology for a curd product based on dry ingredients were determined. The amino acid composition and content of essential components in the developed product were determined, and the biological and nutritional value were calculated. The use of dry ingredients for the production of a curd product makes it possible to manufac- ture the product in the absence of raw milk. The formulation of the product is designed taking into account the needs of the body in old age. The incorporation of spelt increases the biological value of the curd product to 81.5%.

Applying of component system development in object methodology, case study

Directory of Open Access Journals (Sweden)

Milan Mišovič

2013-01-01

Full Text Available To create computarization target software as a component system has been a very strong requirement for the last 20 years of software developing. Finally, the architectural components are self-contained units, presenting not only partial and overall system behavior, but also cooperating with each other on the basis of their interfaces. Among others, components have allowed flexible modification of processes the behavior of which is the foundation of components behavior without changing the life of the component system. On the other hand, the component system makes it possible, at design time, to create numerous new connections between components and thus creating modified system behaviors. This all enables the company management to perform, at design time, required behavioral changes of processes in accordance with the requirements of changing production and market.The development of software which is generally referred to as SDP (Software Development Process contains two directions. The first one, called CBD (Component–Based Development, is dedicated to the development of component–based systems CBS (Component–based System, the second target is the development of software under the influence of SOA (Service–Oriented Architecture. Both directions are equipped with their different development methodologies. The subject of this paper is only the first direction and application of development of component–based systems in its object–oriented methodologies. The requirement of today is to carry out the development of component-based systems in the framework of developed object–oriented methodologies precisely in the way of a dominant style. In some of the known methodologies, however, this development is not completely transparent and is not even recognized as dominant. In some cases, it is corrected by the special meta–integration models of component system development into an object methodology.This paper presents a case study

Critical success factors model developing for sustainable Kaizen implementation in manufactur-ing industry in Ethiopia

Directory of Open Access Journals (Sweden)

Haftu Hailu

2017-12-01

Full Text Available The purpose of the research is to identify critical success factors and model developing for sustaining kaizen implementation. Peacock shoe is one of the manufacturing industries in Ethiopia facing challenges on sustaining. The methodology followed is factor analysis and empirically testing hypothesis. A database was designed using SPSS version 20. The survey was validated using statistical validation using the Cronbach alpha index; the result is 0.908. The KMO index value was obtained for the 32 items and had a value of 0.642 with Bartlett's Test of Sphericity Approx. Chi-Square 4503.007, degree of freedom 496 and significance value 0.000. A factor analysis by principal components and varimax rotation was applied for finding the critical success factors. Finding designates that 32 items were merged into eight critical success factors. All the eight factors together explain for 76.941 % of the variance. Multiple regression model analysis has indicated that some of the critical success factors had relationship with success indicators. Due to constraint of time, the researcher focused only at peacock shoe manufacturing industry. Other limitation also includes the absence of any local research that shows the critical success factors at the moment.

Microstructure investigation of bronze/steel brazed joints proposed for HHF components of ITER manufacturing

Energy Technology Data Exchange (ETDEWEB)

Kalinin, G.M. [Research and Development Institute of Power Engineering, P.O. Box 788, Moscow 101000 (Russian Federation)], E-mail: gmk@nikiet.ru; Krestnikov, N.S. [Research and Development Institute of Power Engineering, P.O. Box 788, Moscow 101000 (Russian Federation); Jarovinskiy, Yu.L.; Makhin, I.D.; Nikolaev, V.V. [Rocket and Space Corporation ' Energia' , Korolev, Lenina Street 4-a, Moscow 141070 (Russian Federation); Skladnov, K.S.; Strebkov, Yu.S.; Zolotarev, V.B. [Research and Development Institute of Power Engineering, P.O. Box 788, Moscow 101000 (Russian Federation)

2008-12-15

Brazing is considered as one of the perspective option of high heat flux components of ITER manufacturing. CuCrZr bronze, austenitic steel AISI 321-type and PM-17-type (Ni-Mn-Fe-Si-Sn-B alloy) brazed material were used for the development of brazing technology. Two type of brazing have been studied within the framework of recent investigation: - Hot isostatic pressing (HIP)-assisted brazing. - Furnace-assisted brazing (with uniaxial compression loading). For the hydrostatic pressing (HIP) the brazed components were pressed out for about 175 MPa during 2.5 h at the temperature 1035-1040 deg. C. For the furnace-assisted brazing all components were inserted into the sealed can, vacuumed and heated up to brazing temperature {approx}950 deg. C. Fast cooling and ageing heat treatment (500 deg. C and 4 h) were applied to provide high strength of CuCrZr bronze. Microsections of specimens cut from the joints were studied by optical microscopy and by scanning electron microscopy (SEM). The microstructure, distribution of alloying elements of base metals and of brazed material components were studied in the joints. Results of these studies are discussed in this paper. The data shows that there is a potential for using more simple and cheap (in comparison with common HIP) technologies of bronze to steel joining with satisfactory quality.

Development of the Sixty Watt Heat-Source hardware components

International Nuclear Information System (INIS)

McNeil, D.C.; Wyder, W.C.

1995-01-01

The Sixty Watt Heat Source is a nonvented heat source designed to provide 60 thermal watts of power. The unit incorporates a plutonium-238 fuel pellet encapsulated in a hot isostatically pressed General Purpose Heat Source (GPHS) iridium clad vent set. A molybdenum liner sleeve and support components isolate the fueled iridium clad from the T-111 strength member. This strength member serves as the pressure vessel and fulfills the impact and hydrostatic strength requirements. The shell is manufactured from Hastelloy S which prevents the internal components from being oxidized. Conventional drawing operations were used to simplify processing and utilize existing equipment. The deep drawing reqirements for the molybdenum, T-111, and Hastelloy S were developed from past heat source hardware fabrication experiences. This resulted in multiple step drawing processes with intermediate heat treatments between forming steps. The molybdenum processing included warm forming operations. This paper describes the fabrication of these components and the multiple draw tooling developed to produce hardware to the desired specifications. copyright 1995 American Institute of Physics

Cleaning Process Development for Metallic Additively Manufactured Parts

Science.gov (United States)

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.

3D additive manufactured 316L components microstructural features and changes induced by working life cycles

Science.gov (United States)

Pace, M. L.; Guarnaccio, A.; Dolce, P.; Mollica, D.; Parisi, G. P.; Lettino, A.; Medici, L.; Summa, V.; Ciancio, R.; Santagata, A.

2017-10-01

The ability of processing through laser beams different kinds of metallic powders for direct production of 3D components with complex geometries has been gaining an impressive and growing attention for specific industrial applications. The process which can be distinguished as Selective Laser Sintering or Selective Laser Melting is even considered, more generally, as Additive Manufacturing where layer by layer material is built by the interaction between a laser beam and a powder bed. The rapid heating of the powder due to the laser beam energy transfer process followed by a rapid cooling rate induces within the manufactured material a cellular structure with fine sub-grains, which are in the range of few hundreds of micrometers. These metastable structures, which are smaller than the grain size in conventionally manufactured 316L stainless steel components, can undertake towards a recrystallization process due to either heat or mechanical treatments. For instance, when sub-grain boundaries of the cells are enriched with Mo and higher concentration of dislocation, dynamical processes occur generating local residual stresses. In these circumstances the segregation of Mo in cell boundaries is out of thermodynamic equilibrium conditions so that microstructures and phases are metastable. In the range of 1100-1400 °C heat treatments a complete dissolution of Mo in the Fe matrix with a gradual disappearance of sub-microns cell is observed feeding the growth of larger austenitic sub-grains formation. It follows a higher degree of Mo dissolution in the material matrix and a decrease of dislocation's concentration (Saeidi et al., 2015) [1]. In the work here presented we point out which are the microstructural features of stainless steel 316L components realized by Additive Manufacturing. Furthermore, the occurrence of a microstructural evolution is presented after experiencing to fatigue of 80000 cycles some door joints obtained by this technique. A decrease of dislocation

Additive Manufacturing of Fuel Injectors

Energy Technology Data Exchange (ETDEWEB)

Sadek Tadros, Dr. Alber Alphonse [Edison Welding Institute, Inc., Columbus, OH (United States); Ritter, Dr. George W. [Edison Welding Institute, Inc., Columbus, OH (United States); Drews, Charles Donald [Edison Welding Institute, Inc., Columbus, OH (United States); Ryan, Daniel [Solar Turbines Inc., San Diego, CA (United States)

2017-10-24

Additive manufacturing (AM), also known as 3D-printing, has been shifting from a novelty prototyping paradigm to a legitimate manufacturing tool capable of creating components for highly complex engineered products. An emerging AM technology for producing metal parts is the laser powder bed fusion (L-PBF) process; however, industry manufacturing specifications and component design practices for L-PBF have not yet been established. Solar Turbines Incorporated (Solar), an industrial gas turbine manufacturer, has been evaluating AM technology for development and production applications with the desire to enable accelerated product development cycle times, overall turbine efficiency improvements, and supply chain flexibility relative to conventional manufacturing processes (casting, brazing, welding). Accordingly, Solar teamed with EWI on a joint two-and-a-half-year project with the goal of developing a production L-PBF AM process capable of consistently producing high-nickel alloy material suitable for high temperature gas turbine engine fuel injector components. The project plan tasks were designed to understand the interaction of the process variables and their combined impact on the resultant AM material quality. The composition of the high-nickel alloy powders selected for this program met the conventional cast Hastelloy X compositional limits and were commercially available in different particle size distributions (PSD) from two suppliers. Solar produced all the test articles and both EWI and Solar shared responsibility for analyzing them. The effects of powder metal input stock, laser parameters, heat treatments, and post-finishing methods were evaluated. This process knowledge was then used to generate tensile, fatigue, and creep material properties data curves suitable for component design activities. The key process controls for ensuring consistent material properties were documented in AM powder and process specifications. The basic components of the project

Integrating developing country manufacturing industries into global supply chain

Directory of Open Access Journals (Sweden)

Fasika Bete Georgise

2014-01-01

Full Text Available Purpose: Due to globalization of manufacturing activities, the arena of competition and competitiveness advantage is moving from firms towards supply chains and networks. With the recent advancement of information and communication technologies this participation are becoming as common business practice in developed countries firms. Companies were more integrated into the world market for the global nature of the sourcing, manufacturing and distribution. These changes create both challenges and opportunities for the manufacturing industries in developing countries. The objective of this paper is to examine the level of inter-organizational and intra-organizational supply chain integration practices in developing country, Ethiopia.Design/methodology/approach: An industrial questionnaires survey was used to collect the current practices of the manufacturing industries in Ethiopia as an example of the developing countries. Descriptive statistics is primarily used for the analysis.Findings: Results show a low level of supply chain relationship both in intra and inter organizational supply chain integration level among members. Accordingly, such issues require much attention to facilitate a greater integration within the supply chains in the Ethiopian manufacturing industries.Research limitations/implications: The paper focuses on examining the practices of Ethiopian manufacturing industries empirical data. The interpretation of results should be taken with prudence.Originality/Value: The manufacturing industry in developing countries (MIDC has been a part of the global supply chains for long time as a supplier of raw material and manufacturer of primary products. Currently, the MIDC is trying to access the different markets segment of the world even with new products starting from their local market to the complex and dynamic international market. Nevertheless, their supply chains are inefficient and hence, their competitiveness level far from the

Changes in flavor components and microbial flora during Fukuyama rice vinegar manufacture.

OpenAIRE

円谷, 悦造; 正井, 博之; ETSUZO, ENTANI; HIROSHI, MASAI; (株)中埜酢店中埜生化学研究所; (株)中埜酢店中埜生化学研究所; Nakano Biochemical Research Institute, Nakano Vinegar Co., Ltd.,; Nakano Biochemical Research Institute, Nakano Vinegar Co., Ltd.,

1985-01-01

Fukuyama rice vinegar is a type of Japanese vinegar that has been produced by a traditional method using a pot as a surface fermentor in the Fukuyama district of Kagoshima prefecture. There have been few detailed studies of the fermentation process of this vineger. Therefore, changes in the flavor components and microbial flora of Fukuyama rice vinegar were examined during the manufacturing process.The maximum viable cell counts of yeasts were observed at the early stage. Alcohols, such as et...

A system approach for reducing the environmental impact of manufacturing and sustainability improvement of nano-scale manufacturing

Science.gov (United States)

Yuan, Yingchun

This dissertation develops an effective and economical system approach to reduce the environmental impact of manufacturing. The system approach is developed by using a process-based holistic method for upstream analysis and source reduction of the environmental impact of manufacturing. The system approach developed consists of three components of a manufacturing system: technology, energy and material, and is useful for sustainable manufacturing as it establishes a clear link between manufacturing system components and its overall sustainability performance, and provides a framework for environmental impact reductions. In this dissertation, the system approach developed is applied for environmental impact reduction of a semiconductor nano-scale manufacturing system, with three case scenarios analyzed in depth on manufacturing process improvement, clean energy supply, and toxic chemical material selection. The analysis on manufacturing process improvement is conducted on Atomic Layer Deposition of Al2O3 dielectric gate on semiconductor microelectronics devices. Sustainability performance and scale-up impact of the ALD technology in terms of environmental emissions, energy consumption, nano-waste generation and manufacturing productivity are systematically investigated and the ways to improve the sustainability of the ALD technology are successfully developed. The clean energy supply is studied using solar photovoltaic, wind, and fuel cells systems for electricity generation. Environmental savings from each clean energy supply over grid power are quantitatively analyzed, and costs for greenhouse gas reductions on each clean energy supply are comparatively studied. For toxic chemical material selection, an innovative schematic method is developed as a visual decision tool for characterizing and benchmarking the human health impact of toxic chemicals, with a case study conducted on six chemicals commonly used as solvents in semiconductor manufacturing. Reliability of

Laser Additive Manufacturing of F/M Steels for Radiation Tolerant Nuclear Components

Energy Technology Data Exchange (ETDEWEB)

Lienert, Thomas J. [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Maloy, Stuart Andrew [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

2017-11-02

According to the Nuclear Energy R&D Roadmap Report submitted to Congress in 2010, one the key challenges facing the nuclear energy industry involves development of new reactor designs with reduced capital costs. Two related R&D objectives outlined in the report include: 1) Making improvements in the affordability of new reactors; and 2) Development of structural materials to withstand irradiation for longer periods. Laser additive manufacturing (LAM) is particularly well suited for more rapid and economical fabrication of reactor components relative to current fabrication methods. The proposed work involving LAM directly addresses the two R&D objectives outlined above relevant to the pertinent mission problems. The classical Materials Science approach involving development of Process/Structure/Property/Performance (P/S/P/P) relations was employed in this project. Processing included LAM and heat-treating. Thermal cycling during LAM is discussed here, and phase diagrams and continuous cooling transformation (CCT) diagrams are used to rationalize microstructural evolution. Structures were characterized including grain size & morphology, volume fraction, morphology, composition and location of carbides in as-deposited and heat-treated conditions. In the simplest sense, the goal was to control microstructures through process manipulation with a view toward optimizing properties and performance in service.

Manufacturing Initiative

Data.gov (United States)

National Aeronautics and Space Administration — The Advanced Manufacturing Technologies (AMT) Project supports multiple activities within the Administration's National Manufacturing Initiative. A key component of...

Sustainable Development in Indian Automotive Component Clusters

Science.gov (United States)

Bhaskaran, E.

2013-01-01

India is the world's second fastest growing auto market and boasts of the sixth largest automobile industry after China, the US, Germany, Japan and Brazil. The Indian auto component industry recorded its highest year-on-year growth of 34.2 % in 2010-2011, raking in revenue of US 39.9 billion; major contribution coming from exports at US five billion and fresh investment from the US at around US two billion. For inclusive growth and sustainable development most of the auto components manufacturers has adopted the cluster development approach. The objective is to study the technical efficiency (θ), peer weights (λ i ), input slacks (S-) and output slacks (S+) of four Auto Component Clusters (ACC) in India. The methodology adopted is using Data Envelopment Analysis of Input Oriented Banker Charnes Cooper Model by taking number of units and number of employments as inputs and sales and exports in crores as an outputs. The non-zero λ i 's represents the weights for efficient clusters. The S > 0 obtained for one ACC reveals the excess no. of units (S-) and employment (S-) and shortage in sales (S+) and exports (S+). However the variable returns to scale are increasing for three clusters, constant for one more cluster and with nil decrease. To conclude, for inclusive growth and sustainable development, the inefficient ACC should increase their turnover and exports, as decrease in no. of enterprises and employment is practically not possible. Moreover for sustainable development, the ACC should strengthen infrastructure interrelationships, technology interrelationships, procurement interrelationships, production interrelationships and marketing interrelationships to increase productivity and efficiency to compete in the world market.

A Strategic Knowledge Map for the Research and Development Department in a Manufacturing Company

Directory of Open Access Journals (Sweden)

Śliwa Małgorzata

2016-01-01

Full Text Available Knowledge is a corporate resource, being grounds for initiating activities, which is important in a dynamic economy. The difficulties related to obtaining tacit knowledge, related primarily to experience and observation of the knowledge employee (Mendryk, 2011, encourage the companies to use tools supporting knowledge management and location. This article attempts at designing a dedicated, strategic knowledge map for a research and development department in a manufacturing company. Based on the reference works, the detailed characteristics of specific sources of knowledge in a manufacturing company and tools supporting the process of converting the tacit knowledge into explicit one, for example, the knowledge maps, were devised. Then, a strategic knowledge map model was designed for the research and development department (hereinafter abbreviated as SKM – R&D in the manufacturing company, comprising the following components: (1 fields of knowledge, (2 internal and external processes in the R&D department, and (3 sources of knowledge. Then, a practical implementation of the SKM – R&D model was presented.

Defect recognition in CFRP components using various NDT methods within a smart manufacturing process

Science.gov (United States)

Schumacher, David; Meyendorf, Norbert; Hakim, Issa; Ewert, Uwe

2018-04-01

The manufacturing process of carbon fiber reinforced polymer (CFRP) components is gaining a more and more significant role when looking at the increasing amount of CFRPs used in industries today. The monitoring of the manufacturing process and hence the reliability of the manufactured products, is one of the major challenges we need to face in the near future. Common defects which arise during manufacturing process are e.g. porosity and voids which may lead to delaminations during operation and under load. To find irregularities and classify them as possible defects in an early stage of the manufacturing process is of high importance for the safety and reliability of the finished products, as well as of significant impact from an economical point of view. In this study we compare various NDT methods which were applied to similar CFRP laminate samples in order to detect and characterize regions of defective volume. Besides ultrasound, thermography and eddy current, different X-ray methods like radiography, laminography and computed tomography are used to investigate the samples. These methods are compared with the intention to evaluate their capability to reliably detect and characterize defective volume. Beyond the detection and evaluation of defects, we also investigate possibilities to combine various NDT methods within a smart manufacturing process in which the decision which method shall be applied is inherent within the process. Is it possible to design an in-line or at-line testing process which can recognize defects reliably and reduce testing time and costs? This study aims to show up opportunities of designing a smart NDT process synchronized to the production based on the concepts of smart production (Industry 4.0). A set of defective CFRP laminate samples and different NDT methods were used to demonstrate how effective defects are recognized and how communication between interconnected NDT sensors and the manufacturing process could be organized.

Additive Manufacturing of Hierarchical Multi-Phase High-Entropy Alloys for Nuclear Component

Energy Technology Data Exchange (ETDEWEB)

Li, Nan [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

2017-10-10

In recent years, high entropy alloys (HEAs), composed of four or more metallic elements mixed in equal or near equal atomic percent, have attracted significant attention due to their excellent mechanical properties and good corrosion resistance. They show significant promise as candidates for high temperature fission and fusion structural applications. However, the conventional synthesis methods are unlikely to present an industrially suitable route for the production and use of HEAs. Recognizing rapidly evolving additive manufacturing (AM) techniques, the goal of this proposal is to optimize the AM process to fabricate HEAs with predesigned chemical compositions and phase morphologies for nuclear components. For this project, two HEAs FeCrNiMn and FeCrNiMnAl have been successfully synthesized. Correlated mechanical response has been systematically characterized under a variety of laser processing and ion irradiations. Both high entropy alloys are found to present comparable swelling and extraordinary irradiation tolerance (limited voids and stabilized phase structure under high irradiation dose). In addition, the microstructure and radiation-induced hardening can be tailored by laser processing under additive manufacturing. And we have assembled at LANL a unique database of HEAs containing a total of 674 compositions with Phase Stability information. Based on this, the machine learning and Artificial Intelligence capability now are established to predict the microstructure of casted HEAs by given chemical compositions. This unique integration will lead to an optimal AM recipe for fabricating radiation tolerant HEAs. The development of both modeling models and experimental capability will also benefit other programs at LANL.

Bionic Manufacturing: Towards Cyborg Cells and Sentient Microbots.

Science.gov (United States)

Srivastava, Sarvesh Kumar; Yadav, Vikramaditya G

2018-05-01

Bio-inspired engineering applies biological design principles towards developing engineering solutions but is not practical as a manufacturing paradigm. We advocate 'bionic manufacturing', a synergistic fusion of biotic and abiotic components, to transition away from bio-inspiration toward bio-augmentation to address current limitations in bio-inspired manufacturing. Copyright © 2017 Elsevier Ltd. All rights reserved.

Rapid Response Manufacturing (RRM). Final CRADA report

Energy Technology Data Exchange (ETDEWEB)

Cain, W.D. [Lockheed Martin Energy Systems, Inc., Oak Ridge, TN (United States); Waddell, W.L. [National Centers for Manufacturing Sciences, Ann Arbor, MI (United States)

1997-08-28

A major accomplishment of the Rapid Response Manufacturing (RRM) project was the development of a broad-based generic framework for automating and integrating the design-to-manufacturing activities associated with machined part products. Key components of the framework are a manufacturing model that integrates product and process data in a consistent, minimally redundant manner, an advanced computer-aided engineering working environment, knowledge-based software systems for design, process planning, and manufacturing and new production technologies for making products directly from design application software.

Manufacturing Hydraulic Components for the Primary Double Entry S-Pump Model

Directory of Open Access Journals (Sweden)

S. Iu. Kuptsov

2015-01-01

Full Text Available The article describes a new design of the primary pump to run in powerful units (more than 1 GW of power plants. The new construction has some advantages such as compactness, theoretical lack of radial and axial forces, and high efficiency in a wide range of flow. The abovementioned advantages can be possible owing to applying an innovative shape of the pump flow path. An impeller with the guide vanes forms the three-row single stage in the each row axial double entry blade system. The inlet and outlet parts have a shape of the involute that can ensure (according to calculated data the efficiency and stability in a wide range of flow because of a lack of the spiral parts. The results of numerical calculations of the pump working flow theoretically confirm that demanding parameters of the pump (H=286 m; Q=1,15 m3 /s can be obtained with competitive efficiency. To verify the proposed advantages of the construction, there was decision made to conduct the real physical experiment. For this purpose the small model of a real pump was designed with parameters H=14 m, Q=13 l/s. Construction of the pump model has a cartridge conception. In addition, there is a possibility for quick replacement of the some parts of the blade system in case of operational development of the pump. In order to obtain hydraulic characteristics of the pump to say nothing of the electromotor the torque gauge coupling is used. Numerical calculations for the pump model were also performed which confirm the operability. For manufacturing of the blade system the new perspective technology is applied. The main hydraulic components (impellers and guide vanes are made of ABS plastic by using 3D-printer. According to this technology parts are made layer by layer by means of welded plastic filament. Using this method the satisfactory tolerance (approximately ±0,3 mm of the parts was obtained. At that moment, it is possible to create the parts with the maximum size no higher than 150 mm

Progress of High Heat Flux Component Manufacture and Heat Load Experiments in China

Energy Technology Data Exchange (ETDEWEB)

Liu, X.; Lian, Y.; Xu, Z.; Chen, J.; Chen, L.; Wang, Q.; Duan, X., E-mail: xliu@swip.ac.cn [Southwestern Institute of Physics, Chengu (China); Luo, G. [Institute of Plasma Physics, Chinese Academy of Sciences, Hefei (China); Yan, Q. [University of Science and Technology Beijing, Beijing (China)

2012-09-15

Full text: High heat flux components for first wall and divertor are the key subassembly of the present fusion experiment apparatus and fusion reactors in the future. It is requested the metallurgical bonding among the plasma facing materials (PFMs), heat sink and support materials. As to PFMs, ITER grade vacuum hot pressed beryllium CN-G01 was developed in China and has been accepted as the reference material of ITER first wall. Additionally pure tungsten and tungsten alloys, as well as chemical vapor deposition (CVD) W coating are being developed for the aims of ITER divertor application and the demand of domestic fusion devices, and significant progress has been achieved. For plasma facing components (PFCs), high heat flux components used for divertor chamber are being studied according to the development program of the fusion experiment reactor of China. Two reference joining techniques of W/Cu mockups for ITER divertor chamber are being developed, one is mono-block structure by pure copper casting of tungsten surface following by hot iso-static press (HIP), and another is flat structure by brazing. The critical acceptance criteria of high heat flux components are their high heat load performance. A 60 kW Electron-beam Material testing Scenario (EMS-60) has been constructed at Southwestern Institute of Physics (SWIP),which adopts an electron beam welding gun with maximum energy of 150 keV and 150 x 150 mm{sup 2} scanning area by maximum frame rate of 30 kHz. Furthermore, an Engineering Mockup testing Scenario (EMS-400) facility with 400 kW electron-beam melting gun is under construction and will be available by the end of this year. After that, China will have the comprehensive capability of high heat load evaluation from PFMs and small-scale mockups to engineering full scale PFCs. A brazed W/CuCrZr mockup with 25 x 25 x 40 mm{sup 3} in dimension was tested at EMS-60. The heating and cooling time are 10 seconds and 15 seconds, respectively. The experiment

Emerging technologies in arthroplasty: additive manufacturing.

Science.gov (United States)

Banerjee, Samik; Kulesha, Gene; Kester, Mark; Mont, Michael A

2014-06-01

Additive manufacturing is an industrial technology whereby three-dimensional visual computer models are fabricated into physical components by selectively curing, depositing, or consolidating various materials in consecutive layers. Although initially developed for production of simulated models, the technology has undergone vast improvements and is currently increasingly being used for the production of end-use components in various aerospace, automotive, and biomedical specialties. The ability of this technology to be used for the manufacture of solid-mesh-foam monolithic and coated components of complex geometries previously considered unmanufacturable has attracted the attention of implant manufacturers, bioengineers, and orthopedic surgeons. Currently, there is a paucity of reports describing this fabrication method in the orthopedic literature. Therefore, we aimed to briefly describe this technology, some of the applications in other orthopedic subspecialties, its present use in hip and knee arthroplasty, and concerns with the present form of the technology. As there are few reports of clinical trials presently available, the true benefits of this technology can only be realized when studies evaluating the clinical and radiographic outcomes of cementless implants manufactured with additive manufacturing report durable fixation, less stress shielding, and better implant survivorship. Nevertheless, the authors believe that this technology holds great promise and may potentially change the conventional methods of casting, machining, and tooling for implant manufacturing in the future. Thieme Medical Publishers 333 Seventh Avenue, New York, NY 10001, USA.

Applications of dimensional micro metrology to the product and process quality control in manufacturing of precision polymer micro components

DEFF Research Database (Denmark)

Tosello, Guido; Hansen, Hans Nørgaard; Gasparin, Stefania

2009-01-01

Precision manufacturing of micro injection moulded (mu IM) components presents challenges in terms of quality control due to the miniaturization of product dimensions and tolerances. This paper addresses product compliance with specifications, focusing on tolerances of dimensions and position on mu...... IM components selected from industrial production. Two systems were analysed: a tactile coordinate measuring machine (CMM) with sub-micrometer uncertainty and an optical CMM allowing fast measurements suitable for in-line quality control. Product quality control capability, measuring uncertainty...... and calibration guidelines are discussed for both systems. Finally, a new approach for the manufacturing of hybrid micro polymer-metal calibrated objects is proposed....

Indigenous Manufacturing realization of TWIN Source

Science.gov (United States)

Pandey, R.; Bandyopadhyay, M.; Parmar, D.; Yadav, R.; Tyagi, H.; Soni, J.; Shishangiya, H.; Sudhir Kumar, D.; Shah, S.; Bansal, G.; Pandya, K.; Parmar, K.; Vuppugalla, M.; Gahlaut, A.; Chakraborty, A.

2017-04-01

TWIN source is two RF driver based negative ion source that has been planned to bridge the gap between single driver based ROBIN source (currently operational) and eight river based DNB source (to be operated under IN-TF test facility). TWIN source experiments have been planned at IPR keeping the objective of long term domestic fusion programme to gain operational experiences on vacuum immersed multi driver RF based negative ion source. High vacuum compatible components of twin source are designed at IPR keeping an aim on indigenous built in attempt. These components of TWIN source are mainly stainless steel and OFC-Cu. Being high heat flux receiving components, one of the major functional requirements is continuous heat removal via water as cooling medium. Hence for the purpose stainless steel parts are provided with externally milled cooling lines and that shall be covered with a layer of OFC-cu which would be on the receiving side of high heat flux. Manufacturability of twin source components requires joining of these dissimilar materials via process like electrode position, electron beam welding and vacuum brazing. Any of these manufacturing processes shall give a vacuum tight joint having proper joint strength at operating temperature and pressure. Taking the indigenous development effort vacuum brazing (in non-nuclear environment) has been opted for joining of dissimilar materials of twin source being one of the most reliable joining techniques and commercially feasible across the suppliers of country. Manufacturing design improvisation for the components has been done to suit the vacuum brazing process requirement and to ease some of the machining without comprising over the functional and operational requirements. This paper illustrates the details on the indigenous development effort, design improvisation to suits manufacturability, vacuum brazing basics and its procedures for twin source components.

PDC Journeys to Product Analysis Development and Additive Manufacturing?

International Nuclear Information System (INIS)

Shalina Sheik Muhamad

2015-01-01

The technology for product development and manufacturing has gone through many advancements. It is widely recognised that it would provide competitive advantage for engineering organization in term of product development cycle, productivity, sustainability and efficiency. We begin by describing the general characteristic of design process that will need to be integrated in product life cycle management. In Nuclear Malaysia, especially in engineering design activities the majority have been using 3D modelling. This paper discusses on the current product design practiced in Nuclear Malaysia, new product development process and new manufacturing technique which is additive manufacturing. (author)

Development of textile-reinforced carbon fibre aluminium composites manufactured with gas pressure infiltration methods

OpenAIRE

W. Hufenbach; M. Gude; A. Czulak; J. Śleziona; A. Dolata-Grosz; M. Dyzia

2009-01-01

Purpose: The aim of his paper is to show potential of textile-reinforced carbon fibre aluminium composite with advantage of the lightweight construction of structural components subjected to thermo-mechanical stress.Design/methodology/approach: The manufacture of specimens of the carbon fibre-reinforced aluminium was realised with the aid of an advanced differential gas pressure infiltration technique, which was developed at ILK, TU Dresden.Findings: The gas pressure infiltration technology e...

A framework for the computer-aided planning and optimisation of manufacturing processes for components with functional graded properties

Science.gov (United States)

Biermann, D.; Gausemeier, J.; Heim, H.-P.; Hess, S.; Petersen, M.; Ries, A.; Wagner, T.

2014-05-01

In this contribution a framework for the computer-aided planning and optimisation of functional graded components is presented. The framework is divided into three modules - the "Component Description", the "Expert System" for the synthetisation of several process chains and the "Modelling and Process Chain Optimisation". The Component Description module enhances a standard computer-aided design (CAD) model by a voxel-based representation of the graded properties. The Expert System synthesises process steps stored in the knowledge base to generate several alternative process chains. Each process chain is capable of producing components according to the enhanced CAD model and usually consists of a sequence of heating-, cooling-, and forming processes. The dependencies between the component and the applied manufacturing processes as well as between the processes themselves need to be considered. The Expert System utilises an ontology for that purpose. The ontology represents all dependencies in a structured way and connects the information of the knowledge base via relations. The third module performs the evaluation of the generated process chains. To accomplish this, the parameters of each process are optimised with respect to the component specification, whereby the result of the best parameterisation is used as representative value. Finally, the process chain which is capable of manufacturing a functionally graded component in an optimal way regarding to the property distributions of the component description is presented by means of a dedicated specification technique.

3D-Printing: How Additive Manufacturing impacts Supply Chain Business Processes and Management Components

OpenAIRE

Oettmeier, Katrin; Hofmann, Erik

2016-01-01

Purpose The business implications of additive manufacturing (AM) are explored; specific focus thereby lies on the impact of AM technology adoption in customized parts production. Design/methodology/approach Based on two explorative case studies from the hearing aid industry, the impact of AM technology adoption on supply chain business processes and management components is analyzed. General systems theory and a supply chain management framework serve as theoretical underpinning....

Development of strength-hardness relationships in additively manufactured titanium alloys

Energy Technology Data Exchange (ETDEWEB)

Keist, Jayme S., E-mail: keist@psu.edu; Palmer, Todd A., E-mail: tap103@psu.edu

2017-05-02

A major concern for additively manufactured (AM) Ti-6Al-4V components is how AM processing parameters and post-process heat treatments impact the resulting mechanical behavior. The applicability of using microhardness measurements as a predictive tool for yield and tensile strengths of AM Ti-6Al-4V would provide a rapid and useful screening mechanism for ensuring that properties meet requirements in complex geometries. However, microhardness measurements on Ti-6Al-4V exhibit high levels of data variability due to the orientational impact of the α phase. In order to overcome this variability in hardness measurements, a methodology for aggregating microhardness data in individual builds has been developed and validated. By compiling mean microhardness values from various AM components produced by electron beam based directed energy deposition (DED), laser based DED, and laser based powder bed fusion (PBF) processes in the as-deposited and post-process heat treated conditions, strong linear correlations between strength and hardness can be developed in AM materials having a lamellar α+β microstructure. With the addition of strain hardening and α phase orientation contributions to the mean microhardness measurement, the strength-hardness correlations of AM Ti-6Al-4V followed empirically derived models, opening the possibility of using these models to predict strengths from AM components regardless of the AM process or post-process state.

U.S. Offshore Wind Manufacturing and Supply Chain Development

Energy Technology Data Exchange (ETDEWEB)

Hamilton, Bruce [Navigant Consulting, Inc., Burlington, MA (United States)

2013-02-22

This report seeks to provide an organized, analytical approach to identifying and bounding uncertainties around offshore wind manufacturing and supply chain capabilities; projecting potential component-level supply chain needs under three demand scenarios; and identifying key supply chain challenges and opportunities facing the future U.S. market and current suppliers of the nation’s landbased wind market.

Indigenous procurement of nuclear components at Tarapur (Paper No. 013)

International Nuclear Information System (INIS)

Verma, D.K.; Moss, V.J.

1987-02-01

The Tarapur Atomic Power Station (TAPS) was the first nuclear power station in developing countries and the first twin BWR units in the world. The Station has two units of boiling water reactor of very early design; along with its turbo-generator and supporting systems; constructed by M/s. I.G.E. on turnkey basis. Based on vendor recommendations initial operating spares for 5 years of operation were purchased from original equipment manufacturers. This does not call for the participation of the ultimate user; in the design, development, manufacture and quality control and user's participation remained confined to assemble the acceptable component(s) procured from original source in the assembly. As early as 1972, Plant initiated indigenising the nuclear components by gradually increasing the contribution of indigenous industry with due participation of the departmental agencies. Procurement of nuclear components requires development of engineering to an extent; where interphase communication between TAPS and counterpart indigenous industry is practicable to motivate them. Feedback from operation and maintenance practices is also utilised effectively. For some of the components initial sample were developed at TAPS and subsequently bulk fabrication was taken by industry. This paper describes manufacture, quality control during the process of manufacture and procurement of indigenous nuclear components relevant to Tarapur Atomic Power Station. (author)

Post Processing Methods used to Improve Surface Finish of Products which are Manufactured by Additive Manufacturing Technologies: A Review

Science.gov (United States)

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.

Investigation into CO2 laser cleaning of titanium alloys for gas-turbine component manufacture

International Nuclear Information System (INIS)

Turner, M.W.; Crouse, P.L.; Li, L; Smith, A.J.E.

2006-01-01

This paper reports results of the investigation into the feasibility of using a CO 2 laser technology to perform critical cleaning of gas-turbine aero-engine components for manufacture. It reports the results of recent trials and relates these to a thermal model of the cleaning mechanisms, and describes resultant component integrity. The paper defines the experimental conditions for the laser cleaning of various aerospace-grade contaminated titanium alloys, using a continuous wave CO 2 laser. Laser cleaning of Ti64 proved successful for electron beam welding, but not for the more sensitive Ti6246. For diffusion bonding the trials produced a defective standard of joint. Effects of oxide formation is modelled and examined experimentally

Additive manufacturing of Ti-6Al-4V components by shaped metal deposition: Microstructure and mechanical properties

International Nuclear Information System (INIS)

Baufeld, Bernd; Biest, Omer Van der; Gault, Rosemary

2010-01-01

Shaped metal deposition (SMD) is a relatively new technology of additive manufacturing, which creates near-net shaped components by additive manufacture utilizing tungsten inert gas welding. Especially for Ti alloys, which are difficult to shape by traditional methods and for which the loss of material during machining is also very costly, SMD has great advantages. In the case of Ti-6Al-4V the dense SMD components exhibit large, columnar prior β grains, with a Widmanstaetten α/β microstructure. These prior β grains are slightly tilted in a direction following the temperature field resulting from the moving welding torch. The ultimate tensile strength is between 929 and 1014 MPa, depending on orientation and location of the tensile specimens. Tensile testing vertically to the deposition layers exhibits a strain at failure of 16 ± 3%, while testing parallel to the layers gives a lower value of about 9%.

U.S. Wind Energy Manufacturing and Supply Chain: A Competitiveness Analysis

Energy Technology Data Exchange (ETDEWEB)

Fullenkamp, Patrick H; Holody, Diane S

2014-06-15

The goal of the project was to develop a greater understanding of the key factors determining wind energy component manufacturing costs and pricing on a global basis in order to enhance the competitiveness of U.S. manufacturers, and to reduce installed systems cost. Multiple stakeholders including DOE, turbine OEMs, and large component manufactures will all benefit by better understanding the factors determining domestic competitiveness in the emerging offshore and next generation land-based wind industries. Major objectives of this project were to: 1. Carry out global cost and process comparisons for 5MW jacket foundations, blades, towers, and permanent magnet generators; 2. Assess U.S. manufacturers’ competitiveness and potential for cost reduction; 3. Facilitate informed decision-making on investments in U.S. manufacturing; 4. Develop an industry scorecard representing the readiness of the U.S. manufacturers’ to produce components for the next generations of wind turbines, nominally 3MW land-based and 5MW offshore; 5. Disseminate results through the GLWN Wind Supply Chain GIS Map, a free website that is the most comprehensive public database of U.S. wind energy suppliers; 6. Identify areas and develop recommendations to DOE on potential R&D areas to target for increasing domestic manufacturing competitiveness, per DOE’s Clean Energy Manufacturing Initiative (CEMI). Lists of Deliverables 1. Cost Breakdown Competitive Analyses of four product categories: tower, jacket foundation, blade, and permanent magnet (PM) generator. The cost breakdown for each component includes a complete Bill of Materials with net weights; general process steps for labor; and burden adjusted by each manufacturer for their process categories of SGA (sales general and administrative), engineering, logistics cost to a common U.S. port, and profit. 2. Value Stream Map Competitiveness Analysis: A tool that illustrates both information and material flow from the point of getting a

Manufacturing knowledge management strategy

OpenAIRE

Shaw , Duncan; Edwards , John

2006-01-01

Abstract The study sought to understand the components of knowledge management strategy from the perspective of staff in UK manufacturing organisations. To analyse this topic we took an empirical approach and collaborated with two manufacturing organisations. Our main finding centres on the key components of a knowledge management strategy, and the relationships between it and manufacturing strategy and corporate strategy. Other findings include: the nature of knowledge in manufact...

Use of reliability engineering in development and manufacturing of metal parts

International Nuclear Information System (INIS)

Khan, A.; Iqbal, M.A.; Asif, M.

2005-01-01

The reliability engineering predicts modes of failures and weak links before the system is built instead of failure case study. The reliability engineering analysis will help in the manufacturing economy, assembly accuracy and qualification by testing, leading to production of metal parts in an aerospace industry. This methodology will also minimize the performance constraints in any requirement for the application of metal components in aerospace systems. The reliability engineering predicts the life of the parts under loading conditions whether dynamic or static. Reliability predictions can help engineers in making decisions about design of components, materials selection and qualification under applied stress levels. Two methods of reliability prediction i.e. Part Stress Analysis and Part Count have been used in this study. In this paper we will discuss how these two methods can be used to measure reliability of a system during development phases, which includes the measuring effect of environmental and operational variables. The equations are used to measure the reliability of each type of component, as well as, integration for measuring system applied for the reliability analysis. (author)

ITER central solenoid manufacturing R and D

International Nuclear Information System (INIS)

Jay Jayakumar, R.; Tsuji, H.; Ohsaki, O.

2001-01-01

The International Thermonuclear Experimental Reactor (ITER) Engineering Design Activity (EDA) includes the development of high performance superconductors, high current joints between superconducting cables and insulating materials. Also in the EDA, the resulting products of this R and D are incorporated in a Central Solenoid Model Coil which utilizes full size conductors. The manufacturing of the model coil and components has led to the development of the design, materials, tooling and process which are fully applicable to the manufacture of the ITER relevant CS coil. The R and D is essentially complete and final stages of the CS Model Coil manufacturing are underway. (author)

ITER central solenoid manufacturing R and D

International Nuclear Information System (INIS)

Jayakumar, R.J.; Tsuji, H.; Ohsaki, O.

1999-01-01

The International Thermonuclear Experimental Reactor (ITER) Engineering Design Activity (EDA) includes the development of high performance superconductors, high current joints between superconducting cables and insulating materials. Also in the EDA, the resulting products of this R and D are incorporated in a Central Solenoid Model Coil which utilizes full size conductors. The manufacturing of the model coil and components has led to the development of the design, materials, tooling and process which are fully applicable to the manufacture of the ITER relevant CS coil. The R and D is essentially complete and final stages of the CS Model Coil manufacturing are underway. (author)

Technical cost modelling for a novel semi-solid metal (SSM) casting processes for automotive component manufacturing

CSIR Research Space (South Africa)

Tlale, NS

2008-09-01

Full Text Available to predict the cost structure of a newly developed manufacturing process if it is to be considered by manufacturing enterprises for development to substitute a process that is in use. The costs of the new SSM technologies was established by technical cost...

Achievement Report for fiscal 1997 on developing a silicon manufacturing process with reduced energy consumption. Development of silicon mass-production manufacturing technology for solar cells; 1997 nendo energy shiyo gorika silicon seizo process kaihatsu. Taiyo denchiyo silicon ryosanka seizo gijutsu no kaihatsu

Energy Technology Data Exchange (ETDEWEB)

NONE

1998-03-01

In order to manufacture silicon for solar cells, development is intended on a technology to manufacture silicon (SOG-Si) for solar cells by means of metallurgical methods using metallic silicon with purity generally available as an interim starting material. The silicon is required of p-type electric conductivity characteristics with specific resistance of 0.5 to 1.5 ohm per cm, to be sufficient even with 6-7N as compared to silicon for semiconductors (11-N), and to be low in cost. While the NEDO fluid bed process and the metallurgical NEDO direct reduction process have been developed based on the technology to manufacture silicon for semiconductors, the basic policy was established to develop a new manufacturing method using commercially available high-purity metallic silicon as an interim starting material, with an objective to achieve cost as low as capable of responding to small-quantity phase production for proliferation purpose. Removal of boron and phosphor has been the main issue in the development, whereas SOG-Si was manufactured in a laboratory scale by combining with the conventional component technologies in fiscal 1991 and 1992. The scale was expanded to 20 kg since fiscal 1993, and a five year plan starting fiscal 1996 was decided to develop the technology for industrial scale. Fiscal 1997 has promoted the development by using the 20-kg scale device, and introduced facilities to develop technology for mass-production scale. (NEDO)

Integration of Manufacturing and Development in Emerging Markets

DEFF Research Database (Denmark)

Søberg, Peder Veng; Wæhrens, Brian Vejrum

2011-01-01

The paper investigates the problems related to functional integration between manufacturing activities and R&D activities in emerging markets within multinational companies. A framework to this end is developed and illustrated in relation to four cases from multinational companies, which have...... established R&D and manufacturing in China or India. The findings point to the importance of contingencies such as industrial clock speed, technological complexity, as well as the extent to which local adaptation is needed. Keywords: Co-location, Emerging markets, Functional integration, Manufacturing, R&D....

Manufacturing and joining technologies for helium cooled divertors

International Nuclear Information System (INIS)

Aktaa, J.; Basuki, W.W.; Weber, T.; Norajitra, P.; Krauss, W.; Konys, J.

2014-01-01

Highlights: • The manufacturing and joining technologies developed at KIT for helium cooled divertors are reviewed and critically discussed. • Various technologies have been pursued and further developed aiming divertor components with very high quality and sufficient reliability. • Very promising routes have been found for which however still R and D works are necessary. • Technologies developed are also useful for other divertor and even blanket concepts, particularly those with tungsten armor. - Abstract: In the helium cooled (HC) divertor, developed at KIT for a fusion power plant, tungsten has been selected as armor as well as structural material due to its crucial properties: high melting point, very low sputtering yield, good thermal conductivity, high temperature strength, low thermal expansion and low activation. Thereby the armor tungsten is attached to the structural tungsten by thermally conductive joint. Due to the brittleness of tungsten at low temperatures its use as structural material is limited to the high temperature part of the component and a structural joint to the reduced activation ferritic martensitic steel EUROFER97 is foreseen. Hence, to realize the selected hybrid material concept reliable tungsten–steel and tungsten–tungsten joints have been developed and will be reported in this paper. In addition, the modular design of the HC divertor requires tungsten armor tiles and tungsten structural thimbles to be manufactured in high numbers with very high quality. Due to the high strength and low temperature brittleness of tungsten special manufacturing techniques need to be developed for the production of parts with no cavities inside and/or surface flaws. The main achievement in developing the respective manufacturing technologies will be presented and discussed. To achieve the objectives mentioned above various manufacturing and joining technologies are pursued. Their later applicability depends on the level of development

Development of the plasma facing components for the dome-liner component of the ITER divertor

International Nuclear Information System (INIS)

Luconi, U.; Di Marco, M.; Federici, A.; Grattarola, M.; Gualco, G.; Larrea, J.M.; Merola, M.; Ozzano, C.; Pasquale, G.

2005-01-01

On the basis of the design and the specification of the dome-liner elaborated by EFDA, a manufacturing route based on high temperature brazing has been developed and proved by means of the fabrication and testing of several samples and mock-ups. The dome is protected with tungsten armour tiles joined onto heat sinks obtained from a bimetallic plate made of precipitation hardened copper-chromium-zirconium alloy and stainless steel realized by explosion bonding. The brazed joint between the tungsten tiles and the heat sink has been qualified by means of thermal fatigue tests on small-scale mock-ups in reactor relevant conditions. The properties of the explosion bonding joint between the front copper alloy plate to the rear steel backing has been assessed by means of an extensive metallurgical and mechanical test program according to the specification provided by EFDA. The dimensional stability during the fabrication route has been investigated by means of the realization of a relevant curved component that has been dimensionally tested after the completion of each step of the manufacturing route. The results of the experimental activity are presented and discussed in this paper

Manufacturing of ceramic microcomponents by a rapid prototyping process chain

International Nuclear Information System (INIS)

Knitter, R.; Bauer, W.; Goehring, D.; Hausselt, J.

2001-01-01

Manufacturing of new ceramic components may be improved significantly by the use of rapid prototyping processes especially in the development of miniaturized or micropatterned components. Most known generative ceramic molding processes do not provide a sufficient resolution for the fabrication of microstructured components. In contrast to this, a rapid prototyping process chain that for example, combines micro-stereolithography and low-pressure injection molding, allows the rapid manufacturing of ceramic microcomponents from functional models to preliminary or small-lot series. (orig.)

Work-related musculoskeletal disorders (WMDs) risk assessment at core assembly production of electronic components manufacturing company

Science.gov (United States)

Yahya, N. M.; Zahid, M. N. O.

2018-03-01

This study conducted to assess the work-related musculoskeletal disorders (WMDs) among the workers at core assembly production in an electronic components manufacturing company located in Pekan, Pahang, Malaysia. The study is to identify the WMDs risk factor and risk level. A set of questionnaires survey based on modified Nordic Musculoskeletal Disorder Questionnaires have been distributed to respective workers to acquire the WMDs risk factor identification. Then, postural analysis was conducted in order to measure the respective WMDs risk level. The analysis were based on two ergonomics assessment tools; Rapid Upper Limb Assessment (RULA) and Rapid Entire Body Assessment (REBA). The study found that 30 respondents out of 36 respondents suffered from WMDs especially at shoulder, wrists and lower back. The WMDs risk have been identified from unloading process, pressing process and winding process. In term of the WMDs risk level, REBA and RULA assessment tools have indicated high risk level to unloading and pressing process. Thus, this study had established the WMDs risk factor and risk level of core assembly production in an electronic components manufacturing company at Malaysia environment.

The Experiment Method for Manufacturing Grid Development on Single Computer

Institute of Scientific and Technical Information of China (English)

XIAO Youan; ZHOU Zude

2006-01-01

In this paper, an experiment method for the Manufacturing Grid application system development in the single personal computer environment is proposed. The characteristic of the proposed method is constructing a full prototype Manufacturing Grid application system which is hosted on a single personal computer with the virtual machine technology. Firstly, it builds all the Manufacturing Grid physical resource nodes on an abstraction layer of a single personal computer with the virtual machine technology. Secondly, all the virtual Manufacturing Grid resource nodes will be connected with virtual network and the application software will be deployed on each Manufacturing Grid nodes. Then, we can obtain a prototype Manufacturing Grid application system which is working in the single personal computer, and can carry on the experiment on this foundation. Compared with the known experiment methods for the Manufacturing Grid application system development, the proposed method has the advantages of the known methods, such as cost inexpensively, operation simple, and can get the confidence experiment result easily. The Manufacturing Grid application system constructed with the proposed method has the high scalability, stability and reliability. It is can be migrated to the real application environment rapidly.

Chalon/Saint-Marcel manufacturing plant

International Nuclear Information System (INIS)

2008-01-01

AREVA is the world leader in the design and construction of nuclear power plants, the manufacture of heavy components, and the supply of nuclear fuel and nuclear services such as maintenance and inspection. The Equipment Division provides the widest range of nuclear components and equipment, manufactured at its two facilities in Jeumont, northern France, and St. Marcel, in Burgundy. The St. Marcel plant, set on 35 ha (87.5 acres) near Chalon-sur-Saone, was established in 1973 in a region with a long history of specialized metalworking and mechanical activities to meet the demand for non-military nuclear requirements in France. The site offers two advantages: - excellent facilities for loading and transporting heavy components on the Saone river, - it's proximity to other group sites. Since its completion in 1975, the Chalon/St. Marcel facility has manufactured all the heavy components for French pressurized water reactors (PWRs) ranging from 900 MW to 1500 MW. It has also completed a significant number of export contracts that have made AREVA world leader. Nearly 600 heavy components (reactor vessels, steam generators, pressurizers and closure heads) have been manufactured or are currently being manufactured since the plant opened in 1975. The plant is at the heart of the manufacturing chain for nuclear steam supply systems (NSSS) supplied by AREVA. On the basis of engineering data, the plant manufactures reactor vessels, reactor vessel internals, steam generators, pressurizers and related components such as accumulators, auxiliary heat exchangers and supporting elements. Vessel upper internals Other similar components such as reactor vessels for boiling water reactors (BWR) or high temperature reactors (HTR) and other types of steam generators can also be manufactured in the plant (for example Once Through Steam Generators - OTSG). The basic activities performed at Chalon/St. Marcel are metalworking and heavy machining. These activities are carried out in strict

Manufacturing Development of the NCSX Modular Coil Windings

International Nuclear Information System (INIS)

Chrzanowski, JH; Fogarty, PJ; Heitzenroeder, PJ; Meighan, T.; Nelson, B.; Raftopoulos, S.; Williamson, D.

2005-01-01

The modular coils on the National Compact Stellarator Experiment (NCSX) present a number of significant engineering challenges due to their complex shapes, requirements for high dimensional accuracy and the high current density required in the modular coils due to space constraints. In order to address these challenges, an R and D program was established to develop the conductor, insulation scheme, manufacturing techniques, and procedures. A prototype winding named Twisted Racetrack Coil (TRC) was of particular importance in dealing with these challenges. The TRC included a complex shaped winding form, conductor, insulation scheme, leads and termination, cooling system and coil clamps typical of the modular coil design. Even though the TRC is smaller in size than a modular coil, its similar complex geometry provided invaluable information in developing the final design, metrology techniques and development of manufacturing procedures. In addition a discussion of the development of the copper rope conductor including ''Keystoning'' concerns; the epoxy impregnation system (VPI) plus the tooling and equipment required to manufacture the modular coils will be presented

An updated methodology to review developing-country vaccine manufacturer viability.

Science.gov (United States)

Luter, Nicholas; Kumar, Ritu; Hozumi, Dai; Lorenson, Tina; Larsen, Shannon; Gowda, Bhavya; Batson, Amie

2017-07-05

In 1997, Milstien, Batson, and Meaney published "A Systematic Method for Evaluating the Potential Viability of Local Vaccine Producers." The paper identified characteristics of successful vaccine manufacturers and developed a viability framework to evaluate their performance. This paper revisits the original study after two decades to determine the ability of the framework to predict manufacturer success. By reconstructing much of the original dataset and conducting in-depth interviews, the authors developed informed views on the continued viability of manufacturers in low- and middle-income country markets. Considering the marked changes in the market and technology landscape since 1997, the authors find the viability framework to be predictive and a useful lens through which to evaluate manufacturer success or failure. Of particular interest is how incumbent and potentially new developing-country vaccine manufacturers enter and sustain production in competitive international markets and how they integrate (or fail to integrate) new technology into the production process. Ultimately, most manufacturers will need to meet global quality standards to be viable. As governments and donors consider investments in vaccine producers, the updated viability factors will be a useful tool in evaluating the prospects of manufacturers over the mid to long term. The paper emphasizes that while up-front investments are important, other critical factors-including investments in a national regulatory authority, manufacturer independence, and ability to adapt and adopt new technology-are necessary to ensure viability. Copyright © 2017 The Author(s). Published by Elsevier Ltd.. All rights reserved.

Recent Developments in Abrasive Hybrid Manufacturing Processes

Directory of Open Access Journals (Sweden)

Ruszaj Adam

2017-06-01

Full Text Available Recent dynamic development of abrasive hybrid manufacturing processes results from application of a new difficult for machining materials and improvement of technological indicators of manufacturing processes already applied in practice. This tendency also occurs in abrasive machining processes which are often supported by ultrasonic vibrations, electrochemical dissolution or by electrical discharges. In the paper we present the review of new results of investigations and new practical applications of Abrasive Electrodischarge (AEDM and Electrochemical (AECM Machining.

Hot radial pressing: An alternative technique for the manufacturing of plasma-facing components

International Nuclear Information System (INIS)

Visca, E.; Libera, S.; Mancini, A.; Mazzone, G.; Pizzuto, A.; Testani, C.

2005-01-01

The Hot radial pressing (HRP) manufacturing technique is based on the radial diffusion bonding principle performed between the cooling tube and the armour tile. The bonding is achieved by pressurizing the cooling tube while the joining interface is kept at the vacuum and temperature conditions. This technique has been used for the manufacturing of relevant mock-ups of the ITER divertor vertical target. Tungsten monoblock mock-ups were successfully tested to high heat flux thermal fatigue (20 MW/m 2 of absorbed heat flux for 1000 cycles). After these good results the activity is now focused on the developing of a manufacturing process suitable also for the CFC monoblock mock-ups. A FE calculation was performed to investigate the stress involved in the CFC tiles during the process and to avoid the CFC fracture. The results obtained by the FE calculation and by the test performed in air simulating a HRP manufacturing process for a CFC monoblock mock-ups is reported in the paper

High heat flux actively cooled plasma facing components development, realization and first results in Tore Supra

Energy Technology Data Exchange (ETDEWEB)

Grosman, A. [Association Euratom-CEA, Centre d' Etudes de Cadarache, 13 - Saint-Paul-lez-Durance (France). Dept. de Recherches sur la Fusion Controlee

2004-07-01

The development, design, manufacture and testing of actively cooled high heat flux plasma facing components (PFC) has been an essential stage towards long powerful tokamak operations for Tore-Supra, it lasted about 10 years. This paper deals with the toroidal pumped limiter (TPL) that is able to sustain up to 10 MW/m{sup 2} of nominal heat flux. This device is based on hardened copper alloy heat sink structures covered by a carbon fiber composite armour, it resulted in the manufacturing of 600 elementary components, called finger elements, to achieve the 7.6 m{sup 2} TPL. This assembly has been operating in Tore-Supra since spring 2002. Some difficulties occurred during the manufacturing phase, the valuable industrial experience is summarized in the section 2. The permanent monitoring of PFC surface temperature all along the discharge is performed by a set of 6 actively cooled infrared endoscopes. The heat flux monitoring and control issue but also the progress made in our understanding of the deuterium retention in long discharges are described in the section 3. (A.C.)

High heat flux actively cooled plasma facing components development, realization and first results in Tore Supra

International Nuclear Information System (INIS)

Grosman, A.

2004-01-01

The development, design, manufacture and testing of actively cooled high heat flux plasma facing components (PFC) has been an essential stage towards long powerful tokamak operations for Tore-Supra, it lasted about 10 years. This paper deals with the toroidal pumped limiter (TPL) that is able to sustain up to 10 MW/m 2 of nominal heat flux. This device is based on hardened copper alloy heat sink structures covered by a carbon fiber composite armour, it resulted in the manufacturing of 600 elementary components, called finger elements, to achieve the 7.6 m 2 TPL. This assembly has been operating in Tore-Supra since spring 2002. Some difficulties occurred during the manufacturing phase, the valuable industrial experience is summarized in the section 2. The permanent monitoring of PFC surface temperature all along the discharge is performed by a set of 6 actively cooled infrared endoscopes. The heat flux monitoring and control issue but also the progress made in our understanding of the deuterium retention in long discharges are described in the section 3. (A.C.)

An analytic framework for developing inherently-manufacturable pop-up laminate devices

International Nuclear Information System (INIS)

Aukes, Daniel M; Goldberg, Benjamin; Wood, Robert J; Cutkosky, Mark R

2014-01-01

Spurred by advances in manufacturing technologies developed around layered manufacturing technologies such as PC-MEMS, SCM, and printable robotics, we propose a new analytic framework for capturing the geometry of folded composite laminate devices and the mechanical processes used to manufacture them. These processes can be represented by combining a small set of geometric operations which are general enough to encompass many different manufacturing paradigms. Furthermore, such a formulation permits one to construct a variety of geometric tools which can be used to analyze common manufacturability concepts, such as tool access, part removability, and device support. In order to increase the speed of development, reduce the occurrence of manufacturing problems inherent with current design methods, and reduce the level of expertise required to develop new devices, the framework has been implemented in a new design tool called popupCAD, which is suited for the design and development of complex folded laminate devices. We conclude with a demonstration of utility of the tools by creating a folded leg mechanism. (paper)

Manufacturing Vision Development – Process and Dialogue

DEFF Research Database (Denmark)

Dukovska-Popovska, Iskra

This Ph.D. project has been conducted in the context of PRODUCTION+5 methodology for devel¬oping manufacturing visions for companies, and related to Experimental Laboratory for Production. Both have been established in the Center for Industrial Production. The empirical parts of the research invo...... involve case studies of three companies that are part of the MCD-process. The cases primarily are focusing on the process and the dialogue dur¬ing the manufacturing vision development.......This Ph.D. project has been conducted in the context of PRODUCTION+5 methodology for devel¬oping manufacturing visions for companies, and related to Experimental Laboratory for Production. Both have been established in the Center for Industrial Production. The empirical parts of the research...

Development of instruments and components for SANS and PNS

Energy Technology Data Exchange (ETDEWEB)

Park, Kook Nam; Lee, Chang Hee; Lee, C. H. and others

2000-11-01

The base floor of SANS was constructed by the 27 steel plates with horizontal flatness of {+-}0.5mm. That is for the two dimensional position sensitivity neutron detector(2D-PSD), which is operated in vacuum chamber, as moving smoothly. Concerned to the equipments, we designed and installed the inner-shielding of the PNS which will be used for research of magnetic structure and critical phenomena of the materials. In the development of experimental devices, we have designed and manufactured a beam-stop exchange unit and a detector carriage which are used for 2D-PSD. The detector carriage is to control the distance between sample and detector. The beam-stop exchange unit is to protect detector from exposure of direct neutron beam. Especially, many experimental devices or instruments such as high-resolution collimator, components for low temperature facility, multi-purpose vacuum chamber, etc. were made in domestic, it is worth meaningful in domestic availability and standardization for the neutron instrument component.

Investigation of plasma arc welding as a method for the additive manufacturing of titanium-(6)aluminum-(4)vanadium alloy components

Science.gov (United States)

Stavinoha, Joe N.

The process of producing near net-shape components by material deposition is known as additive manufacturing. All additive manufacturing processes are based on the addition of material with the main driving forces being cost reduction and flexibility in both manufacturing and product design. With wire metal deposition, metal is deposited as beads side-by-side and layer-by-layer in a desired pattern to build a complete component or add features on a part. There are minimal waste products, low consumables, and an efficient use of energy and feedstock associated with additive manufacturing processes. Titanium and titanium alloys are useful engineering materials that possess an extraordinary combination of properties. Some of the properties that make titanium advantageous for structural applications are its high strength-to-weight ratio, low density, low coefficient of thermal expansion, and good corrosion resistance. The most commonly used titanium alloy, Ti-6Al-4V, is typically used in aerospace applications, pressure vessels, aircraft gas turbine disks, cases and compressor blades, and surgical implants. Because of the high material prices associated with titanium alloys, the production of near net-shape components by additive manufacturing is an attractive option for the manufacturing of Ti-6Al-4V alloy components. In this thesis, the manufacturing of cylindrical Ti-6Al-4V alloy specimens by wire metal deposition utilizing the plasma arc welding process was demonstrated. Plasma arc welding is a cost effective additive manufacturing technique when compared to other current additive manufacturing methods such as laser beam welding and electron beam welding. Plasma arc welding is considered a high-energy-density welding processes which is desirable for the successful welding of titanium. Metal deposition was performed using a constant current plasma arc welding power supply, flow-purged welding chamber, argon shielding and orifice gas, ERTi-5 filler metal, and Ti-6Al

Small Scale Turbopump Manufacturing Technology and Material Processes

Science.gov (United States)

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

2011-01-01

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

The identification of a sensitizing component used in the manufacturing of an ink ribbon

Science.gov (United States)

Anderson, Stacey E.; Tapp, Loren; Durgam, Srinivas; Meade, B. Jean; Jackson, Laurel G.; Cohen, David E.

2015-01-01

Skin diseases including dermatitis constitute ≈ 30% of all occupational illnesses, with a high incidence in the printing industry. An outbreak of contact dermatitis among employees at an ink ribbon manufacturing plant was investigated by scientists from the National Institute for Occupational Safety and Health (NIOSH). Employees in the process areas of the plant were exposed to numerous chemicals and many had experienced skin rashes, especially after the introduction of a new ink ribbon product. To identify the causative agent(s) of the occupational dermatitis, the murine local lymph node assay (LLNA) was used to identify the potential of the chemicals used in the manufacture of the ink ribbon to induce allergic contact dermatitis. Follow-up patch testing with the suspected allergens was conducted on exposed employees. Polyvinyl butyral, a chemical component used in the manufacture of the ink ribbon in question and other products, tested positive in the LLNA, with an EC3 of 3.6%, which identifies it as a potential sensitizer; however, no employees tested positive to this chemical during skin patch testing. This finding has implications beyond those described in this report because of occupational exposure to polyvinyl butyral outside of the printing industry. PMID:22375946

Hot forming and quenching pilot process development for low cost and low environmental impact manufacturing.

Science.gov (United States)

Hall, Roger W.; Foster, Alistair; Herrmann Praturlon, Anja

2017-09-01

The Hot Forming and in-tool Quenching (HFQ®) process is a proven technique to enable complex shaped stampings to be manufactured from high strength aluminium. Its widespread uptake for high volume production will be maximised if it is able to wholly amortise the additional investment cost of this process compared to conventional deep drawing techniques. This paper discusses the use of three techniques to guide some of the development decisions taken during upscaling of the HFQ® process. Modelling of Process timing, Cost and Life-cycle impact were found to be effective tools to identify where development budget could be focused in order to be able to manufacture low cost panels of different sizes from many different alloys in a sustainable way. The results confirm that raw material cost, panel trimming, and artificial ageing were some of the highest contributing factors to final component cost. Additionally, heat treatment and lubricant removal stages played a significant role in the overall life-cycle assessment of the final products. These findings confirmed development priorities as novel furnace design, fast artificial ageing and low-cost alloy development.

GCS component development cycle

Science.gov (United States)

Rodríguez, Jose A.; Macias, Rosa; Molgo, Jordi; Guerra, Dailos; Pi, Marti

2012-09-01

The GTC1 is an optical-infrared 10-meter segmented mirror telescope at the ORM observatory in Canary Islands (Spain). First light was at 13/07/2007 and since them it is in the operation phase. The GTC control system (GCS) is a distributed object & component oriented system based on RT-CORBA8 and it is responsible for the management and operation of the telescope, including its instrumentation. GCS has used the Rational Unified process (RUP9) in its development. RUP is an iterative software development process framework. After analysing (use cases) and designing (UML10) any of GCS subsystems, an initial component description of its interface is obtained and from that information a component specification is written. In order to improve the code productivity, GCS has adopted the code generation to transform this component specification into the skeleton of component classes based on a software framework, called Device Component Framework. Using the GCS development tools, based on javadoc and gcc, in only one step, the component is generated, compiled and deployed to be tested for the first time through our GUI inspector. The main advantages of this approach are the following: It reduces the learning curve of new developers and the development error rate, allows a systematic use of design patterns in the development and software reuse, speeds up the deliverables of the software product and massively increase the timescale, design consistency and design quality, and eliminates the future refactoring process required for the code.

Green electronics manufacturing creating environmental sensible products

CERN Document Server

Wang, John X

2012-01-01

Going ""green"" is becoming a major component of the mission for electronics manufacturers worldwide. While this goal seems simplistic, it poses daunting dilemmas. Yet, to compete effectively in the global economy, manufacturers must take the initiative to drive this crucial movement. Green Electronics Manufacturing: Creating Environmental Sensible Products provides you with a complete reference to design, develop, build, and install an electronic product with special consideration for the product's environmental impacts during its whole life cycle. The author discusses how to integrate the st

Dimensional metrology for process and part quality control in micro manufacturing

DEFF Research Database (Denmark)

Hansen, Hans Nørgaard; Tosello, Guido; Gasparin, Stefania

2011-01-01

dimensions are scaled down and geometrical complexity of objects is increased, the available measurement technologies appear not sufficient. New solutions for measuring principles and instrumentation, tolerancing rules and procedures as well as traceability and calibration are necessary if micro......Micro manufacturing has gained interest over the last decade as the demand for micro mechanical components has increased. The need for dimensional metrology at micro scale is evident both in terms of quality assurance of components and products and in terms of process control. As critical...... manufacturing is to develop into industrial manufacturing solutions. In this paper the application of dimensional precision metrology to both component and process quality control will be demonstrated. The parts investigated are micro injection moulded polymer parts, typical for the field of micro manufacturing....

Quality assurance experience in the manufacture of PFBR reactor vessel during technology development work

International Nuclear Information System (INIS)

Shanmugam, K.; Chandramohan, R.; Ramamurthy, M.K.

1996-01-01

An efficient and proper implementation of quality assurance in the technology development works of Prototype Fast Breeder Reactor (PFBR) main vessel was undertaken to achieve the desired quality and dimensional accuracy of main vessel. In this paper an attempt has been made to bring out the methods and procedures adopted to implement the quality assurance programme on important activities including approval of documents, material, general requirements for manufacture of SS components, inspection procedures, forming and welding of petals, non-destructive testing etc. (author)

Results from ITER Vacuum Vessel Sector Manufacturing Development in Europe

International Nuclear Information System (INIS)

Jones, L.

2006-01-01

Significant results have been achieved since the previous SOFT conference, when the manufacturing development work required to prepare for the ITER Vacuum Vessel Sector was described. The contract for the manufacture of a full-size, 20 Ton poloidal part of the inboard section, fabricated according to the ITER reference manufacturing route, including bracing fixtures, welding applications, restraint effects, and fit-up aspects is approaching completion. Since the main aim of the work is to establish the practicability of achieving the tight dimensional tolerances, an accompanying SYSWELD analysis programme has been validation by instrumented welding coupons, and then used for predicting the distortion of the actual construction. A local machining tool has been developed to allow the requirement for machining of the cylindrical features at a late stage of manufacture. Experimental and analytical work has also been carried out to establish the possibility of 3-D cold-forming large sections of walls of the VV. A manufacturing programme to validate an alternative method of fabricating parts of the double-walled VV, utilising e-beam welding only and avoiding the quality issues of the one-sided access and inspection of the closing welds is presented. This paper describes the results of the manufacturing development programme and the future activities. (author)

Atomic and close-to-atomic scale manufacturing—A trend in manufacturing development

Science.gov (United States)

Fang, Fengzhou

2016-12-01

Manufacturing is the foundation of a nation's economy. It is the primary industry to promote economic and social development. To accelerate and upgrade China's manufacturing sector from "precision manufacturing" to "high-performance and high-quality manufacturing", a new breakthrough should be found in terms of achieving a "leap-frog development". Unlike conventional manufacturing, the fundamental theory of "Manufacturing 3.0" is beyond the scope of conventional theory; rather, it is based on new principles and theories at the atomic and/or closeto- atomic scale. Obtaining a dominant role at the international level is a strategic move for China's progress.

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

International Nuclear Information System (INIS)

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

2015-01-01

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

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

Energy Technology Data Exchange (ETDEWEB)

Anderson, Scott [Lockheed Martin Corporation, Denver, CO (United States). Space Systems Company; Baca, Georgina [Lockheed Martin Corporation, Denver, CO (United States). Space Systems Company; O' Connor, Michael [Lockheed Martin Corporation, Denver, CO (United States). Space Systems Company

2015-12-31

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

A proposed centralised distribution model for the South African automotive component industry

Directory of Open Access Journals (Sweden)

Micheline J. Naude

2009-12-01

Full Text Available Purpose: This article explores the possibility of developing a distribution model, similar to the model developed and implemented by the South African pharmaceutical industry, which could be implemented by automotive component manufacturers for supply to independent retailers. Problem Investigated: The South African automotive components distribution chain is extensive with a number of players of varying sizes, from the larger spares distribution groups to a number of independent retailers. Distributing to the smaller independent retailers is costly for the automotive component manufacturers. Methodology: This study is based on a preliminary study of an explorative nature. Interviews were conducted with a senior staff member from a leading automotive component manufacturer in KwaZulu Natal and nine participants at a senior management level at five of their main customers (aftermarket retailers. Findings: The findings from the empirical study suggest that the aftermarket component industry is mature with the role players well established. The distribution chain to the independent retailer is expensive in terms of transaction and distribution costs for the automotive component manufacturer. A proposed centralised distribution model for supply to independent retailers has been developed which should reduce distribution costs for the automotive component manufacturer in terms of (1 the lowest possible freight rate; (2 timely and controlled delivery; and (3 reduced congestion at the customer's receiving dock. Originality: This research is original in that it explores the possibility of implementing a centralised distribution model for independent retailers in the automotive component industry. Furthermore, there is a dearth of published research on the South African automotive component industry particularly addressing distribution issues. Conclusion: The distribution model as suggested is a practical one and should deliver added value to automotive

Development of Cranial Bone Surrogate Structures Using Stereolithographic Additive Manufacturing

Science.gov (United States)

2017-09-29

Additive Manufacturing by Jared M Gardner and Thomas A Plaisted Approved for public release; distribution is unlimited...Laboratory Development of Cranial Bone Surrogate Structures Using Stereolithographic Additive Manufacturing by Thomas A Plaisted Weapons...Structures Using Stereolithographic Additive Manufacturing 5a. CONTRACT NUMBER 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 6. AUTHOR(S) Jared

Achievement report on developing inverse manufacturing system in fiscal 1998; 1998 nendo inverse manufacturing system no kaihatsu seika hokokusho

Energy Technology Data Exchange (ETDEWEB)

NONE

2000-03-01

Research and development has been performed on a circulating type production system, or an inverse manufacturing system, to minimize the environmental load in the entire life cycle of industrial products from design to manufacturing, maintenance, recovery, and re-utilization. In developing the recycling information system, discussion and extraction were executed on the data to be exchanged between manufacturers and users in the inverse society. A new individual parts history control system was developed. In developing the recycling processing system, a prototype system was evaluated by using hypothetical data, wherein the possibility of improving the recycling processing efficiency and reducing the cost was verified. In addition, trial design was made on a recycling processing plant in consideration of the cost effect to get the future plant image. In fabricating the inverse manufacturing products, a prototype concept model was made for information terminal devices. Development was performed on such elementary technologies as the easy-to-disintegrate structure technology, self-integration connecting structure and environmental hysteresis detection system. (NEDO)

An Assessment of Nondestructive Evaluation Capability for Complex Additive Manufacturing Aerospace Components

Science.gov (United States)

Walker, James; Beshears, Ron; Lambert, Dennis; Tilson, William

2016-01-01

The primary focus of this work is to investigate some of the fundamental relationships between processing, mechanical testing, materials characterization, and NDE for additively manufactured (AM) components using the powder bed fusion direct melt laser sintered process. The goal is to understand the criticality of defects unique to the AM process and then how conventional nondestructive evaluation methods as well as some of the more non-traditional methods such as computed tomography, are effected by the AM material. Specific defects including cracking, porosity and partially/unfused powder will be addressed. Besides line-of-site NDE, as appropriate these inspection capabilities will be put into the context of complex AM geometries where hidden features obscure, or inhibit traditional NDE methods.

Advanced Material Strategies for Next-Generation Additive Manufacturing.

Science.gov (United States)

Chang, Jinke; He, Jiankang; Mao, Mao; Zhou, Wenxing; Lei, Qi; Li, Xiao; Li, Dichen; Chua, Chee-Kai; Zhao, Xin

2018-01-22

Additive manufacturing (AM) has drawn tremendous attention in various fields. In recent years, great efforts have been made to develop novel additive manufacturing processes such as micro-/nano-scale 3D printing, bioprinting, and 4D printing for the fabrication of complex 3D structures with high resolution, living components, and multimaterials. The development of advanced functional materials is important for the implementation of these novel additive manufacturing processes. Here, a state-of-the-art review on advanced material strategies for novel additive manufacturing processes is provided, mainly including conductive materials, biomaterials, and smart materials. The advantages, limitations, and future perspectives of these materials for additive manufacturing are discussed. It is believed that the innovations of material strategies in parallel with the evolution of additive manufacturing processes will provide numerous possibilities for the fabrication of complex smart constructs with multiple functions, which will significantly widen the application fields of next-generation additive manufacturing.

Advanced Material Strategies for Next-Generation Additive Manufacturing

Directory of Open Access Journals (Sweden)

Jinke Chang

2018-01-01

Full Text Available Additive manufacturing (AM has drawn tremendous attention in various fields. In recent years, great efforts have been made to develop novel additive manufacturing processes such as micro-/nano-scale 3D printing, bioprinting, and 4D printing for the fabrication of complex 3D structures with high resolution, living components, and multimaterials. The development of advanced functional materials is important for the implementation of these novel additive manufacturing processes. Here, a state-of-the-art review on advanced material strategies for novel additive manufacturing processes is provided, mainly including conductive materials, biomaterials, and smart materials. The advantages, limitations, and future perspectives of these materials for additive manufacturing are discussed. It is believed that the innovations of material strategies in parallel with the evolution of additive manufacturing processes will provide numerous possibilities for the fabrication of complex smart constructs with multiple functions, which will significantly widen the application fields of next-generation additive manufacturing.

Advanced Material Strategies for Next-Generation Additive Manufacturing

Science.gov (United States)

Chang, Jinke; He, Jiankang; Zhou, Wenxing; Lei, Qi; Li, Xiao; Li, Dichen

2018-01-01

Additive manufacturing (AM) has drawn tremendous attention in various fields. In recent years, great efforts have been made to develop novel additive manufacturing processes such as micro-/nano-scale 3D printing, bioprinting, and 4D printing for the fabrication of complex 3D structures with high resolution, living components, and multimaterials. The development of advanced functional materials is important for the implementation of these novel additive manufacturing processes. Here, a state-of-the-art review on advanced material strategies for novel additive manufacturing processes is provided, mainly including conductive materials, biomaterials, and smart materials. The advantages, limitations, and future perspectives of these materials for additive manufacturing are discussed. It is believed that the innovations of material strategies in parallel with the evolution of additive manufacturing processes will provide numerous possibilities for the fabrication of complex smart constructs with multiple functions, which will significantly widen the application fields of next-generation additive manufacturing. PMID:29361754

Ceramic-Based 4D Components: Additive Manufacturing (AM) of Ceramic-Based Functionally Graded Materials (FGM) by Thermoplastic 3D Printing (T3DP).

Science.gov (United States)

Scheithauer, Uwe; Weingarten, Steven; Johne, Robert; Schwarzer, Eric; Abel, Johannes; Richter, Hans-Jürgen; Moritz, Tassilo; Michaelis, Alexander

2017-11-28

In our study, we investigated the additive manufacturing (AM) of ceramic-based functionally graded materials (FGM) by the direct AM technology thermoplastic 3D printing (T3DP). Zirconia components with varying microstructures were additively manufactured by using thermoplastic suspensions with different contents of pore-forming agents (PFA), which were co-sintered defect-free. Different materials were investigated concerning their suitability as PFA for the T3DP process. Diverse zirconia-based suspensions were prepared and used for the AM of single- and multi-material test components. All of the samples were sintered defect-free, and in the end, we could realize a brick wall-like component consisting of dense (<1% porosity) and porous (approx. 5% porosity) zirconia areas to combine different properties in one component. T3DP opens the door to the AM of further ceramic-based 4D components, such as multi-color, multi-material, or especially, multi-functional components.

Competitive manufacturing strategies for the manufacturing industries in Turkey

OpenAIRE

Ulusoy, Gündüz; Ulusoy, Gunduz

2003-01-01

In this study, results of the research into competitive manufacturing strategies of companies in four different sector studies covering 82 companies from the electronics, cement, automotive manufacturers, and appliances part and component suppliers in Turkey are presented. The data used in the study are gathered by conducting four sector surveys in 1997 and 1998 using a questionnaire supported by some follow-up interviews and site visits. A competitive manufacturing strategy is represented he...

Bio-reinforced composite development for additive manufacturing: Nanocellulose-PLA

Energy Technology Data Exchange (ETDEWEB)

Tekinalp, Halil L. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Lu, Yuan [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Kunc, Vlastimil [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Duty, Chad E. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Love, Lonnie J. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Peter, William H. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Ozcan, Soydan [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

2016-07-01

Additive manufacturing (AM) is transitioning from being only a prototyping method towards becoming a manufacturing technique for the quick production of parts with complex geometries. For the complete realization of this transition, the mechanical properties of the printed parts have to meet the requirements of actual load-bearing structural components. Integration of a reinforcing second phase into a polymer is a viable approach for the improvement of resins mechanical performance. Addition of carbon fibers into acrylonitrile-butadiene-styrene (ABS) has already been shown to improve its mechanical properties compared to the neat ABS resin (both additively manufactured), and led to the manufacture of world s first 3D-printed car. However, both ABS resin and carbon fibers are petroleum-based products, and there is a continuous search for alternative, bio-sourced, renewable materials as a feedstock for manufacturing. Towards this direction, we have investigated the potential of cellulose nanofibril-reinforced polylactic acid (PLA) resin systems as an alternative. CNF-PLA composite systems with up to 40 wt% CNF loadings were prepared via compression molding technique and tested. Significant improvements in both tensile strength (80%) and elastic modulus (128%) were observed. Filaments prepared from the same compositions were also successfully 3D-printed into tensile testing specimens with up to 30% CNF concentrations, and showed similar improvements in mechanical performance. Although CNFs were not individually dispersed in PLA matrix, they were observed to be well blended with the polymer based on SEM micrographs. In summary, preparation and 3D-printing of a 100% bio-based feedstock material with the mechanical properties comparable to the carbon fiber-ABS system was successfully demonstrated that it can open up new window of opportunities in the additive manufacturing industry. Acknowledgement Research sponsored by the U.S. Department of Energy, Office of Energy

On the development of high quality NiTi shape memory and pseudoelastic parts by additive manufacturing

International Nuclear Information System (INIS)

Haberland, Christoph; Elahinia, Mohammad; Walker, Jason M; Meier, Horst; Frenzel, Jan

2014-01-01

Additive manufacturing provides an attractive processing method for nickel–titanium (NiTi) shape memory and pseudoelastic parts. In this paper, we show how the additive manufacturing process affects structural and functional properties of additively manufactured NiTi and how the process parameter set-up can be optimized to produce high quality NiTi parts and components. Comparisons of shape recovery due to shape memory and pseudoelasticity in additively manufactured and commercial NiTi exhibit promising potential for this innovative processing method. (paper)

Development work for the manufacture of a blanket shield prototype for ITER

International Nuclear Information System (INIS)

Boireau, B.; Boudot, C.; Cottin, A.; Lorenzetto, P.; Jacquinot, F.; Bucci, P.; Gillia, O.; Vidotto, F.

2006-01-01

In the frame of the blanket development for ITER, an R-and-D programme was implemented for the manufacture of a shield prototype by powder Hot Isostatic Pressing (HIPping). The shield consists of a Stainless steel forged block drilled and machined, at the back of which 3D bent tubes are HIPped inside a powder layer. This paper describes the development work through the manufacturing of several mock ups that leads us to be confident for the shield prototype manufacturing. The paper is divided into 2 parts, the first one related to the machining development and validation, the second one relating to the HIP development and validation. A partial full scale mock up for the machining development (machined PFSMU) was manufactured with no particular problems, all the main identified difficulties in machining like deep drilling and castellation machining where overcome and the mock up was conform to the specification. The manufacturing of a HIPped PFSMU for the HIP development was done after the manufacturing of smaller mock-ups each representing a particular detailed design point. A computer simulation work gave us some design recommendation, and the compared analysis of the numerical simulation and experimental results lead us to predict the distortions on the PFSMU HIPped mock up. The HIPped distortions that were the main uncertainty were assessed through small mock ups and bigger one. The mechanical characteristics of the joints are conform to the specification. Associated to the mock up manufacturing is the ultrasonic test development which consists in designing and manufacturing a miniaturized probe travelling inside the bent tube after the HIP cycle to examine the joint tube / powder among others. This ultrasonic development allowed the examination of the HIPped PFSMU mock up that concluded this development work. (author)

Simulation of Assembly Line Balancing in Automotive Component Manufacturing

Science.gov (United States)

Jamil, Muthanna; Mohd Razali, Noraini

2016-02-01

This study focuses on the simulation of assembly line balancing in an automotive component in a vendor manufacturing company. A mixed-model assembly line of charcoal canister product that is used in an engine system as fuel's vapour filter was observed and found that the current production rate of the line does not achieve customer demand even though the company practices buffer stock for two days in advance. This study was carried out by performing detailed process flow and time studies along the line. To set up a model of the line by simulation, real data was taken from a factory floor and tested for distribution fit. The data gathered was then transformed into a simulation model. After verification of the model by comparing it with the actual system, it was found that the current line efficiency is not at its optimum condition due to blockage and idle time. Various what-if analysis were applied to eliminate the cause. Proposed layout shows that the line is balanced by adding buffer to avoid the blockage. Whereas, manpower is added the stations to reduce process time therefore reducing idling time. The simulation study was carried out using ProModel software.

Design and manufacture of high performance hollow engine valves by Additive Layer Manufacturing

International Nuclear Information System (INIS)

Cooper, D.; Thornby, J.; Blundell, N.; Henrys, R.; Williams, M.A.; Gibbons, G.

2015-01-01

Highlights: • High performance engine valve has been redesigned and optimised for and using ALM. • FEA was utilised to optimise and select a design for manufacture and testing. • Micro computed tomography was used in design and validation as an NDT technique. • Real world test of components was conducted to evaluate their performance. • Has demonstrated the potential for ALM in a high performance engineering context. - Abstract: Additive Layer Manufacture (ALM) of metallic components provides significant opportunities for the reduction of component weight, in order to realise improvements in vehicle fuel efficiency or performance. This paper examines the potential benefits of ALM with regard to reducing the weight of Internal Combustion Engine inlet or exhaust valves. A case study component is presented, for which an improved ALM design has been created, manufactured and evaluated. Micro-Computed Tomography (μ-CT) scanning was utilised to reverse engineer an original component, and to assess the ALM component’s internal geometry and material integrity. The case study valve was re-designed using Finite Element Analysis (FEA) to select a light weighted design which provides a conservative 9.4 g, (20%) weight saving on the Original Equipment Manufacturer (OEM) component. An engine test of over 175,000 cycles at between 2000 and 9500 rpm was conducted, after which μ-CT scanning confirmed no evidence of internal cracking, failure or significant deformation

Production Equipment and Processes for Bulk Formed Micro Components

DEFF Research Database (Denmark)

Paldan, Nikolas Aulin; Arentoft, Mogens; Eriksen, Rasmus Solmer

2007-01-01

Manufacturing techniques for production of small precise metallic parts has gained interest during recent years, an interest led by an industrial demand for components for integrated products like mobile phones, personal digital assistants (PDAs), mp3-players and in the future for spare parts...... has been developed and used to form a number of industrial micro parts in aluminium and silver, with ongoing work on forming of titanium. Manufacture of billets by cropping has been examined using a simple test rig and an automatic cropping device has been designed, manufactured and tested....... for the human body. Micro components have also found several applications within the medical, audiological and dental industry, applications that impose increased demands for biocompatible and corrosion-resistant materials and cleanness. So far these micro components have mainly been manufactured by traditional...

Nuclear fuel manufacture at PJSC NCCP. Technology development and quality assurance

International Nuclear Information System (INIS)

Goncharov, Yu.; Enin, A.; Kustov, L.; Mokshin, I.; Pluzhnikov, D.

2015-01-01

This report presents the PJSC NCCP fuel performance results and measures for improvement of FA and component manufacturing technique. Also it is demonstrated the process capacities, starting from UF6 procurement, its processing, and actual production of finished fuel assemblies as well as FA mounting and modifications of TVSA design

Development of manufacturing process for production of 500 MWe calandria sheets

International Nuclear Information System (INIS)

Hariharan, R.; Ramesh, P.; Lakshminarayana, B.; Bhaskara Rao, C.V.; Pande, P.; Agarwala, G.C.

1992-01-01

Calandria tubes made of zircaloy-2 are being used as structural components in pressurised heavy water power reactors. The sheets required for producing calandria tube for 235 MWe reactors are being manufactured at Zircaloy Fabrication Plant (ZFP), NFC utilizing a 2 Hi/4 Hi rolling mill procured for the purpose, by carrying out cold rolling process to achieve the required size after hot rolling suitable extruded slabs. Due to limitation of width of the sheet that can be rolled with the mill as well as the size of the slab that can be extruded with the existing press, difficulties arose in producing acceptable full length sheets of size 6600 mm long x 435 mm wide x 1.6 mm thick for manufacturing 500 MWe calandria tube. This paper deals with the details of the process problem resolved. They are: (a)designing of suitable hot and cold rolling pass schedules, (b)selection and standardization of process parameters such as beta quenching, hot rolling and cold rolling, and (c)details of the overall manufacturing process. Due to implementation of above, sheets required for manufacturing 500 MWe calandria tube sheets were successfully rolled. About 40 nos. of acceptable full length sheets have already been manufactured. (author). 1 fig., 3 tabs

Manufacturing of cells and stacks for SOFC development, test and demonstration projects and SOFC hotbox design development

Energy Technology Data Exchange (ETDEWEB)

2008-09-15

The purpose of this project is to support the continued SOFC development through manufacturing process optimization and manufacturing of SOFC cells and stacks. These cells and stacks will serve as a necessary base for the development activities and for the establishment of a number of test and demonstration activities. The manufacture will also help provide operating experience and reduce manufacturing cost. Another main focus of the manufacturing is to assure technical improvements and reliability. It is imperative to the eventual success of the technology that test and demonstration is carried out in the pre-market conditions that will exist for the next years in the three market segments targeted by TOFC (Distributed generation, micro CHP and APU incl. marine APU). Finally, the project also includes development activities focusing on the stack-system interface (hotbox design development) and on dealing with transients and start up and shut down times, which is of particular importance for APU and micro CHP applications. Three topics are addressed:1) Cell manufacture, including production development, capacity lift and manuf. of cells for test and demonstration; 2) Stack manufacture and test, including a test facility, stack manuf. and test of stacks in a system at HCV; 3) Hotbox design development, including design, prototype construction and testing. The progress of this project is documented. Major achievements are successful manufacture of adequate amounts of cells and stacks according to the application. Furthermore significant over-performance in design, construction and test of a methanol based hotbox prototype as well as publication of this. (au)

Development of Prototype HTS Components for Magnetic Suspension Applications

Science.gov (United States)

Haldar, P.; Hoehn, J., Jr.; Selvamanickam, V.; Farrell, R. A.; Balachandran, U.; Iyer, A. N.; Peterson, E.; Salazar, K.

1996-01-01

We have concentrated on developing prototype lengths of bismuth and thallium based silver sheathed superconductors by the powder-in-tube approach to fabricate high temperature superconducting (HTS) components for magnetic suspension applications. Long lengths of mono and multi filament tapes are presently being fabricated with critical current densities useful for maglev and many other applications. We have recently demonstrated the prototype manufacture of lengths exceeding 1 km of Bi-2223 multi filament conductor. Long lengths of thallium based multi-filament conductor have also been fabricated with practical levels of critical current density and improved field dependence behavior. Test coils and magnets have been built from these lengths and characterized over a range of temperatures and background fields to determine their performance. Work is in progress to develop, fabricate and test HTS windings that will be suitable for magnetic suspension, levitation and other electric power related applications.

An Indexing Scheme for Case-Based Manufacturing Vision Development

DEFF Research Database (Denmark)

Wang, Chengbo; Johansen, John; Luxhøj, James T.

2004-01-01

with the competence improvement of an enterprises manufacturing system. There are two types of cases within the CBRM – an event case (EC) and a general supportive case (GSC). We designed one set of indexing vocabulary for the two types of cases, but a different indexing representation structure for each of them......This paper focuses on one critical element, indexing – retaining and representing knowledge in an applied case-based reasoning (CBR) model for supporting strategic manufacturing vision development (CBRM). Manufacturing vision (MV) is a kind of knowledge management concept and process concerned...

The development of clean-burning, noncatalytic manufactured fireplaces

International Nuclear Information System (INIS)

Broome, F.H.

1992-01-01

Concern for the air quality of this country in general and the Western states in particular has brought sharp focus from regulators on the emissions of Particulate Matter (PM) from all wood-burning appliances. This concern was a driving force which led to the development of a clean-burning fireplace. Many Western areas have begun to limit installation of wood-burning appliances in new construction. Some jurisdictions allow only Environmental Protection Agency (EPA) certified appliances. Currently no federal test methods or standards exist for fireplaces so the Manufactured Fireplace Industry, through the Hearth Products Association (HPA), set about to develop suitable test methods and standards for manufactured fireplaces

Development of STEP-NC Adaptor for Advanced Web Manufacturing System

Science.gov (United States)

Ajay Konapala, Mr.; Koona, Ramji, Dr.

2017-08-01

Information systems play a key role in the modern era of Information Technology. Rapid developments in IT & global competition calls for many changes in basic CAD/CAM/CAPP/CNC manufacturing chain of operations. ‘STEP-NC’ an enhancement to STEP for operating CNC machines, creating new opportunities for collaborative, concurrent, adaptive works across the manufacturing chain of operations. Schemas and data models defined by ISO14649 in liaison with ISO10303 standards made STEP-NC file rich with feature based, rather than mere point to point information of G/M Code format. But one needs to have a suitable information system to understand and modify these files. Various STEP-NC information systems are reviewed to understand the suitability of STEP-NC for web manufacturing. Present work also deals with the development of an adaptor which imports STEP-NC file, organizes its information, allowing modifications to entity values and finally generates a new STEP-NC file to export. The system is designed and developed to work on web to avail additional benefits through the web and also to be part of a proposed ‘Web based STEP-NC manufacturing platform’ which is under development and explained as future scope.

Applying a manufacturing vision development prototype in practice

DEFF Research Database (Denmark)

Wang, Chengbo; Luxhøj, James T.; Johansen, John

2005-01-01

The primary objective of this paper is to summarise the empirical application of a designed case-based manufacturing vision (MV) development prototype (CBRM). This empirical application is undertaken using case study strategy, due to its ability to answer the research questions regarding...... enterprise. The three real world cases (companies) were selected in the USA within different industrial segments. The application results suggest that the CBRM is supportive of the decision-making process for tackling strategic manufacturing issues....

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

Science.gov (United States)

Sirirojvisuth, Apinut

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

Ultrasonic NDE Simulation for Composite Manufacturing Defects

Science.gov (United States)

Leckey, Cara A. C.; Juarez, Peter D.

2016-01-01

The increased use of composites in aerospace components is expected to continue into the future. The large scale use of composites in aerospace necessitates the development of composite-appropriate nondestructive evaluation (NDE) methods to quantitatively characterize defects in as-manufactured parts and damage incurred during or post manufacturing. Ultrasonic techniques are one of the most common approaches for defect/damage detection in composite materials. One key technical challenge area included in NASA's Advanced Composite's Project is to develop optimized rapid inspection methods for composite materials. Common manufacturing defects in carbon fiber reinforced polymer (CFRP) composites include fiber waviness (in-plane and out-of-plane), porosity, and disbonds; among others. This paper is an overview of ongoing work to develop ultrasonic wavefield based methods for characterizing manufacturing waviness defects. The paper describes the development and implementation of a custom ultrasound simulation tool that is used to model ultrasonic wave interaction with in-plane fiber waviness (also known as marcelling). Wavefield data processing methods are applied to the simulation data to explore possible routes for quantitative defect characterization.

The artifacts of component-based development

International Nuclear Information System (INIS)

Rizwan, M.; Qureshi, J.; Hayat, S.A.

2007-01-01

Component based development idea was floated in a conference name Mass Produced Software Components in 1968 (1). Since then engineering and scientific libraries are developed to reuse the previously developed functions. This concept is now widely used in SW development as component based development (CBD). Component-based software engineering (CBSE) is used to develop/ assemble software from existing components (2). Software developed using components is called component where (3). This paper presents different architectures of CBD such as Active X, common object request broker architecture (CORBA), remote method invocation (RMI) and simple object access protocol (SOAP). The overall objective of this paper is to support the practice of CBD by comparing its advantages and disadvantages. This paper also evaluates object oriented process model to adapt it for CBD. (author)

Additive manufacturing of ceramics: Stereolithography versus binder jetting

OpenAIRE

Nachum, Sarig; Vogt, Joachim; Raether, Friedrich

2016-01-01

Stereolithography and Binder Jetting are two promising Additive Manufacturing techniques for the fabrication of complex ceramics components. The Fraunhofer Center for High Temperature Material and Design HTL/DE has experience in the fabrication and development of ceramic and metallic components with both technologies. This paper describes and compares the respective process setups as well as the advantages and disadvantages of both techniques, and discusses future challenges and developments ...

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

International Nuclear Information System (INIS)

Ilyas, Ismet P

2013-01-01

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

Development and Hot-fire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

Science.gov (United States)

Gradl, Paul R.; Greene, Sandy Elam; Protz, Christopher S.; Ellis, David L.; Lerch, Bradley A.; Locci, Ivan E.

2017-01-01

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder-bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. NASA's efforts include a 4K lbf thrust liquid oxygen/methane (LOX/CH4) combustion chamber and subscale thrust chambers for 1.2K lbf LOX/hydrogen (H2) applications that have been designed and fabricated with SLM GRCop-84. The same technologies for these lower thrust applications are being applied to 25-35K lbf main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Improved Methods for Production Manufacturing Processes in Environmentally Benign Manufacturing

Directory of Open Access Journals (Sweden)

Yan-Yan Wang

2011-09-01

Full Text Available How to design a production process with low carbon emissions and low environmental impact as well as high manufacturing performance is a key factor in the success of low-carbon production. It is important to address concerns about climate change for the large carbon emission source manufacturing industries because of their high energy consumption and environmental impact during the manufacturing stage of the production life cycle. In this paper, methodology for determining a production process is developed. This methodology integrates process determination from three different levels: new production processing, selected production processing and batch production processing. This approach is taken within a manufacturing enterprise based on prior research. The methodology is aimed at providing decision support for implementing Environmentally Benign Manufacturing (EBM and low-carbon production to improve the environmental performance of the manufacturing industry. At the first level, a decision-making model for new production processes based on the Genetic Simulated Annealing Algorithm (GSAA is presented. The decision-making model considers not only the traditional factors, such as time, quality and cost, but also energy and resource consumption and environmental impact, which are different from the traditional methods. At the second level, a methodology is developed based on an IPO (Input-Process-Output model that integrates assessments of resource consumption and environmental impact in terms of a materials balance principle for batch production processes. At the third level, based on the above two levels, a method for determining production processes that focus on low-carbon production is developed based on case-based reasoning, expert systems and feature technology for designing the process flow of a new component. Through the above three levels, a method for determining the production process to identify, quantify, assess, and optimize the

Surrogate Final Technical Report for "Solar: A Photovoltaic Manufacturing Development Facility"

Energy Technology Data Exchange (ETDEWEB)

Farrar, Paul [State University of New York Research Foundation, Albany, NY (United States)

2014-06-27

The project goal to create a first-of-a-kind crystalline Silicon (c-Si) photovoltaic (PV) Manufacturing & Technology Development Facility (MDF) that will support the growth and maturation of a strong domestic PV manufacturing industry, based on innovative and differentiated technology, by ensuring industry participants can, in a timely and cost-effective manner, access cutting-edge manufacturing equipment and production expertise needed to accelerate the transition of innovative technologies from R&D into manufacturing.

Empirical component model to predict the overall performance of heating coils: Calibrations and tests based on manufacturer catalogue data

International Nuclear Information System (INIS)

Ruivo, Celestino R.; Angrisani, Giovanni

2015-01-01

Highlights: • An empirical model for predicting the performance of heating coils is presented. • Low and high heating capacity cases are used for calibration. • Versions based on several effectiveness correlations are tested. • Catalogue data are considered in approach testing. • The approach is a suitable component model to be used in dynamic simulation tools. - Abstract: A simplified methodology for predicting the overall behaviour of heating coils is presented in this paper. The coil performance is predicted by the ε-NTU method. Usually manufacturers do not provide information about the overall thermal resistance or the geometric details that are required either for the device selection or to apply known empirical correlations for the estimation of the involved thermal resistances. In the present work, heating capacity tables from the manufacturer catalogue are used to calibrate simplified approaches based on the classical theory of heat exchangers, namely the effectiveness method. Only two reference operating cases are required to calibrate each approach. The validity of the simplified approaches is investigated for a relatively high number of operating cases, listed in the technical catalogue of a manufacturer. Four types of coils of three sizes of air handling units are considered. A comparison is conducted between the heating coil capacities provided by the methodology and the values given by the manufacturer catalogue. The results show that several of the proposed approaches are suitable component models to be integrated in dynamic simulation tools of air conditioning systems such as TRNSYS or EnergyPlus

A new vision of plasma facing components

Energy Technology Data Exchange (ETDEWEB)

Nygren, Richard E., E-mail: renygre@sandia.gov [Sandia National Laboratories, Albuquerque, NM (United States); Youchison, Dennis L. [Oak Ridge National Laboratory, Oak Ridge, TN (United States); Wirth, Brian D. [University of Tennessee, Knoxville, TN (United States); Snead, Lance L.

2016-11-01

Highlights: • New approach recommended to develop refractory fusion plasma facing components. • Need to develop engineered materials architecture with nano-features. • Need to develop PFCs with gas jet cooling with very fine scale for jet arrays. • Emphasis on role of additive manufacturing as needed method for fabrication. - Abstract: This paper advances a vision for plasma facing components (PFCs) that includes the following points. The solution for plasma facing materials likely consists of engineered structures in which the layer of plasma facing material (PFM) is integrated with an engineered structure that cools the PFM and may also transition with graded composition. The key to achieving this PFC architecture will likely lie in advanced manufacturing methods, e.g., additive manufacturing, that can produce layers with controlled porosity and features such as micro-fibers and/or nano-particles that can collect He and transmutation products, limit tritium retention, and do all this in a way that maintains adequate robustness for a satisfactory lifetime. This vision has significant implications for how we structure a development program.

Development and Hotfire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

Science.gov (United States)

Gradl, Paul R.; Greene, Sandy; Protz, Chris

2017-01-01

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA’s Marshall Space Flight Center (MSFC) has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. MSFC’s efforts include a 4,000 pounds-force thrust liquid oxygen/methane (LOX/CH4) combustion chamber. Small thrust chambers for 1,200 pounds-force LOX/hydrogen (H2) applications have also been designed and fabricated with SLM GRCop-84. Similar chambers have also completed development with an Inconel 625 jacket bonded to the GRCop-84 material, evaluating direct metal deposition (DMD) laser- and arc-based techniques. The same technologies for these lower thrust applications are being applied to 25,000-35,000 pounds-force main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Additive Manufacturing for Affordable Rocket Engines

Science.gov (United States)

West, Brian; Robertson, Elizabeth; Osborne, Robin; Calvert, Marty

2016-01-01

Additive manufacturing (also known as 3D printing) technology has the potential to drastically reduce costs and lead times associated with the development of complex liquid rocket engine systems. NASA is using 3D printing to manufacture rocket engine components including augmented spark igniters, injectors, turbopumps, and valves. NASA is advancing the process to certify these components for flight. Success Story: MSFC has been developing rocket 3D-printing technology using the Selective Laser Melting (SLM) process. Over the last several years, NASA has built and tested several injectors and combustion chambers. Recently, MSFC has 3D printed an augmented spark igniter for potential use the RS-25 engines that will be used on the Space Launch System. The new design is expected to reduce the cost of the igniter by a factor of four. MSFC has also 3D printed and tested a liquid hydrogen turbopump for potential use on an Upper Stage Engine. Additive manufacturing of the turbopump resulted in a 45% part count reduction. To understanding how the 3D printed parts perform and to certify them for flight, MSFC built a breadboard liquid rocket engine using additive manufactured components including injectors, turbomachinery, and valves. The liquid rocket engine was tested seven times in 2016 using liquid oxygen and liquid hydrogen. In addition to exposing the hardware to harsh environments, engineers learned to design for the new manufacturing technique, taking advantage of its capabilities and gaining awareness of its limitations. Benefit: The 3D-printing technology promises reduced cost and schedule for rocket engines. Cost is a function of complexity, and the most complicated features provide the largest opportunities for cost reductions. This is especially true where brazes or welds can be eliminated. The drastic reduction in part count achievable with 3D printing creates a waterfall effect that reduces the number of processes and drawings, decreases the amount of touch

Optical components for the Nova laser

International Nuclear Information System (INIS)

Wallerstein, E.P.; Baker, P.C.; Brown, N.J.

1982-01-01

In addition to its other characteristics, the Nova Laser Fusion facility may well be the largest precision optical project ever undertaken. Moreover, during the course of construction, concurrent research and development has been successfully conducted, and has resulted in significant advances in various technical areas, including manufacturing efficiency. Although assembly of the first two beams of Nova is just commencing, the optical production, including construction of the special facilities required for many of the components, has been underway for over three years, and many phases of the optical manufacturing program for the first 10 beams will be completed within the next two years. On the other hand, new requirements for second and third harmonic generation have created the need to initiate new research and development. This work has been accomplished through the enormous cooperation DOE/LLNL has received from commercial industry on this project. In many cases, industry, where much of the optical component research and development and virtually all of the manufacturing is being done, has made substantial investment of its own funds in facilities, equipment, and research and development, in addition to those supplied by DOE/LLNL

Experience with quality assurance in fuel design and manufacturing

International Nuclear Information System (INIS)

Holzer, R.; Nilson, F.

1984-01-01

The Quality Assurance/Quality Control activities for nuclear fuel design and manufacturing described here are coordinated under a common ''Quality Assurance System For Fuel Assemblies and Associated Core Components'' which regulates the QA-functions of the development, design and manufacturing of fuel assemblies independent of the organizational assignment of the contributing technical groups. Some essential characteristics of the system are shown, using examples from design control, procurement, manufacturing and qualification of special processes. The experience is very good, it allowed a flexible and well controlled implementation of design and manufacturing innovations and contributed to the overall good fuel behavior. (orig.)

Development of an Automated LIBS Analytical Test System Integrated with Component Control and Spectrum Analysis Capabilities

International Nuclear Information System (INIS)

Ding Yu; Tian Di; Chen Feipeng; Chen Pengfei; Qiao Shujun; Yang Guang; Li Chunsheng

2015-01-01

The present paper proposes an automated Laser-Induced Breakdown Spectroscopy (LIBS) analytical test system, which consists of a LIBS measurement and control platform based on a modular design concept, and a LIBS qualitative spectrum analysis software and is developed in C#. The platform provides flexible interfacing and automated control; it is compatible with different manufacturer component models and is constructed in modularized form for easy expandability. During peak identification, a more robust peak identification method with improved stability in peak identification has been achieved by applying additional smoothing on the slope obtained by calculation before peak identification. For the purpose of element identification, an improved main lines analysis method, which detects all elements on the spectral peak to avoid omission of certain elements without strong spectral lines, is applied to element identification in the tested LIBS samples. This method also increases the identification speed. In this paper, actual applications have been carried out. According to tests, the analytical test system is compatible with components of various models made by different manufacturers. It can automatically control components to get experimental data and conduct filtering, peak identification and qualitative analysis, etc. on spectral data. (paper)

Using Additive Manufacturing to Mitigate the Risks of Limited Key Ship Components of the Zumwalt-Class Destroyer

Science.gov (United States)

2016-12-01

and services are high tech and defense-specific in nature; therefore, there is often only one qualified provider/supplier available. Moreover...support for low-volume and obsolete parts. From commercial aviation and luxury car manufacturers to major defense contractors and the DOD, financial...components that are currently obsolete or approaching obsolescence through 2019 (Southard, 2016). The iPDA is critical to support the distributed

Application of a B ampersand W developed computer aided pictorial process planning system to CQMS for manufacturing process control

International Nuclear Information System (INIS)

Johanson, D.C.; VandeBogart, J.E.

1992-01-01

Babcock ampersand Wilcox (B ampersand W) will utilize its internally developed Computer Aided Pictorial Process Planning or CAPPP (pronounced open-quotes cap cubedclose quotes) system to create a paperless manufacturing environment for the Collider Quadruple Magnets (CQM). The CAPPP system consists of networked personal computer hardware and software used to: (1) generate and maintain the documents necessary for product fabrication, (2) communicate the information contained in these documents to the production floor, and (3) obtain quality assurance and manufacturing feedback information from the production floor. The purpose of this paper is to describe the various components of the CAPPP system and explain their applicability to product fabrication, specifically quality assurance functions

A Study On The Practical Application Of Repair Development Methods For Aerospace Components

Science.gov (United States)

Moedano, Jesus A.

In the industry of manufacturing, each gas turbine engine component begins in a raw state such as bar stock and is routed through manufacturing processes to define its final form before being installed on the engine. What is the follow-up to this part? What happens when over time and usage it wears? Several factors have created a section of the manufacturing industry known as aftermarket to support the customer in their need for restoration and repair of their original product. Once a product has reached a wear factor or cycle limit that cannot be ignored, one of the options is to have it repaired to maintain use of the core. This research investigated the study into the creation and application of repair development methodology that can be utilized by current and new manufacturing engineers of the world. Those who have been in this field for some time will find the process thought provoking while the engineering students can develop a foundation of thinking to prepare for the common engineering problems they will be tasked to resolve. The examples, figures and tables are true issues of the industry though the data will have been changed due to proprietary factors. The results of the study reveals, under most scenarios, a solid process can be followed to proceed with the best options for repair based on the initial discrepancy. However, this methodology will not be a "catch-all" process but a guidance that will develop the proper thinking in evaluation of the repair options and the possible failure modes of each choice. As with any continuous improvement tool, further research is needed to test the applicability of this process in other fields.

Manufacturing technologies for direct methanol fuel cells (DMFCs)

Energy Technology Data Exchange (ETDEWEB)

Gluesen, Andreas; Mueller, Martin; Kimiaie, Nicola; Konradi, Irene; Mergel, Juergen; Stolten, Detlef [Forschungszentrum Juelich (Germany). Inst. of Energy Research - IEF-3: Fuel Cells

2010-07-01

Fuel cell research is focussing on increasing power density and lifetime and reducing costs of the whole fuel cell system. In order to reach these aims, it is necessary to develop appropriately designed components outgoing from high quality materials, a suitable manufacturing process and a well balanced system. To make use of the advantages that can be obtained by developing production technology, we are mainly improving the coating and assembling techniques for polymer electrolyte fuel cells, especially Direct Methanol Fuel Cells (DMFCs). Coating is used for making fuel cell electrodes as well as highly conductive contacts. Assembling is used to join larger components like membrane electrode assemblies (MEAs) and bipolar units consisting of flow fields and the separator plate, as well as entire stacks. On the one hand a reproducible manufacturing process is required to study fine differences in fuel cell performance affected by new materials or new designs. On the other hand a change in each parameter of the manufacturing process itself can change product properties and therefore affect fuel cell performance. As a result, gas diffusion electrodes (GDEs) are now produced automatically in square-meter batches, the hot-pressing of MEAs is a fully automated process and by pre-assembling the number of parts that have to be assembled in a stack was reduced by a factor of 10. These achievements make DMFC manufacturing more reproducible and less error-prone. All these and further developments of manufacturing technology are necessary to make DMFCs ready for the market. (orig.)

Precision reconstruction of manufactured free-form components

Science.gov (United States)

Ristic, Mihailo; Brujic, Djordje; Ainsworth, Iain

2000-03-01

Manufacturing needs in many industries, especially the aerospace and the automotive, involve CAD remodeling of manufactured free-form parts using NURBS. This is typically performed as part of 'first article inspection' or 'closing the design loop.' The reconstructed model must satisfy requirements such as accuracy, compatibility with the original CAD model and adherence to various constraints. The paper outlines a methodology for realizing this task. Efficiency and quality of the results are achieved by utilizing the nominal CAD model. It is argued that measurement and remodeling steps are equally important. We explain how the measurement was optimized in terms of accuracy, point distribution and measuring speed using a CMM. Remodeling steps include registration, data segmentation, parameterization and surface fitting. Enforcement of constraints such as continuity was performed as part of the surface fitting process. It was found necessary that the relevant algorithms are able to perform in the presence of measurement noise, while making no special assumptions about regularity of data distribution. In order to deal with real life situations, a number of supporting functions for geometric modeling were required and these are described. The presented methodology was applied using real aeroengine parts and the experimental results are presented.

Applying a Knowledge Management Modeling Tool for Manufacturing Vision (MV) Development

DEFF Research Database (Denmark)

Wang, Chengbo; Luxhøj, James T.; Johansen, John

2004-01-01

This paper introduces an empirical application of an experimental model for knowledge management within an organization, namely a case-based reasoning model for manufacturing vision development (CBRM). The model integrates the development process of manufacturing vision with the methodology of case......-based reasoning. This paper briefly describes the model's theoretical fundamentals and its conceptual structure; conducts a detailed introduction of the critical elements within the model; exhibits a real world application of the model; and summarizes the review of the model through academia and practice. Finds...... that the CBRM is supportive to the decision-making process of applying and augmenting organizational knowledge. It provides a new angle to tackle strategic management issues within the manufacturing system of a business operation. Explores a new proposition within strategic manufacturing management by enriching...

Integration of Manufacturing and Development in Emerging Markets

DEFF Research Database (Denmark)

Søberg, Peder Veng; Wæhrens, Brian Vejrum

2014-01-01

The chapter investigates the problems related to the functional integration between manufacturing activities and research and development (R&D) activities in emerging markets within multinational companies. A framework to this end is developed and illustrated through four case studies from...... as an integral part of corporate relocation decisions....

Unit operation in food manufacturing and processing. Shokuhin seizo/kako ni okeru tan'i sosa

Energy Technology Data Exchange (ETDEWEB)

Matsuno, R. (Kyoto Univ., Kyoto (Japan). Faculty of Aguriculture)

1993-09-05

Processed foods must be produced in mass, cheap and safe and should be suitable for the delicate taste of human being. Food tastes are effected by an outlook on human attitude, and the surrounding environment. And these factors are reflected to unit operation in food manufacturing and processing and it is clarified that there are many technical difficulties. The characteristics of unit operation for food manufacturing and processing are that the food materials are a multicomponent system, moreover, a very small amount of aroma components, taste components, vitamin, physiologically activation materials and so on are more important than the main components, and also inapplicable of the model centering to the most quantitative component. The purpose of unit operation in food manufacturing and processing is to produce the properties of matter matching to human sense, and therefore there are many problems left unsolved. The development of analytical technology also has an influence on manufacturing and processing technology. Consequently, food manufacturing and processing technology must be based on general science. It is necessary to develop unit operation with an understanding of mutual effect between food and human body.

Benefits of Hot Isostatic Pressure/Powdered Metal (HIP/PM) and Additive Manufacturing (AM) To Fabricate Advanced Energy System Components

Energy Technology Data Exchange (ETDEWEB)

Horton, Nancy [Energy Industries of Ohio, Cleveland, OH (United States); Sheppard, Roy [Energy Industries of Ohio, Cleveland, OH (United States)

2016-12-31

Advanced Energy systems require large, complex components produced from materials capable of withstanding severe operating environments (high temperature, pressure, corrosivity). Such parts can be difficult to source, as conventional material processing technologies must be tailored to ensure a safe and cost effective approach to large-scale manufacture of quality structural advanced alloy components that meet the performance specifications of AE systems. (HIP/PM) has shown advantages over other manufacturing methods when working with these materials. For example, using HIP’ing in lieu of casting means significant savings in raw material costs, which for expensive, high-nickel alloys can be considerable for large-scale production. Use of HIP/PM also eliminates the difficulties resulting from reactivity of these materials in the molten state and facilitates manufacture of the large size requirements of the AE industry, producing a part that is defect and porosity free, thus further reducing or eliminating time and expense of post processing machining and weld repair. New advances in Additive Manufacturing (AM) techniques make it possible to further expand the benefits of HIP/PM in producing AE system components to create an even more robust manufacturing approach. Traditional techniques of welding and forming sheet metal to produce the HIP canisters can be time consuming and costly, with limitations on the complexity of part which can be achieved. A key benefit of AM is the freedom of design that it offers, so use of AM could overcome such challenges, ultimately enabling redesign of complete energy systems. A critical step toward this goal is material characterization of the required advanced alloys, for use in AM. Using Haynes 282, a high nickel alloy of interest to the Fossil Energy community, particularly for Advanced-UltraSuperCritical (AUSC) operating environments, as well as the crosscutting interests of the aerospace, defense and medical markets, this

Potential of direct metal deposition technology for manufacturing thick functionally graded coatings and parts for reactors components

International Nuclear Information System (INIS)

Thivillon, L.; Bertrand, Ph.; Laget, B.; Smurov, I.

2009-01-01

Direct metal deposition (DMD) is an automated 3D deposition process arising from laser cladding technology with co-axial powder injection to refine or refurbish parts. Recently DMD has been extended to manufacture large-size near-net-shape components. When applied for manufacturing new parts (or their refinement), DMD can provide tailored thermal properties, high corrosion resistance, tailored tribology, multifunctional performance and cost savings due to smart material combinations. In repair (refurbishment) operations, DMD can be applied for parts with a wide variety of geometries and sizes. In contrast to the current tool repair techniques such as tungsten inert gas (TIG), metal inert gas (MIG) and plasma welding, laser cladding technology by DMD offers a well-controlled heat-treated zone due to the high energy density of the laser beam. In addition, this technology may be used for preventative maintenance and design changes/up-grading. One of the advantages of DMD is the possibility to build functionally graded coatings (from 1 mm thickness and higher) and 3D multi-material objects (for example, 100 mm-sized monolithic rectangular) in a single-step manufacturing cycle by using up to 4-channel powder feeder. Approved materials are: Fe (including stainless steel), Ni and Co alloys, (Cu,Ni 10%), WC compounds, TiC compounds. The developed coatings/parts are characterized by low porosity (<1%), fine microstructure, and their microhardness is close to the benchmark value of wrought alloys after thermal treatment (Co-based alloy Stellite, Inox 316L, stainless steel 17-4PH). The intended applications concern cooling elements with complex geometry, friction joints under high temperature and load, light-weight mechanical support structures, hermetic joints, tubes with complex geometry, and tailored inside and outside surface properties, etc

Potential of direct metal deposition technology for manufacturing thick functionally graded coatings and parts for reactors components

Science.gov (United States)

Thivillon, L.; Bertrand, Ph.; Laget, B.; Smurov, I.

2009-03-01

Direct metal deposition (DMD) is an automated 3D deposition process arising from laser cladding technology with co-axial powder injection to refine or refurbish parts. Recently DMD has been extended to manufacture large-size near-net-shape components. When applied for manufacturing new parts (or their refinement), DMD can provide tailored thermal properties, high corrosion resistance, tailored tribology, multifunctional performance and cost savings due to smart material combinations. In repair (refurbishment) operations, DMD can be applied for parts with a wide variety of geometries and sizes. In contrast to the current tool repair techniques such as tungsten inert gas (TIG), metal inert gas (MIG) and plasma welding, laser cladding technology by DMD offers a well-controlled heat-treated zone due to the high energy density of the laser beam. In addition, this technology may be used for preventative maintenance and design changes/up-grading. One of the advantages of DMD is the possibility to build functionally graded coatings (from 1 mm thickness and higher) and 3D multi-material objects (for example, 100 mm-sized monolithic rectangular) in a single-step manufacturing cycle by using up to 4-channel powder feeder. Approved materials are: Fe (including stainless steel), Ni and Co alloys, (Cu,Ni 10%), WC compounds, TiC compounds. The developed coatings/parts are characterized by low porosity (<1%), fine microstructure, and their microhardness is close to the benchmark value of wrought alloys after thermal treatment (Co-based alloy Stellite, Inox 316L, stainless steel 17-4PH). The intended applications concern cooling elements with complex geometry, friction joints under high temperature and load, light-weight mechanical support structures, hermetic joints, tubes with complex geometry, and tailored inside and outside surface properties, etc.

Potential of direct metal deposition technology for manufacturing thick functionally graded coatings and parts for reactors components

Energy Technology Data Exchange (ETDEWEB)

Thivillon, L.; Bertrand, Ph.; Laget, B. [Ecole Nationale d' Ingenieurs de Saint-Etienne (ENISE), DIPI Laboratory, 58 rue Jean Parot, 42023 Saint-Etienne cedex 2 (France); Smurov, I. [Ecole Nationale d' Ingenieurs de Saint-Etienne (ENISE), DIPI Laboratory, 58 rue Jean Parot, 42023 Saint-Etienne cedex 2 (France)], E-mail: smurov@enise.fr

2009-03-31

Direct metal deposition (DMD) is an automated 3D deposition process arising from laser cladding technology with co-axial powder injection to refine or refurbish parts. Recently DMD has been extended to manufacture large-size near-net-shape components. When applied for manufacturing new parts (or their refinement), DMD can provide tailored thermal properties, high corrosion resistance, tailored tribology, multifunctional performance and cost savings due to smart material combinations. In repair (refurbishment) operations, DMD can be applied for parts with a wide variety of geometries and sizes. In contrast to the current tool repair techniques such as tungsten inert gas (TIG), metal inert gas (MIG) and plasma welding, laser cladding technology by DMD offers a well-controlled heat-treated zone due to the high energy density of the laser beam. In addition, this technology may be used for preventative maintenance and design changes/up-grading. One of the advantages of DMD is the possibility to build functionally graded coatings (from 1 mm thickness and higher) and 3D multi-material objects (for example, 100 mm-sized monolithic rectangular) in a single-step manufacturing cycle by using up to 4-channel powder feeder. Approved materials are: Fe (including stainless steel), Ni and Co alloys, (Cu,Ni 10%), WC compounds, TiC compounds. The developed coatings/parts are characterized by low porosity (<1%), fine microstructure, and their microhardness is close to the benchmark value of wrought alloys after thermal treatment (Co-based alloy Stellite, Inox 316L, stainless steel 17-4PH). The intended applications concern cooling elements with complex geometry, friction joints under high temperature and load, light-weight mechanical support structures, hermetic joints, tubes with complex geometry, and tailored inside and outside surface properties, etc.

The Development of a Practical Framework for the Implementation of JIT Manufacturing

OpenAIRE

Hallihan, A.

1996-01-01

This research develops a framework to guide practitioners through the process of implementing Just In Time manufacturing in the commercial aircraft manufacturing industry. The scope of Just In Time manufacturing is determined through an analysis of its evolution and current use. Current approaches to its implementation are reviewed and shortcomings are identified. A requirement to allow practitioners to tailor the approach to the implementation of Just In Time manufacturing, ...

Development of High Temperature Capacitor Technology and Manufacturing Capability

Energy Technology Data Exchange (ETDEWEB)

None, None

2011-05-15

The goal of the Development of High Temperature Capacitor Technology and Manufacturing Capability program was to mature a production-ready supply chain for reliable 250°C FPE (fluorinated polyester) film capacitors by 2011. These high-temperature film capacitors enable both the down hole drilling and aerospace industries by enabling a variety of benefits including: - Deeper oil exploration in higher temperature and pressure environments - Enabling power electronic and control equipment to operate in higher temperature environments - Enabling reduced cooling requirements of electronics - Increasing reliability and life of capacitors operating below rated temperature - Enabling capacitors to handle higher electrical losses without overheating. The key challenges to bringing the FPE film capacitors to market have been manufacturing challenges including: - FPE Film is difficult to handle and wind, resulting in poor yields - Voltage breakdown strength decreases when the film is wound into capacitors (~70% decrease) - Encapsulation technologies must be improved to enable higher perature operation - Manufacturing and test cycle time is very long As a direct result of this program most of the manufacturing challenges have been met. The FPE film production metalization and winding yield has increased to over 82% from 70%, and the voltage breakdown strength of the wound capacitors has increased 270% to 189 V/μm. The high temperature packaging concepts are showing significant progress including promising results for lead attachments and hermetic packages at 200°C and non-hermetic packages at 250°C. Manufacturing and test cycle time will decrease as the market for FPE capacitors develops.

Manufacturing of Zirconium products at Chepetsky Mechanical Plant, Stock Company. Prospects of development and products quality assurance

International Nuclear Information System (INIS)

Vergazov, K.; Shtuza, M.; Lozitsky, S.; Kutyavin, A.

2015-01-01

The report described all the steps required to fabricate zirconium components, starting from the procurement of feed material up to rolling of sheets, tubes, bars and manufacture of the applicable parts required to manufacture fuel assemblies. Automated state-of-the-art equipment used for advanced productivity, as well as various installations able to perform numerous inspection steps to assure quality of the manufactured products was showcased. The challenges to be addressed in the nearest future were also presented

Competitive Manufacturing: New Strategies for Regional Development.

Science.gov (United States)

Rosenfeld, Stuart A.

In the past, economic development in the rural United States, particularly in the rural South, relied principally on the attractiveness of a low-wage work force to mass-production manufacturing industries. Now however, the viability of the traditional mass-production economy's organizational structure and operating procedures has been eroded by…

PREFACE: Trends in Aerospace Manufacturing 2009 International Conference

Science.gov (United States)

Ridgway, Keith; Gault, Rosemary; Allen, Adrian

2011-12-01

The aerospace industry is rapidly changing. New aircraft structures are being developed and aero-engines are becoming lighter and more environmentally friendly. In both areas, innovative materials and manufacturing methods are used in an attempt to get maximum performance for minimum cost. At the same time, the structure of the industry has changed and there has been a move from large companies designing, manufacturing components and assembling aircraft to one of large global supply chains headed by large system integrators. All these changes have forced engineers and managers to bring in innovations in design, materials, manufacturing technologies and supply chain management. In September 2009, the Advanced Manufacturing Research Centre (AMRC) at the University of Sheffield held the inaugural Trends in Aerospace Manufacturing conference (TRAM09). This brought together 28 speakers over two days, who presented in sessions on advanced manufacturing trends for the aerospace sector. Areas covered included new materials, including composites, advanced machining, state of the art additive manufacturing techniques, assembly and supply chain issues.

EXTENDED WARRANTY STRATEGIES FOR ONLINE SHOPPING SUPPLY CHAIN WITH COMPETING SUPPLIERS CONSIDERING COMPONENT RELIABILITY

Institute of Scientific and Technical Information of China (English)

Xinghong Qin; Qiang Su; Samuel H.Huang

2017-01-01

This article presents the issue of extended warranty and management strategies in a three-echelon competing online shopping supply chain with price-and base warranty period-dependent demand.We employ game theory to develop decision models to explore the interactions between component suppliers and the manufacturer,as well as competition between two component suppliers.Products and extended warranty are sold by an online store,which is the leader in the Stackelberg game.Two scenarios are considered:either the manufacturer offers a prepaid extended warranty to customers or doses not.In each scenario,base warranties are assumed to be bundled with products.Our results show that when the manufacturer's repair costs change in a proper range,providing extended warranty can benefit both the manufacturer and the online store;otherwise,the manufacturer has no incentive to offer the extended warranty.Reducing repair costs,improving component reliability,or shortening the base warranty period allows the manufacturer to realize significantly better value of the extended warranty.High component reliability benefits both the manufacturer and the online store,with the manufacturer reaping more benefit.Extending the length of the base warranty adversely affects profit of the manufacturer and the value of the extended warranty.

Development of granular powder manufacturing technology by spray pyrolysis

International Nuclear Information System (INIS)

Katoh, Yoshiyuki; Kawase, Keiichi; Takahashi, Yoshiharu; Todokoro, Akio

1996-01-01

For shortening of mixed-oxide (MOX) fuel manufacturing process and improvement in treatment of MOX-powder, we have been developing the granular powder production technology. Since the granular powders have excellent fluidity owing to the spherical shape, there is the possibility of modifying scattering and adcering of the powder in the process equipment. In this paper, spray pyrolysis process in adopted as the process of manufacturing the granular powders and the basic feasibility study has been carried out. The experimental results show that the manufactured granular powders have excellent fluidity and the diameter of the powders is controllable. Furthermore, high density pellets are formed by sintering the powders. Thus, it is clarified that this process is promising for the actual MOX fuel fabrication. (author)

Design and Testing of a Hall Effect Thruster with Additively Manufactured Components

Science.gov (United States)

Hopping, Ethan

The UAH-78AM is a low-power Hall effect thruster developed at the University of Alabama in Huntsville to study the application of low-cost additive manufacturing in the design and fabrication of Hall thrusters. The goal of this project is to assess the feasibility of using unconventional materials to produce a low-cost functioning Hall effect thruster and consider how additive manufacturing can expand the design space and provide other benefits. The thruster features channel walls and a propellant distributor that were manufactured using 3D printing with a variety of materials including ABS, ULTEM, and glazed ceramic. A version of the thruster was tested at NASA Glenn Research Center to obtain performance metrics and to validate the ability of the thruster to produce thrust and sustain a discharge. The design of the thruster and the transient performance measurements are presented here. Measured thrust ranged from 17.2 mN to 30.4 mN over a discharge power of 280 W to 520 W with an anode Isp range of 870 s to 1450 s. Temperature limitations of materials used for the channel walls and propellant distributor limit the ability to run the thruster at thermal steady-state. While the current thruster design is not yet ready for continuous operation, revisions to the device that could enable longer duration tests are discussed.

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

Science.gov (United States)

Nanzetta, Philip

1992-01-01

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

Sustainable Micro-Manufacturing of Micro-Components via Micro Electrical Discharge Machining

Directory of Open Access Journals (Sweden)

Valeria Marrocco

2011-12-01

Full Text Available Micro-manufacturing emerged in the last years as a new engineering area with the potential of increasing peoples’ quality of life through the production of innovative micro-devices to be used, for example, in the biomedical, micro-electronics or telecommunication sectors. The possibility to decrease the energy consumption makes the micro-manufacturing extremely appealing in terms of environmental protection. However, despite this common belief that the micro-scale implies a higher sustainability compared to traditional manufacturing processes, recent research shows that some factors can make micro-manufacturing processes not as sustainable as expected. In particular, the use of rare raw materials and the need of higher purity of processes, to preserve product quality and manufacturing equipment, can be a source for additional environmental burden and process costs. Consequently, research is needed to optimize micro-manufacturing processes in order to guarantee the minimum consumption of raw materials, consumables and energy. In this paper, the experimental results obtained by the micro-electrical discharge machining (micro-EDM of micro-channels made on Ni–Cr–Mo steel is reported. The aim of such investigation is to shed a light on the relation and dependence between the material removal process, identified in the evaluation of material removal rate (MRR and tool wear ratio (TWR, and some of the most important technological parameters (i.e., open voltage, discharge current, pulse width and frequency, in order to experimentally quantify the material waste produced and optimize the technological process in order to decrease it.

Using CORBA to integrate manufacturing cells to a virtual enterprise

Science.gov (United States)

Pancerella, Carmen M.; Whiteside, Robert A.

1997-01-01

It is critical in today's enterprises that manufacturing facilities are not isolated from design, planning, and other business activities and that information flows easily and bidirectionally between these activities. It is also important and cost-effective that COTS software, databases, and corporate legacy codes are well integrated in the information architecture. Further, much of the information generated during manufacturing must be dynamically accessible to engineering and business operations both in a restricted corporate intranet and on the internet. The software integration strategy in the Sandia Agile Manufacturing Testbed supports these enterprise requirements. We are developing a CORBA-based distributed object software system for manufacturing. Each physical machining device is a CORBA object and exports a common IDL interface to allow for rapid and dynamic insertion, deletion, and upgrading within the manufacturing cell. Cell management CORBA components access manufacturing devices without knowledge of any device-specific implementation. To support information flow from design to planning data is accessible to machinists on the shop floor. CORBA allows manufacturing components to be easily accessible to the enterprise. Dynamic clients can be created using web browsers and portable Java GUI's. A CORBA-OLE adapter allows integration to PC desktop applications. Other commercial software can access CORBA network objects in the information architecture through vendor API's.

Fabrication of high performance components for Indian nuclear reactors

International Nuclear Information System (INIS)

Jayaraj, R.N.

2011-01-01

Nuclear Fuel Complex (NFC), a Unit of the Department of Atomic Energy (DAE) has been engaged for well over three-and-half decades in the manufacture of fuels for Pressurized Heavy Water Reactors (PHWRs) and Boiling Water Reactors (BWRs). All the fuel assembly components, like, fuel clad tubes, end plugs, spacers, spacer grids etc. are also being manufactured at NFC in Zirconium alloy material. Apart from the regular production of these components and finished fuel assemblies, NFC has also been engaged in the production of Zirconium alloy reactor core structurals, like, pressure tubes, calandria tubes, garter springs and reactivity control mechanisms for PHWRs and square channels for BWRs. While all these structural components are produced through standardized flow sheets, there have been continuous innovations carried out in the processes to meet the ever increasing end-use characteristics laid down by the utilities. The paper enumerates various aspects of different technologies developed at NFC for the manufacture of high performance components for reactor applications

Measures of International Manufacturing and Trade of Clean Energy Technologies

Energy Technology Data Exchange (ETDEWEB)

Engel-Cox, Jill; Sandor, Debbie; Keyser, David; Mann, Margaret

2017-05-25

The technologies that produce clean energy, such as solar photovoltaic panels and lithium ion batteries for electric vehicles, are globally manufactured and traded. As demand and deployment of these technologies grows exponentially, the innovation to reach significant economies of scale and drive down energy production costs becomes less in the technology and more in the manufacturing of the technology. Manufacturing innovations and other manufacturing decisions can reduce costs of labor, materials, equipment, operating costs, and transportation, across all the links in the supply chain. To better understand the manufacturing aspect of the clean energy economy, we have developed key metrics for systematically measuring and benchmarking international manufacturing of clean energy technologies. The metrics are: trade, market size, manufacturing value-added, and manufacturing capacity and production. These metrics were applied to twelve global economies and four representative technologies: wind turbine components, crystalline silicon solar photovoltaic modules, vehicle lithium ion battery cells, and light emitting diode packages for efficient lighting and other consumer products. The results indicated that clean energy technologies are being developed via complex, dynamic, and global supply chains, with individual economies benefiting from different technologies and links in the supply chain, through both domestic manufacturing and global trade.

Additive Manufacturing of Hierarchical Porous Structures

Energy Technology Data Exchange (ETDEWEB)

Grote, Christopher John [Los Alamos National Lab. (LANL), Los Alamos, NM (United States). Materials Science and Technology Division. Polymers and Coatings

2016-08-30

Additive manufacturing has become a tool of choice for the development of customizable components. Developments in this technology have led to a powerful array of printers that t serve a variety of needs. However, resin development plays a crucial role in leading the technology forward. This paper addresses the development and application of printing hierarchical porous structures. Beginning with the development of a porous scaffold, which can be functionalized with a variety of materials, and concluding with customized resins for metal, ceramic, and carbon structures.

A study on the applications of AI in finishing of additive manufacturing parts

Science.gov (United States)

Fathima Patham, K.

2017-06-01

Artificial intelligent and computer simulation are the technological powerful tools for solving complex problems in the manufacturing industries. Additive Manufacturing is one of the powerful manufacturing techniques that provide design flexibilities to the products. The products with complex shapes are directly manufactured without the need of any machining and tooling using Additive Manufacturing. However, the main drawback of the components produced using the Additive Manufacturing processes is the quality of the surfaces. This study aims to minimize the defects caused during Additive Manufacturing with the aid of Artificial Intelligence. The developed AI system has three layers, each layer is trying to eliminate or minimize the production errors. The first layer of the AI system optimizes the digitization of the 3D CAD model of the product and hence reduces the stair case errors. The second layer of the AI system optimizes the 3D printing machine parameters in order to eliminate the warping effect. The third layer of AI system helps to choose the surface finishing technique suitable for the printed component based on the Degree of Complexity of the product and the material. The efficiency of the developed AI system was examined on the functional parts such as gears.

Development of Integration in Manufacturing

DEFF Research Database (Denmark)

Sørensen, Torben; Trostmann, Erik

1996-01-01

significance to all manufacturing industries.International standardization based on the product model definition standard STEP (ISO10303) is playing a key role in promoting a modern approach to Product Data Technology. The initial release of STEP, consisting of twelve essential parts, has recently been...... must be extended to cope with descriptions of functional behavior of products.In the robotics area, Computer Aided Robotics (CAR) systems for design, off-line programming, and simulation are currently increasing their model features with new topics, such as multi-body dynamics, realistic motion......Current international developments in the broad field of Product Data Technology are advancing rapidly and are leading up to new levels of technology in product model definition, product model communications, enterprise integration and cooperation. These developments will be of strategic...

The DARPA manufacturing initiative in high temperature superconductivity

International Nuclear Information System (INIS)

Adams, K.R.

1989-01-01

The Defense Advanced Research Projects Agency (DARPA) has a very aggressive Technology Base program in high temperature superconductivity. This program is expected to provide the basis for a specialized set of military products - passive microwave and millimeter wave devices - within the next three years. In order to get these high leverage products into military systems, a manufacturing base must be developed for HTSC components. A plan for DARPA in HTSC manufacturing is directly coupled with the ongoing DARPA materials and device oriented R and D program. In essence, this plan recommends a three phased effort: 1. Phase I (two years); Fund companies through R and D contracts for specialized HTSC components; prepare a detailed plan and develop an HTSC consortium. 2. Phase II (six years): Establish an HTSC Sematech initiative for electronic applications, including active devices. 3. Phase III (optional): Continue the HTSC Sematech with emphasis on high power applications

Efficiency and Innovation in U.S. Manufacturing Energy Use

Energy Technology Data Exchange (ETDEWEB)

None

2005-06-01

The NAM has partnered with the Alliance to Save Energy to develop this booklet for manufacturers who want to achieve more strategic control over rising energy costs. Being better energy managers is important not only for each company, but is also an essential component in achieving a low-inflation, high-growth economy. We hope that the opportunities outlined in this booklet will encourage manufacturers to make energy efficiency a part of standard operating procedure.

Experimental study on hollow structural component by explosive welding

Energy Technology Data Exchange (ETDEWEB)

Duan, Mianjun, E-mail: dmjwl@163.com [PLA University of Science and Technology, Nanjing 210007 (China); Wei, Ling, E-mail: 386006087@qq.com [Tongda College, Nanjing University of Posts and Telecommunication, Nanjing 210007 (China); Hong, Jin [PLA University of Science and Technology, Nanjing 210007 (China); Ran, Hong [Southwestern Institute of Physics, Chengdu 610041 (China); Ma, Rui; Wang, Yaohua [PLA University of Science and Technology, Nanjing 210007 (China)

2014-12-15

Highlights: • This paper relates to a study on a thin double-layers hollow structural component by using an explosive welding technology. • This thin double-layer hollow structural component is an indispensable component required for certain core equipment of thermonuclear experimental reactor. • An adjusted explosive welding technology for manufacturing an inconel625 hollow structural component was developed which cannot be made by common technology. • The result shows that a metallurgical bonding was realized by the ribs and slabs of the hollow sheet. • The shearing strength of bonding interface exceeds that of the parent metal. - Abstract: A large thin-walled hollow structural component with sealed channels is required for the vacuum chamber of a thermonuclear experimental reactor, with inconel625 as its fabrication material. This hollow structural component is rarely manufactured by normal machining method, and its manufacture is also problematic in the field of explosive welding. With this in mind, we developed an adjusted explosive welding technology which involves a two-step design, setting and annealing technology. The joints were evaluated using optical microscope and scanning electron microscope, and a mechanical experiment was conducted, involving micro-hardness test, cold helium leak test and hydraulic pressure test. The results showed that a metallurgical bonding was realized by the ribs and slabs, and the shearing strength of the bonding interface exceeded that of the parent metal. Hence, the hollow structural component has a good comprehensive mechanical performance and sealing property.

Experimental study on hollow structural component by explosive welding

International Nuclear Information System (INIS)

Duan, Mianjun; Wei, Ling; Hong, Jin; Ran, Hong; Ma, Rui; Wang, Yaohua

2014-01-01

Highlights: • This paper relates to a study on a thin double-layers hollow structural component by using an explosive welding technology. • This thin double-layer hollow structural component is an indispensable component required for certain core equipment of thermonuclear experimental reactor. • An adjusted explosive welding technology for manufacturing an inconel625 hollow structural component was developed which cannot be made by common technology. • The result shows that a metallurgical bonding was realized by the ribs and slabs of the hollow sheet. • The shearing strength of bonding interface exceeds that of the parent metal. - Abstract: A large thin-walled hollow structural component with sealed channels is required for the vacuum chamber of a thermonuclear experimental reactor, with inconel625 as its fabrication material. This hollow structural component is rarely manufactured by normal machining method, and its manufacture is also problematic in the field of explosive welding. With this in mind, we developed an adjusted explosive welding technology which involves a two-step design, setting and annealing technology. The joints were evaluated using optical microscope and scanning electron microscope, and a mechanical experiment was conducted, involving micro-hardness test, cold helium leak test and hydraulic pressure test. The results showed that a metallurgical bonding was realized by the ribs and slabs, and the shearing strength of the bonding interface exceeded that of the parent metal. Hence, the hollow structural component has a good comprehensive mechanical performance and sealing property

Advanced qualification methodology for actively cooled plasma facing components

Science.gov (United States)

Durocher, A.; Escourbiac, F.; Grosman, A.; Boscary, J.; Merola, M.; Cismondi, F.; Courtois, X.; Farjon, J. L.; Missirlian, M.; Schlosser, J.; Tivey, R.

2007-12-01

The use of high heat flux plasma facing components (PFCs) in steady state fusion devices requires high reliability. These components have to withstand heat fluxes in the range 10-20 MW m-2 involving a number of severe engineering constraints. Feedback from the experience of various industrial manufacturings showed that the bonding of the refractory armour material onto the metallic heat sink causes generic difficulties strongly depending on material qualities and specific design. As the heat exhaust capability and lifetime of PFCs during plasma operation are directly linked to the manufacturing quality, a set of qualification activities such as active infrared thermography, lock-in and acoustic measurements were performed during the component development phases following a qualification route. This paper describes the major improvements stemming from better measurement accuracy and refined data processing and analyses recent developments aimed at investigating the capability to qualify the component in situ during its lifetime.

Advanced qualification methodology for actively cooled plasma facing components

International Nuclear Information System (INIS)

Durocher, A.; Escourbiac, F.; Grosman, A.; Boscary, J.; Merola, M.; Cismondi, F.; Courtois, X.; Farjon, J.L.; Missirlian, M.; Schlosser, J.; Tivey, R.

2007-01-01

The use of high heat flux plasma facing components (PFCs) in steady state fusion devices requires high reliability. These components have to withstand heat fluxes in the range 10-20 MW m -2 involving a number of severe engineering constraints. Feedback from the experience of various industrial manufacturings showed that the bonding of the refractory armour material onto the metallic heat sink causes generic difficulties strongly depending on material qualities and specific design. As the heat exhaust capability and lifetime of PFCs during plasma operation are directly linked to the manufacturing quality, a set of qualification activities such as active infrared thermography, lock-in and acoustic measurements were performed during the component development phases following a qualification route. This paper describes the major improvements stemming from better measurement accuracy and refined data processing and analyses recent developments aimed at investigating the capability to qualify the component in situ during its lifetime

Development of Improved Design and 3D Printing Manufacture of Cross-Flow Fan Rotor

Science.gov (United States)

2016-06-01

printer was used to print components of a carbon-fiber composite cross-flow fan rotor . These pieces were assembled and the thrust, power, and thrust...variables. A MarkForged Mark One 3D printer was used to print components of a carbon-fiber composite cross-flow fan rotor . These pieces were assembled... composite parts to be 3D printed. This technology showed promise in rapidly manufacturing complicated blade and rotor geometries. The objective of

Procedure for the qualification of a manufacturer of ingot iron pieces for application in nuclear power plant components

International Nuclear Information System (INIS)

Rahn, K.M.M.; Jusevicius, E.; Michael, H.

1981-01-01

The process for the qualification of 'Sao Caetano do Sul (Acos Villares S/A)' Plant as manufacturers of ingot iron pieces for application in components of Angra 2 and Angra 3 Nuclear Power Plants, is presented. The qualification was executed by IBQN - Instituto Brasileiro de Qualidade Nuclear - the organ officially in charge of the execution of qualification of suppliers of materials for the nuclear industry. (E.G.) [pt

Does Electricity Drive the Development of Manufacturing Sector in Malaysia?

Energy Technology Data Exchange (ETDEWEB)

Husaini, Dzul Hadzwan [Faculty of Economics and Business, Universiti Malaysia Sarawak, Sarawak (Malaysia); Lean, Hooi Hooi, E-mail: hooilean@usm.my [Economics Program, School of Social Sciences, Universiti Sains Malaysia, Penang (Malaysia)

2015-04-22

This paper investigates the relationship between electricity consumption, output, and price in the manufacturing sector in Malaysia. We find that electricity consumption, output, and price are cointegrated in the long run. In addition, it has been found that the relationship between electricity consumption and output is positive. In the long run, we find a unidirectional causality from manufacturing output to electricity consumption. This result indicates that the development of manufacturing sector stimulates greater demand for electricity. Government needs to make sure that the planning of electricity supply in the future is in line with the economic development planning to avoid shortage in electricity supply. In the short run, a unidirectional relationship runs from electricity consumption to output is found. A decrease of energy usage in production might reduce the output growth in short run. Hence, we suggest improving the efficiency of electricity usage and some cost-effective sources of energy.

Does Electricity Drive the Development of Manufacturing Sector in Malaysia?

International Nuclear Information System (INIS)

Husaini, Dzul Hadzwan; Lean, Hooi Hooi

2015-01-01

This paper investigates the relationship between electricity consumption, output, and price in the manufacturing sector in Malaysia. We find that electricity consumption, output, and price are cointegrated in the long run. In addition, it has been found that the relationship between electricity consumption and output is positive. In the long run, we find a unidirectional causality from manufacturing output to electricity consumption. This result indicates that the development of manufacturing sector stimulates greater demand for electricity. Government needs to make sure that the planning of electricity supply in the future is in line with the economic development planning to avoid shortage in electricity supply. In the short run, a unidirectional relationship runs from electricity consumption to output is found. A decrease of energy usage in production might reduce the output growth in short run. Hence, we suggest improving the efficiency of electricity usage and some cost-effective sources of energy.

Development and Manufacture of Polymer-based Electrochromic Devices

DEFF Research Database (Denmark)

Jensen, Jacob; Hösel, Markus; Dyer, Aubrey L.

2015-01-01

-to-roll methods compatible with upscaling and manufacture. The successful approaches to operational devices are presented in detail, as well as areas where future research would have a high impact and accelerate the development such as highly conducting and transparent substrates, electrolytes adapted...

Primary Manufacturing Processes for Fiber Reinforced Composites: History, Development & Future Research Trends

Science.gov (United States)

Tapan Bhatt, Alpa; Gohil, Piyush P.; Chaudhary, Vijaykumar

2018-03-01

Composite Materials are becoming more popular gradually replacing traditional material with extra strength, lighter weight and superior property. The world is exploring use of fiber reinforced composites in all application which includes air, land and water transport, construction industry, toys, instrumentation, medicine and the list is endless. Based on application and reinforcement used, there are many ways to manufactures parts with fiber reinforced composites. In this paper various manufacturing processes have been discussed at length, to make fiber reinforced composites components. The authors have endeavored to include all the processes available recently in composite industry. Paper first highlights history of fiber reinforced composites manufacturing, and then the comparison of different manufacturing process to build composites have been discussed, to give clear understanding on, which process should be selected, based on reinforcement, matrix and application. All though, there are several advantages to use such fiber reinforcement composites, still industries have not grown at par and there is a lot of scope to improve these industries. At last, where India stands today, what are the challenges in market has been highlighted and future market and research trend of exploring such composite industries have been discussed. This work is carried out as a part of research project sanctioned by GUJCOST, Gandhinagar.

77 FR 69634 - International Conference on Harmonisation; Guidance on Q11 Development and Manufacture of Drug...

Science.gov (United States)

2012-11-20

...] International Conference on Harmonisation; Guidance on Q11 Development and Manufacture of Drug Substances... Administration (FDA) is announcing the availability of a guidance entitled ``Q11 Development and Manufacture of... guidance is intended to apply only to the manufacture of drug substance, not the manufacture of finished...

Developing a tool for the preparation of GMP audit of pharmaceutical contract manufacturer.

Science.gov (United States)

Linna, Anu; Korhonen, Mirka; Mannermaa, Jukka-Pekka; Airaksinen, Marja; Juppo, Anne Mari

2008-06-01

Outsourcing is rapidly growing in the pharmaceutical industry. When the manufacturing activities are outsourced, control of the product's quality has to be maintained. One way to confirm contract manufacturer's GMP (Good Manufacturing Practice) compliance is auditing. Audits can be supported for instance by using GMP questionnaires. The objective of this study was to develop a tool for the audit preparation of pharmaceutical contract manufacturers and to validate its contents by using Delphi method. At this phase of the study the tool was developed for non-sterile finished product contract manufacturers. A modified Delphi method was used with expert panel consisting of 14 experts from pharmaceutical industry, authorities and university. The content validity of the developed tool was assessed by a Delphi questionnaire round. The response rate in Delphi questionnaire round was 86%. The tool consisted of 103 quality items, from which 90 (87%) achieved the pre-defined agreement rate level (75%). Thirteen quality items which did not achieve the pre-defined agreement rate were excluded from the tool. The expert panel suggested only minor changes to the tool. The results show that the content validity of the developed audit preparation tool was good.

Manufacturing technologies for photovoltaics and possible means of their development in Russia (Review). Part 1: General approach to the development of photoelectric converters and basic silicon technologies

Science.gov (United States)

Tarasenko, A. B.; Popel', O. S.

2015-11-01

The state and key tendencies of the development of basic technologies for manufacture of photoelectric converters (PECs) in the world are considered, and their advantages and disadvantages are discussed. The first part of the review gives short information on the development of photovoltaics in the world and planes of the development of solar power plants in Russia. Total power of photoelectric plants operating in various countries in 2015 exceeded 150 GW and increased in the last ten years with a rate of approximately 50% per year. Russia made important state decisions on the support of the development of renewable power engineering and developed mechanisms, which were attractive for business, on the stimulation of building of the network of solar power plants with a total power to 1.5 GW in the country to 2020. At the same time, the rigid demands are made with respect to the localization of the production of components of these plants that opens new abilities for the development of the domestic production of photovoltaics manufacture. Data on the efficiency of PECs of various types that are attained in the leading laboratories of the world are given. Particular emphasis has been placed on the consideration of basic silicon technologies of PEC manufacture, which had the widest commercial application. The basic methods for production of polycrystalline silicon and making single-crystal and multicrystal silicon are described. Fundamentals of making techniques for plates, PECs, and photoelectric modules based on single-crystal and polycrystalline silicon are considered. The second part will be devoted to modifications of manufacturing techniques for photoelectric converters, enhancement methods for contact structures, and recommendations of authors with respect to the choice of prospective technologies for the expansion of PEC production in Russia. It will involve formulations and substantiations of the most promising lines of the development of photoelectric

Global Value Chain and Manufacturing Analysis on Geothermal Power Plant Turbines

Energy Technology Data Exchange (ETDEWEB)

Akar, Sertac [National Renewable Energy Laboratory (NREL), Golden, CO (United States); Augustine, Chad R [National Renewable Energy Laboratory (NREL), Golden, CO (United States); Kurup, Parthiv [National Renewable Energy Laboratory (NREL), Golden, CO (United States); Mann, Margaret K [National Renewable Energy Laboratory (NREL), Golden, CO (United States)

2017-10-04

The global geothermal electricity market has significantly grown over the last decade and is expected to reach a total installed capacity of 18.4 GWe in 2021 (GEA, 2016). Currently, geothermal project developers customize the size of the power plant to fit the resource being developed. In particular, the turbine is designed and sized to optimize efficiency and resource utilization for electricity production; most often, other power plant components are then chosen to complement the turbine design. These custom turbine designs demand one-off manufacturing processes, which result in higher manufacturing setup costs, longer lead-times, and higher capital costs overall in comparison to larger-volume line manufacturing processes. In contrast, turbines produced in standard increments, manufactured in larger volumes, could result in lower costs per turbine. This study focuses on analysis of the global supply chain and manufacturing costs for Organic Rankine Cycle (ORC) turboexpanders and steam turbines used in geothermal power plants. In this study, we developed a manufacturing cost model to identify requirements for equipment, facilities, raw materials, and labor. We analyzed three different cases 1) 1 MWe geothermal ORC turboexpander 2) 5 MWe ORC turboexpander and 3) 20 MWe geothermal steam turbine, and calculated the cost of manufacturing the major components, such as the impellers/blades, shaft/rotor, nozzles, inlet guide lanes, disks, and casings. Then we used discounted cash flow (DCF) analysis to calculate the minimum sustainable price (MSP). MSP is the minimum price that a company must sell its product for in order to pay back the capital and operating expenses during the plant lifetime (CEMAC, 2017). The results showed that MSP could highly vary between 893 dollar/kW and 30 dollar/kW based on turbine size, standardization and volume of manufacturing. The analysis also showed that the economy of scale applies both to the size of the turbine and the number

Net Shape Manufacturing of Accelerator Components by High Pressure Combustion Driven Powder Compaction

CERN Document Server

Nagarathnam, Karthik

2005-01-01

We present an overview of the net shape and cost-effective manufacturing aspects of high density accelerator (normal and superconducting) components (e.g., NLC Copper disks) and materials behavior of copper, stainless steel, refractory materials (W, Mo and TZM), niobium and SiC by innovative high pressure Combustion Driven Compaction (CDC) technology. Some of the unique process advantages include high densities, net-shaping, improved surface finish/quality, suitability for simple/complex geometries, synthesis of single as well as multilayered materials, milliseconds of compaction process time, little or no post-machining, and process flexibility. Some of the key results of CDC fabricated sample geometries, process optimization, sintering responses and structure/property characteristics such as physical properties, surface roughness/quality, electrical conductivity, select microstructures and mechanical properties will be presented. Anticipated applications of CDC compaction include advanced x-ray targets, vac...

Recent development of cellular manufacturing systems

Indian Academy of Sciences (India)

be manufactured in a cell, and the machines, which will comprise that cell, can be ... approaches for the CF problem which is referred to as Production Flow Analysis (PFA). ... programming model of cellular manufacturing system design which ...

Development of novel tungsten processing technologies for electro-chemical machining (ECM) of plasma facing components

International Nuclear Information System (INIS)

Holstein, Nils; Krauss, Wolfgang; Konys, Juergen

2011-01-01

Plasma facing components for fusion applications must exhibit long-term stability under extreme conditions, and therefore material imperfections cannot be tolerated due to a high risk of technical failures. To prevent or abolish defects in refractory metals components during the manufacturing process, some methods of electro-chemical machining as S-ECM and C-ECM were developed, enabling both the processing of smooth plain defect-free surfaces of different geometry and the removal of bulk material for the shaping of three-dimensional structures, also without cracks. It is discussed, that tungsten ablation with accurate electro-chemical molding is very sensitive to the kind of electric current, and therefore current investigations focused also on the effects of frequency profiles on the sharpness of edge rounding.

Developments in fuel manufacturing

International Nuclear Information System (INIS)

Ion, S.E.; Harrop, G.; Maricalva Gonzalez, J.

1995-01-01

The status of the investment and R and D programmes in the UK and Spanish fuel fabrication facilities is outlined. Due to a number of circumstances, BNFL and ENUSA have been in the forefront of capital investment, with associated commitment to engineering and scientific research and development. Carrying through this investment has allowed the embodiment of proven state of the art technologies in the design of fuel fabrication plants, with particular emphasis on meeting the future challenge of health and safety, and product quality, at an acceptable cost. ENUSA and BNFL currently supply fuel, not only to their respective 'home' markets but also to France, Belgium, Sweden, and Germany. Both organisations employ an International Business outlook and partake in focused and speculative R and D projects for the design and manufacture of nuclear fuel. (orig./HP)

Development and application of W/Cu flat-type plasma facing components at ASIPP

Science.gov (United States)

Li, Q.; Zhao, S. X.; Sun, Z. X.; Xu, Y.; Li, B.; Wei, R.; Wang, W. J.; Qin, S. G.; Shi, Y. L.; Xie, C. Y.; Wang, J. C.; Wang, X. L.; Missirlian, M.; Guilhem, D.; Liu, G. H.; Yang, Z. S.; Luo, G.-N.

2017-12-01

W/Cu flat-type plasma facing components (PFCs) were widely used in divertor of fusion device because of its advantages, such as low cost, light in weight and good machinability. However, it is very difficult to manufacture them due to the large mismatch between the thermo-mechanical properties of W and Cu. Institute of Plasma Physics, Chinese Academy of Sciences (ASIPP) has successfully developed W/Cu flat-type PFCs for EAST W/Cu divertor project by hot isostatic pressing (HIP) technology. This paper presents the development and application of W/Cu flat-type PFCs at ASIPP. The optimized manufacturing process is to cast pure copper onto the rear side of W tiles at temperature of 1200 °C firstly, and then to HIP the W/Cu tiles onto CuCrZr heat sink at temperature of 600 °C, pressure of 150 MPa and duration of 3 h. W/Cu flat-type testing mock-up for EAST survived 1000 cycles at heat load of 5 MW m-2 in high heat flux tests. And then ASIPP prepared two mock-ups for CEA’s tungsten environment in steady-state tokamak (WEST) project. One mock-up withstood successfully 302 cycles of 20 MW m-2, which are far beyond the design requirement. Since 2014, W/Cu flat-type PFCs were wildly used in EAST upper divertor as baffle and dome components which showed excellent performance in 2015 and 2016 campaigns. Given the success in EAST upper divertor, W/Cu flat-type concept is as well applied in the design of actively cooled Langmuir probes which will be mounted onto EAST divertor targets soon.

Development and application of W/Cu flat-type plasma facing components at ASIPP

International Nuclear Information System (INIS)

Li, Q; Sun, Z X; Xu, Y; Li, B; Wei, R; Wang, W J; Xie, C Y; Wang, J C; Wang, X L; Yang, Z S; Luo, G-N; Zhao, S X; Qin, S G; Shi, Y L; Liu, G H; Missirlian, M; Guilhem, D

2017-01-01

W/Cu flat-type plasma facing components (PFCs) were widely used in divertor of fusion device because of its advantages, such as low cost, light in weight and good machinability. However, it is very difficult to manufacture them due to the large mismatch between the thermo-mechanical properties of W and Cu. Institute of Plasma Physics, Chinese Academy of Sciences (ASIPP) has successfully developed W/Cu flat-type PFCs for EAST W/Cu divertor project by hot isostatic pressing (HIP) technology. This paper presents the development and application of W/Cu flat-type PFCs at ASIPP. The optimized manufacturing process is to cast pure copper onto the rear side of W tiles at temperature of 1200 °C firstly, and then to HIP the W/Cu tiles onto CuCrZr heat sink at temperature of 600 °C, pressure of 150 MPa and duration of 3 h. W/Cu flat-type testing mock-up for EAST survived 1000 cycles at heat load of 5 MW m −2 in high heat flux tests. And then ASIPP prepared two mock-ups for CEA’s tungsten environment in steady-state tokamak (WEST) project. One mock-up withstood successfully 302 cycles of 20 MW m −2 , which are far beyond the design requirement. Since 2014, W/Cu flat-type PFCs were wildly used in EAST upper divertor as baffle and dome components which showed excellent performance in 2015 and 2016 campaigns. Given the success in EAST upper divertor, W/Cu flat-type concept is as well applied in the design of actively cooled Langmuir probes which will be mounted onto EAST divertor targets soon. (paper)

Electronics manufacturing and assembly in Japan

Science.gov (United States)

Kukowski, John A.; Boulton, William R.

1995-02-01

In the consumer electronics industry, precision processing technology is the basis for enhancing product functions and for minimizing components and end products. Throughout Japan, manufacturing technology is seen as critical to the production and assembly of advanced products. While its population has increased less than 30 percent over twenty-five years, Japan's gross national product has increase thirtyfold; this growth has resulted in large part from rapid replacement of manual operations with innovative, high-speed, large-scale, continuously running, complex machines that process a growing number of miniaturized components. The JTEC panel found that introduction of next-generation electronics products in Japan goes hand-in-hand with introduction of new and improved production equipment. In the panel's judgment, Japan's advanced process technologies and equipment development and its highly automated factories are crucial elements of its domination of the consumer electronics marketplace - and Japan's expertise in manufacturing consumer electronics products gives it potentially unapproachable process expertise in all electronics markets.

3D-printed fusion components concepts and validation for the UST-2 stellarator

International Nuclear Information System (INIS)

Queral, V.

2015-01-01

Highlights: • A fabrication method for fusion components is developed and validated. • Synergies obtained from additive manufacturing and non-metal casting. • 3D-printed polyamide hollow truss structure and casting of acrylic resin tested. • UST- 2 stellarator coil frame fabricated to validate the method performance. - Abstract: The geometric complexity and high accuracy simultaneously required in magnetic fusion devices, particularly stellarators and tokamaks, hampers the production of fusion components and devices. Rapid manufacturing construction methods, particularly enhanced for fusion, may contribute to a faster cycle and lower cost production of certain components for tokamaks and stellarators. Casting, cutting, forming, welding and mechanising are conventional production techniques for major fusion components, i.e. coil casings, coil frames, vacuum vessels and blankets. Synergies may emerge by combination of additive manufacturing (3D printing) with conventional manufacturing methods. 3D printing combined with resin moulding is tested by construction of the coil frame and the vacuum vessel of a small stellarator, UST-2. Satisfactory coil frames have been obtained by moulding acrylic resin in a special 3D printed polyamide hollow three-dimensional structure. The conceptual engineering design, construction process and validation of the components are described. The presented manufacturing method might contribute to advance the future 3D printing of larger metallic components for fusion.

3D-printed fusion components concepts and validation for the UST-2 stellarator

Energy Technology Data Exchange (ETDEWEB)

Queral, V., E-mail: vicentemanuel.queral@ciemat.es

2015-10-15

Highlights: • A fabrication method for fusion components is developed and validated. • Synergies obtained from additive manufacturing and non-metal casting. • 3D-printed polyamide hollow truss structure and casting of acrylic resin tested. • UST- 2 stellarator coil frame fabricated to validate the method performance. - Abstract: The geometric complexity and high accuracy simultaneously required in magnetic fusion devices, particularly stellarators and tokamaks, hampers the production of fusion components and devices. Rapid manufacturing construction methods, particularly enhanced for fusion, may contribute to a faster cycle and lower cost production of certain components for tokamaks and stellarators. Casting, cutting, forming, welding and mechanising are conventional production techniques for major fusion components, i.e. coil casings, coil frames, vacuum vessels and blankets. Synergies may emerge by combination of additive manufacturing (3D printing) with conventional manufacturing methods. 3D printing combined with resin moulding is tested by construction of the coil frame and the vacuum vessel of a small stellarator, UST-2. Satisfactory coil frames have been obtained by moulding acrylic resin in a special 3D printed polyamide hollow three-dimensional structure. The conceptual engineering design, construction process and validation of the components are described. The presented manufacturing method might contribute to advance the future 3D printing of larger metallic components for fusion.

Detecting Attacks in CyberManufacturing Systems: Additive Manufacturing Example

Directory of Open Access Journals (Sweden)

Wu Mingtao

2017-01-01

Full Text Available CyberManufacturing System is a vision for future manufacturing where physical components are fully integrated with computational processes in a connected environment. However, realizing the vision requires that its security be adequately ensured. This paper presents a vision-based system to detect intentional attacks on additive manufacturing processes, utilizing machine learning techniques. Particularly, additive manufacturing systems have unique vulnerabilities to malicious attacks, which can result in defective infills but without affecting the exterior. In order to detect such infill defects, the research uses simulated 3D printing process images as well as actual 3D printing process images to compare accuracies of machine learning algorithms in classifying, clustering and detecting anomalies on different types of infills. Three algorithms - (i random forest, (ii k nearest neighbor, and (iii anomaly detection - have been adopted in the research and shown to be effective in detecting such defects.

A risk-based auditing process for pharmaceutical manufacturers.

Science.gov (United States)

Vargo, Susan; Dana, Bob; Rangavajhula, Vijaya; Rönninger, Stephan

2014-01-01

The purpose of this article is to share ideas on developing a risk-based model for the scheduling of audits (both internal and external). Audits are a key element of a manufacturer's quality system and provide an independent means of evaluating the manufacturer's or the supplier/vendor's compliance status. Suggestions for risk-based scheduling approaches are discussed in the article. Pharmaceutical manufacturers are required to establish and implement a quality system. The quality system is an organizational structure defining responsibilities, procedures, processes, and resources that the manufacturer has established to ensure quality throughout the manufacturing process. Audits are a component of the manufacturer's quality system and provide a systematic and an independent means of evaluating the manufacturer's overall quality system and compliance status. Audits are performed at defined intervals for a specified duration. The intention of the audit process is to focus on key areas within the quality system and may not cover all relevant areas during each audit. In this article, the authors provide suggestions for risk-based scheduling approaches to aid pharmaceutical manufacturers in identifying the key focus areas for an audit.

The development of component-based information systems

CERN Document Server

Cesare, Sergio de; Macredie, Robert

2015-01-01

This work provides a comprehensive overview of research and practical issues relating to component-based development information systems (CBIS). Spanning the organizational, developmental, and technical aspects of the subject, the original research included here provides fresh insights into successful CBIS technology and application. Part I covers component-based development methodologies and system architectures. Part II analyzes different aspects of managing component-based development. Part III investigates component-based development versus commercial off-the-shelf products (COTS), includi

Process for the manufacture of adhering NbC layers on components consisting of NiCr alloys

International Nuclear Information System (INIS)

Kleemann, W.

1985-01-01

The invention concerns a process for the manufacture of adhering NbC layers on Ni Cr alloys, whose adhesion is guaranteed in a helium atmosphere even at high temperatures (≥ 950 0 C). Differing from the conventional process in which such layers are applied by thermal spraying, and which does not provide layers adhering at high temperatures, the NbC layers are formed in situ, by applying a niobium layer on the components to be coated and by subsequent carburisation of the niobium layer by means of existing CH 4 impurities in the helium atmosphere. (orig.) [de

Characterization of CuCrZr and CuCrZr/SS joint strength for different blanket components manufacturing conditions

Science.gov (United States)

Gillia, Olivier; Briottet, Laurent; Chu, Isabelle; Lemoine, Patrick; Rigal, Emmanuel; Peacock, Alan

2009-04-01

This work describes studies on the strength of CuCrZr/SS joints for different manufacturing conditions foreseen for the fabrication of blanket components. In the meantime, as junction strength is expected to be strongly related to CuCrZr properties, investigation on the properties of the CuCrZr itself after the different manufacturing conditions is also presented. The initial manufacturing conditions retained were made of a HIP treatment combined with a fast cooling plus a subsequent ageing treatment. For security reasons, the HIP-quenching operation was not possible. A supplementary solutionning cycle with fast cooling has thus been inserted in the heat treatment process just after the HIP bonding treatment. The influence of solutionning temperature (1040 °C or 980 °C), the cooling rate after solutionning (70 °C/min to water quench), the ageing temperature (480 °C or 560 °C) and the HIP temperature (1040 °C or 980 °C) have been addressed. Test results show that the ageing temperature is very important for keeping high strength of material whereas elongation properties are not very sensible to the manufacturing conditions. 1040 °C HIP or solutionning temperature gives better strength properties, as well as a higher cooling rate after solutionning. Concerning samples with joints, it appears that CT test is more selective than other tests since tensile test does not give rupture at joint and KCU test eliminates a route without classifying other routes.

Characterization of CuCrZr and CuCrZr/SS joint strength for different blanket components manufacturing conditions

International Nuclear Information System (INIS)

Gillia, Olivier; Briottet, Laurent; Chu, Isabelle; Lemoine, Patrick; Rigal, Emmanuel; Peacock, Alan

2009-01-01

This work describes studies on the strength of CuCrZr/SS joints for different manufacturing conditions foreseen for the fabrication of blanket components. In the meantime, as junction strength is expected to be strongly related to CuCrZr properties, investigation on the properties of the CuCrZr itself after the different manufacturing conditions is also presented. The initial manufacturing conditions retained were made of a HIP treatment combined with a fast cooling plus a subsequent ageing treatment. For security reasons, the HIP-quenching operation was not possible. A supplementary solutionning cycle with fast cooling has thus been inserted in the heat treatment process just after the HIP bonding treatment. The influence of solutionning temperature (1040 deg. C or 980 deg. C), the cooling rate after solutionning (70 deg. C/min to water quench), the ageing temperature (480 deg. C or 560 deg. C) and the HIP temperature (1040 deg. C or 980 deg. C) have been addressed. Test results show that the ageing temperature is very important for keeping high strength of material whereas elongation properties are not very sensible to the manufacturing conditions. 1040 deg. C HIP or solutionning temperature gives better strength properties, as well as a higher cooling rate after solutionning. Concerning samples with joints, it appears that CT test is more selective than other tests since tensile test does not give rupture at joint and KCU test eliminates a route without classifying other routes.

Safety in a Manufacturing Company

Directory of Open Access Journals (Sweden)

Kopczewski Marian

2017-02-01

Full Text Available The safety systems include the functioning of the institutions of a state, central, and local government, businesses, and social organizations. Research in this discipline should contribute to the development of the theoretical foundations and systems of national and international security and operating systems in the area of technical safety. Technical safety engineering should deal with a design, build, operation, and decommissioning of technical measures in order to minimize the opportunities and the size of their negative impact on the environment, people, and the good of civilization. With this in mind, the main purpose of the research was to evaluate the safety of technical manufacturing company that uses a wide machine park. A plant manufacturing parts and components for automobiles was the audited company.

Analysis 6. Component requirements, competition and export. A survey of innovation related to building components; Analyse 6. Komponentkrav, konkurrence og eksport. En kortlaegning af innovation i byggekomponenter

Energy Technology Data Exchange (ETDEWEB)

Svendsen, Svend

2011-02-15

The report collates several sub-analyses about feasible developments in relation to improved energy requirements for the most important building parts, components and installations for low-energy buildings. The aim is to achieve 75% reduction of energy consumption in the future building class 2020. The findings will contribute to the plans of introducing new building component requirements to force Danish manufacturers to use innovative solutions and to force manufacturers from other countries to market the best products only. (LN)

Developing a cyber-physical system for hybrid manufacturing in an internet-of-things context

NARCIS (Netherlands)

Grefen, P.W.P.J.; Vanderfeesten, I.T.P.; Boultadakis, G.; Gonzalez Garcia, Christian; Garcia-Diaz, Vicente; Pelayo Garcia-Bustelo, B. Cristina; Cueva Lovelle, Juan Manuel

2018-01-01

This chapter describes design and development of the HORSE system for process-oriented hybrid manufacturing that seamlessly integrates human and robotics actors in vertical manufacturing cells that are horizontally coupled in end-to-end manufacturing processes. The HORSE system supports advanced

How Development and Manufacturing Will Need to Be Structured-Heads of Development/Manufacturing May 20-21, 2014 Continuous Manufacturing Symposium.

Science.gov (United States)

Nepveux, Kevin; Sherlock, Jon-Paul; Futran, Mauricio; Thien, Michael; Krumme, Markus

2015-03-01

Continuous manufacturing (CM) is a process technology that has been used in the chemical industry for large-scale mass production of chemicals in single-purpose plants with benefit for many years. Recent interest has been raised to expand CM into the low-volume, high-value pharmaceutical business with its unique requirements regarding readiness for human use and the required quality, supply chain, and liability constraints in this business context. Using a fairly abstract set of definitions, this paper derives technical consequences of CM in different scenarios along the development-launch-supply axis in different business models and how they compare to batch processes. Impact of CM on functions in development is discussed and several operational models suitable for originators and other business models are discussed and specific aspects of CM are deduced from CM's technical characteristics. Organizational structures of current operations typically can support CM implementations with just minor refinements if the CM technology is limited to single steps or small sequences (bin-to-bin approach) and if the appropriate technical skill set is available. In such cases, a small, dedicated group focused on CM is recommended. The manufacturing strategy, as centralized versus decentralized in light of CM processes, is discussed and the potential impact of significantly shortened supply lead times on the organization that runs these processes. The ultimate CM implementation may be seen by some as a totally integrated monolithic plant, one that unifies chemistry and pharmaceutical operations into one plant. The organization supporting this approach will have to reflect this change in scope and responsibility. The other extreme, admittedly futuristic at this point, would be a highly decentralized approach with multiple smaller hubs; this would require a new and different organizational structure. This processing approach would open up new opportunities for products that

How development and manufacturing will need to be structured--heads of development/manufacturing. May 20-21, 2014 Continuous Manufacturing Symposium.

Science.gov (United States)

Nepveux, Kevin; Sherlock, Jon-Paul; Futran, Mauricio; Thien, Michael; Krumme, Markus

2015-03-01

Continuous manufacturing (CM) is a process technology that has been used in the chemical industry for large-scale mass production of chemicals in single-purpose plants with benefit for many years. Recent interest has been raised to expand CM into the low-volume, high-value pharmaceutical business with its unique requirements regarding readiness for human use and the required quality, supply chain, and liability constraints in this business context. Using a fairly abstract set of definitions, this paper derives technical consequences of CM in different scenarios along the development-launch-supply axis in different business models and how they compare to batch processes. Impact of CM on functions in development is discussed and several operational models suitable for originators and other business models are discussed and specific aspects of CM are deduced from CM's technical characteristics. Organizational structures of current operations typically can support CM implementations with just minor refinements if the CM technology is limited to single steps or small sequences (bin-to-bin approach) and if the appropriate technical skill set is available. In such cases, a small, dedicated group focused on CM is recommended. The manufacturing strategy, as centralized versus decentralized in light of CM processes, is discussed and the potential impact of significantly shortened supply lead times on the organization that runs these processes. The ultimate CM implementation may be seen by some as a totally integrated monolithic plant, one that unifies chemistry and pharmaceutical operations into one plant. The organization supporting this approach will have to reflect this change in scope and responsibility. The other extreme, admittedly futuristic at this point, would be a highly decentralized approach with multiple smaller hubs; this would require a new and different organizational structure. This processing approach would open up new opportunities for products that

A component-based groupware development methodology

NARCIS (Netherlands)

Guareis de farias, Cléver; Ferreira Pires, Luis; van Sinderen, Marten J.

2000-01-01

Software development in general and groupware applications in particular can greatly benefit from the reusability and interoperability aspects associated with software components. Component-based software development enables the construction of software artefacts by assembling prefabricated,

Manipulator-controlled manufacturing and on-line testing of composite materials. Subproject: Development and trial of test techniques. Final report

International Nuclear Information System (INIS)

Nuding, W.; Schroeder, P.

1991-10-01

ZAT Juelich was in charge of the assessment of the basic nondestructive materials testing requirements relevant to manufacturing, the application and testing of the hardware and software developed by ITS, the supply of the required X-ray systems including sensors and basic manipulation systems, microfocus X-raying of the newly developed special welding materials, hard-facing parameter studies applicable to components which consist of different composite materials and are characterized by complex geometries, and computer-aided evaluation and scanning of components. The ITS developments were based on nondestructive radiography because radiography provides reliable data about the types, location and sizes of defects. The test object is X-rayed by means of an X-ray tube, and radiograph is displayed on a TV monitor by means of an image intensifying TV chain after improvement of the signal-to-noise ratio by an image processing system. (orig.) [de

Recent advances in fuel product and manufacturing process development

International Nuclear Information System (INIS)

Slember, R.J.; Doshi, P.K.

1987-01-01

This paper discusses advancements in commercial nuclear fuel products and manufacturing made by the Westinghouse Electric Corporation in response to the commercial nuclear fuel industry's demand for high reliability, increased plant availability and improved operating flexibility. The features and benefits of Westinghouse's most advanced fuel products--VANTAGE 5 for PWR plants and QUAD+ for BWR plants--are described, as well as 'high performance' fuel concepts now under development for delivery in the late 1980s. The paper also disusses the importance of in-process quality control throughout manufacturing towards reducing product variability and improving fuel reliability. (author)

3D metal droplet printing development and advanced materials additive manufacturing

Directory of Open Access Journals (Sweden)

Lawrence E. Murr

2017-01-01

Full Text Available While commercial additive manufacturing processes involving direct metal wire or powder deposition along with powder bed fusion technologies using laser and electron beam melting have proliferated over the past decade, inkjet printing using molten metal droplets for direct, 3D printing has been elusive. In this paper we review the more than three decades of development of metal droplet generation for precision additive manufacturing applications utilizing advanced, high-temperature metals and alloys. Issues concerning process optimization, including product structure and properties affected by oxidation are discussed and some comparisons of related additive manufactured microstructures are presented.

An intuitive concept for manufacturing and inspecting of aspherical components

Science.gov (United States)

Chou, Hsiao-Yu; Chang, Keng-Shou

2011-09-01

In this paper we propose an intuitive concept for manufacturing and inspecting of aspherical components. Two types, parabolic and cylinder, of plano-convex and plano-concave aspherical lenses were made by LOH 120S form generation machine. Three form error measurement methods were used known as coordinate measuring machine (CMM), interferometer with CGH null lens and inspection with combined pair lenses. Ultra high accuracy CMM from Panasonic Co., CGH cylinder null and CGH aspheric null from Diffraction International and OWI 150 ASPH CGH interferometer from OptoTech GmbH play the roll for measurement. CMM was used as a surface profiler to inspect the surface shape, and the software GRAPHER was also used as analysis tool to exam asphere numerical datum. The difference between theoretical and practical is as a surface polishing revised reference. The finished plano-convex and plano-concave aspherical lenses can be combined to be a plane lens. The individual and combined lenses were inspected on OPTOTECH OWI 150 ASPH CGH interferometer. The compared interference patterns have shown with the Diffration International CGH Aspheric Null "ASPHERIC 1" and CGH Cylinder Null "H80F2C". Through the procedure, the combined plano-convex and plano-concave aspherical lenses should be a perfect match plane lens and the individual lens might be an aspherical test standard element for quick inspection.

Research regarding reverse engineering for aircraft components

Directory of Open Access Journals (Sweden)

Udroiu Razvan

2017-01-01

Full Text Available Reverse engineering is a useful technique used in manufacturing and design process of new components. In aerospace industry new components can be developed, based on existing components without technical Computer Aided Design (CAD data, in order to reduce the development cycle of new products. This paper proposes a methodology wherein the CAD model of turbine blade can be build using computer aided reverse engineering technique utilising a 5 axis Coordinate Measuring Machine (CMM. The proposed methodology uses a scanning strategy by features, followed by a design methodology for 3D modelling of complex shapes.

Manufacturing network evolution

DEFF Research Database (Denmark)

Yang, Cheng; Farooq, Sami; Johansen, John

2011-01-01

Purpose – This paper examines the effect of changes at the manufacturing plant level on other plants in the manufacturing network and also investigates the role of manufacturing plants on the evolution of a manufacturing network. Design/methodology/approach –The research questions are developed...... different manufacturing plants in the network and their impact on network transformation. Findings – The paper highlights the dominant role of manufacturing plants in the continuously changing shape of a manufacturing network. The paper demonstrates that a product or process change at one manufacturing...... by identifying the gaps in the reviewed literature. The paper is based on three case studies undertaken in Danish manufacturing companies to explore in detail their manufacturing plants and networks. The cases provide a sound basis for developing the research questions and explaining the interaction between...

Characterization of titanium aluminide alloy components fabricated by additive manufacturing using electron beam melting

International Nuclear Information System (INIS)

Murr, L.E.; Gaytan, S.M.; Ceylan, A.; Martinez, E.; Martinez, J.L.; Hernandez, D.H.; Machado, B.I.; Ramirez, D.A.; Medina, F.; Collins, S.; Wicker, R.B.

2010-01-01

Intermetallic, γ-TiAl, equiaxed, small-grain (∼2 μm) structures with lamellar γ/α 2 -Ti 3 Al colonies with average spacing of 0.6 μm have been fabricated by additive manufacturing using electron beam melting (EBM) of precursor, atomized powder. The residual microindentation (Vickers) hardness (HV) averaged 4.1 GPa, corresponding to a nominal yield strength of ∼1.4 GPa (∼HV/3), and a specific yield strength of 0.37 GPa cm 3 g -1 (for a density of 3.76 g cm -3 ), in contrast to 0.27 GPa cm 3 g -1 for EBM-fabricated Ti-6Al-4V components. These results demonstrate the potential to fabricate near net shape and complex titanium aluminide products directly using EBM technology in important aerospace and automotive applications.

Numerical and experimental study of Ti6Al4V components manufactured using powder bed fusion additive manufacturing

OpenAIRE

Zielinski, J.; Mindt, H.-W.; Düchting, J.; Schleifenbaum, J.H.; Megahed, M.

2017-01-01

Powder bed fusion additive manufacturing of titanium alloys is an interesting manufacturing route for many applications requiring high material strength combined with geometric complexity. Managing powder bed fusion challenges, including porosity, surface finish, distortions and residual stresses of as-built material, is the key to bringing the advantages of this process to production main stream. This paper discusses the application of experimental and numerical analysis towards optimizing t...

Global Value Chain and Manufacturing Analysis on Geothermal Power Plant Turbines: Preprint

Energy Technology Data Exchange (ETDEWEB)

Akar, Sertac [National Renewable Energy Laboratory (NREL), Golden, CO (United States); Augustine, Chad R [National Renewable Energy Laboratory (NREL), Golden, CO (United States); Kurup, Parthiv [National Renewable Energy Laboratory (NREL), Golden, CO (United States); Mann, Margaret K [National Renewable Energy Laboratory (NREL), Golden, CO (United States)

2017-11-03

The global geothermal electricity market has significantly grown over the last decade and is expected to reach a total installed capacity of 18.4 GWe in 2021 (GEA, 2016). Currently, geothermal project developers customize the size of the power plant to fit the resource being developed. In particular, the turbine is designed and sized to optimize efficiency and resource utilization for electricity production; most often, other power plant components are then chosen to complement the turbine design. These custom turbine designs demand one-off manufacturing processes, which result in higher manufacturing setup costs, longer lead-times, and higher capital costs overall in comparison to larger-volume line manufacturing processes. In contrast, turbines produced in standard increments, manufactured in larger volumes, could result in lower costs per turbine. This study focuses on analysis of the global supply chain and manufacturing costs for Organic Rankine Cycle (ORC) turboexpanders and steam turbines used in geothermal power plants. In this study, we developed a manufacturing cost model to identify requirements for equipment, facilities, raw materials, and labor. We analyzed three different cases 1) 1 MWe geothermal ORC turboexpander 2) 5 MWe ORC turboexpander and 3) 20 MWe geothermal steam turbine, and calculated the cost of manufacturing the major components, such as the impellers/blades, shaft/rotor, nozzles, inlet guide lanes, disks, and casings. Then we used discounted cash flow (DCF) analysis to calculate the minimum sustainable price (MSP). MSP is the minimum price that a company must sell its product for in order to pay back the capital and operating expenses during the plant lifetime (CEMAC, 2017). The results showed that MSP could highly vary between 893 dollar/kW and 30 dollar/kW based on turbine size, standardization and volume of manufacturing. The analysis also showed that the economy of scale applies both to the size of the turbine and the number

Development and setting of a new system for advanced rheocast components

International Nuclear Information System (INIS)

Rosso, Mario; Peter, I.; Calosso, F.

2011-01-01

This paper presents an overview of alternative methods of production of enhanced performance Al-based alloys components for critical areas. In particular, a new rheocasting system, suitable for the manufacturing of high performance industrial components has been considered. The aforementioned method allows obtaining component quickly and results a more convenient process, from economical point of view than other innovative processes. Two series of components have been produced with A356 and A357 alloys, then have been heat treated using T5 and T6 treatments. On polished transverse sections of samples the microstructure of the alloy has been observed. Their soundness has been previously certified by non destructive tests. Samples for tensile and three point bending tests have been machined directly from the produced components. On the fractured samples, fracture surface analysis has been performed in order to analyze and evaluate the influence of the process and of the alloy on the fracture behaviour.

A framework for development of an intelligent system for design and manufacturing of stamping dies

International Nuclear Information System (INIS)

Hussein, H M A; Kumar, S

2014-01-01

An integration of computer aided design (CAD), computer aided process planning (CAPP) and computer aided manufacturing (CAM) is required for development of an intelligent system to design and manufacture stamping dies in sheet metal industries. In this paper, a framework for development of an intelligent system for design and manufacturing of stamping dies is proposed. In the proposed framework, the intelligent system is structured in form of various expert system modules for different activities of design and manufacturing of dies. All system modules are integrated with each other. The proposed system takes its input in form of a CAD file of sheet metal part, and then system modules automate all tasks related to design and manufacturing of stamping dies. Modules are coded using Visual Basic (VB) and developed on the platform of AutoCAD software

A framework for development of an intelligent system for design and manufacturing of stamping dies

Science.gov (United States)

Hussein, H. M. A.; Kumar, S.

2014-07-01

An integration of computer aided design (CAD), computer aided process planning (CAPP) and computer aided manufacturing (CAM) is required for development of an intelligent system to design and manufacture stamping dies in sheet metal industries. In this paper, a framework for development of an intelligent system for design and manufacturing of stamping dies is proposed. In the proposed framework, the intelligent system is structured in form of various expert system modules for different activities of design and manufacturing of dies. All system modules are integrated with each other. The proposed system takes its input in form of a CAD file of sheet metal part, and then system modules automate all tasks related to design and manufacturing of stamping dies. Modules are coded using Visual Basic (VB) and developed on the platform of AutoCAD software.

Developing novel 3D antennas using advanced additive manufacturing technology

Science.gov (United States)

Mirzaee, Milad

In today's world of wireless communication systems, antenna engineering is rapidly advancing as the wireless services continue to expand in support of emerging commercial applications. Antennas play a key role in the performance of advanced transceiver systems where they serve to convert electric power to electromagnetic waves and vice versa. Researchers have held significant interest in developing this crucial component for wireless communication systems by employing a variety of design techniques. In the past few years, demands for electrically small antennas continues to increase, particularly among portable and mobile wireless devices, medical electronics and aerospace systems. This trend toward smaller electronic devices makes the three dimensional (3D) antennas very appealing, since they can be designed in a way to use every available space inside the devise. Additive Manufacturing (AM) method could help to find great solutions for the antennas design for next generation of wireless communication systems. In this thesis, the design and fabrication of 3D printed antennas using AM technology is studied. To demonstrate this application of AM, different types of antennas structures have been designed and fabricated using various manufacturing processes. This thesis studies, for the first time, embedded conductive 3D printed antennas using PolyLactic Acid (PLA) and Acrylonitrile Butadiene Styrene (ABS) for substrate parts and high temperature carbon paste for conductive parts which can be a good candidate to overcome the limitations of direct printing on 3D surfaces that is the most popular method to fabricate conductive parts of the antennas. This thesis also studies, for the first time, the fabrication of antennas with 3D printed conductive parts which can contribute to the new generation of 3D printed antennas.

A methodology for Manufacturing Execution Systems (MES) implementation

Science.gov (United States)

Govindaraju, Rajesri; Putra, Krisna

2016-02-01

Manufacturing execution system is information systems (IS) application that bridges the gap between IS at the top level, namely enterprise resource planning (ERP), and IS at the lower levels, namely the automation systems. MES provides a media for optimizing the manufacturing process as a whole in a real time basis. By the use of MES in combination with the implementation of ERP and other automation systems, a manufacturing company is expected to have high competitiveness. In implementing MES, functional integration -making all the components of the manufacturing system able to work well together, is the most difficult challenge. For this, there has been an industry standard that specifies the sub-systems of a manufacturing execution systems and defines the boundaries between ERP systems, MES, and other automation systems. The standard is known as ISA-95. Although the advantages from the use of MES have been stated in some studies, not much research being done on how to implement MES effectively. The purpose of this study is to develop a methodology describing how MES implementation project should be managed, utilising the support of ISA- 95 reference model in the system development process. A proposed methodology was developed based on a general IS development methodology. The developed methodology were then revisited based on the understanding about the specific charateristics of MES implementation project found in an Indonesian steel manufacturing company implementation case. The case study highlighted the importance of applying an effective requirement elicitation method during innitial system assessment process, managing system interfaces and labor division in the design process, and performing a pilot deployment before putting the whole system into operation.

Sandia_HighTemperatureComponentEvaluation_2015

Energy Technology Data Exchange (ETDEWEB)

Cashion, Avery T. [Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

2015-03-01

The objective of this project is to perform independent evaluation of high temperature components to determine their suitability for use in high temperature geothermal tools. Development of high temperature components has been increasing rapidly due to demand from the high temperature oil and gas exploration and aerospace industries. Many of these new components are at the late prototype or first production stage of development and could benefit from third party evaluation of functionality and lifetime at elevated temperatures. In addition to independent testing of new components, this project recognizes that there is a paucity of commercial-off-the-shelf COTS components rated for geothermal temperatures. As such, high-temperature circuit designers often must dedicate considerable time and resources to determine if a component exists that they may be able to knead performance out of to meet their requirements. This project aids tool developers by characterization of select COTS component performances beyond published temperature specifications. The process for selecting components includes public announcements of project intent (e.g., FedBizOps), direct discussions with candidate manufacturers,and coordination with other DOE funded programs.

Technological review of the HRP manufacturing process R and D activity

International Nuclear Information System (INIS)

Visca, Eliseo; Pizzuto, A.; Gavila, P.; Riccardi, B.; Roccella, S.; Candura, D.; Sanguinetti, G.P.

2013-01-01

performances obtained from a monoblock medium scale mockup. On the base of these results ENEA-ANSALDO participated to the European programme for the qualification of the manufacturing technology to be used for the procurement of the ITER divertor IVT, according to the F4E specifications. A divertor inner vertical target prototype (400 mm total length) with three plasma facing component units, was successfully tested at ITER relevant thermal heat fluxes. Now, ANSALDO and ENEA are ready to face the challenge of the ITER inner vertical target production, transferring to an industrial production line the experience gained in the development, optimization and qualification of the PBC and HRP processes

Technological review of the HRP manufacturing process R and D activity

Energy Technology Data Exchange (ETDEWEB)

Visca, Eliseo, E-mail: eliseo.visca@enea.it [Associazione EURATOM-ENEA sulla Fusione, C.R. Frascati, Via E. Fermi 45, IT-00044 Frascati (Italy); Pizzuto, A. [Associazione EURATOM-ENEA sulla Fusione, C.R. Frascati, Via E. Fermi 45, IT-00044 Frascati (Italy); Gavila, P.; Riccardi, B. [Fusion For Energy, C. Josep Pla 2, ES-08019 Barcelona (Spain); Roccella, S. [Associazione EURATOM-ENEA sulla Fusione, C.R. Frascati, Via E. Fermi 45, IT-00044 Frascati (Italy); Candura, D.; Sanguinetti, G.P. [Ansaldo Nucleare S.p.A., Corso Perrone 25, IT-16121 Genova (Italy)

2013-10-15

performances obtained from a monoblock medium scale mockup. On the base of these results ENEA-ANSALDO participated to the European programme for the qualification of the manufacturing technology to be used for the procurement of the ITER divertor IVT, according to the F4E specifications. A divertor inner vertical target prototype (400 mm total length) with three plasma facing component units, was successfully tested at ITER relevant thermal heat fluxes. Now, ANSALDO and ENEA are ready to face the challenge of the ITER inner vertical target production, transferring to an industrial production line the experience gained in the development, optimization and qualification of the PBC and HRP processes.

Paper-Less CAD/CAM For Accelerator Components

International Nuclear Information System (INIS)

Franks, R M; Alford, O; Bertolini, L R

2001-01-01

Computer-aided design and manufacture (CAD/CAM) have enabled advances in the design and manufacture of many accelerator components, though government procurement rules tend to inhibit its use. We developed and executed a method that provides adequate documentation for the procurement process, industrial vendor manufacturing processes, and laboratory installation activities. We detail our experiences in the design and manufacture of 60 separate and unique PEP-II Low Energy Ring Interaction Region vacuum chambers totaling ∼ 140m in length as an example of how we used this technique, reducing design effort and manufacturing risk while streamlining the production process. We provide ''lessons learned'' to better implement and execute the process in subsequent iterations. We present our study to determine the estimated savings in the design and production of the Spallation Neutron Source room temperature linac if this process were utilized

Measures to increase the UK-manufactured content of wind turbines

International Nuclear Information System (INIS)

1996-01-01

Little formal work has been undertaken on the subject of component supply. Garrad Hassan (GH) has provided consultancy services to the UK and international wind energy industry, including almost all European wind turbine manufacturers, for more than a decade. Most of this report is based on that experience. Over this period, a good understanding of the market for wind turbines and the associated components has developed. (author)

Electron beam related manufacturing technology development at Lawrence Livermore National Laboratory

International Nuclear Information System (INIS)

Anklam, T.M.

1995-01-01

In the defense community, certain uranium-alloy components have been manufactured by methods which generate large quantities of uranium bearing waste. Our estimates show that these components can be fabricated by vapor deposition and reduce waste generation by more than an order of magnitude. We present results from a series of uranium-alloy vapor deposition tests designed to produce samples of free-standing structures. Both flat plate and cylindrical shells were produced. The deposits were fully dense, defect free and displayed a high quality surface finish. The uranium-alloy was co-evaporated from a single source. Bulk chemistry specifications for the material were met, although some residual variation in chemistry was observed in sample cross sections. After heat treatment, the vapor deposited samples exhibited tensile properties similar to conventional ingot processed material

Integrated Predictive Tools for Customizing Microstructure and Material Properties of Additively Manufactured Aerospace Components

Energy Technology Data Exchange (ETDEWEB)

Radhakrishnan, Balasubramaniam [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Fattebert, Jean-Luc [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Gorti, Sarma B. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Haxhimali, Timor [Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States); El-Wardany, Tahany [United Technologies Research Center (UTRC), East Hartford, CT (United States); Acharya, Ranadip [United Technologies Research Center (UTRC), East Hartford, CT (United States); Staroselsky, Alexander [United Technologies Research Center (UTRC), East Hartford, CT (United States)

2017-12-01

Additive Manufacturing (AM) refers to a process by which digital three-dimensional (3-D) design data is converted to build up a component by depositing material layer-by-layer. United Technologies Corporation (UTC) is currently involved in fabrication and certification of several AM aerospace structural components made from aerospace materials. This is accomplished by using optimized process parameters determined through numerous design-of-experiments (DOE)-based studies. Certification of these components is broadly recognized as a significant challenge, with long lead times, very expensive new product development cycles and very high energy consumption. Because of these challenges, United Technologies Research Center (UTRC), together with UTC business units have been developing and validating an advanced physics-based process model. The specific goal is to develop a physics-based framework of an AM process and reliably predict fatigue properties of built-up structures as based on detailed solidification microstructures. Microstructures are predicted using process control parameters including energy source power, scan velocity, deposition pattern, and powder properties. The multi-scale multi-physics model requires solution and coupling of governing physics that will allow prediction of the thermal field and enable solution at the microstructural scale. The state-of-the-art approach to solve these problems requires a huge computational framework and this kind of resource is only available within academia and national laboratories. The project utilized the parallel phase-fields codes at Oak Ridge National Laboratory (ORNL) and Lawrence Livermore National Laboratory (LLNL), along with the high-performance computing (HPC) capabilities existing at the two labs to demonstrate the simulation of multiple dendrite growth in threedimensions (3-D). The LLNL code AMPE was used to implement the UTRC phase field model that was previously developed for a model binary alloy, and

76 FR 38187 - International Conference on Harmonisation; Draft Guidance on Q11 Development and Manufacture of...

Science.gov (United States)

2011-06-29

...] International Conference on Harmonisation; Draft Guidance on Q11 Development and Manufacture of Drug Substances... Manufacture of Drug Substances.'' The draft guidance was prepared under the auspices of the International... that a draft guidance entitled ``Q11 Development and Manufacture of Drug Substances'' should be made...

Robotics and automation in manufacture

International Nuclear Information System (INIS)

Glasgow, J.R.

1989-01-01

NEI involvement in Heysham II and Torness included contracts for equipment both for the Nuclear Island and for non-nuclear associated plant. Fundamental to the approach to manufacture was the capital investment in plant and facilities to ensure the quality requirements were met with economic production methods and prompt delivery. Some of the production facilities for a selection of varied components are described. Examples of subsequent development of facilities are given to illustrate their current capability. (author)

Improving Project Manufacturing Coordination

Directory of Open Access Journals (Sweden)

Korpivaara Ville

2014-09-01

Full Text Available The objective of this research is to develop firms’ project manufacturing coordination. The development will be made by centralizing the manufacturing information flows in one system. To be able to centralize information, a deep user need assessment is required. After user needs have been identified, the existing system will be developed to match these needs. The theoretical background is achieved through exploring the literature of project manufacturing, development project success factors and different frameworks and tools for development project execution. The focus of this research is rather in customer need assessment than in system’s technical expertise. To ensure the deep understanding of customer needs this study is executed by action research method. As a result of this research the information system for project manufacturing coordination was developed to respond revealed needs of the stakeholders. The new system improves the quality of the manufacturing information, eliminates waste in manufacturing coordination processes and offers a better visibility to the project manufacturing. Hence it provides a solid base for the further development of project manufacturing.

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

Science.gov (United States)

Sampson, Paul G.; Sny, Linda C.

1992-01-01

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

Development of the computer-aided process planning (CAPP system for polymer injection molds manufacturing

Directory of Open Access Journals (Sweden)

J. Tepić

2011-10-01

Full Text Available Beginning of production and selling of polymer products largely depends on mold manufacturing. The costs of mold manufacturing have significant share in the final price of a product. The best way to improve and rationalize polymer injection molds production process is by doing mold design automation and manufacturing process planning automation. This paper reviews development of a dedicated process planning system for manufacturing of the mold for injection molding, which integrates computer-aided design (CAD, computer-aided process planning (CAPP and computer-aided manufacturing (CAM technologies.

Flow Battery System Design for Manufacturability.

Energy Technology Data Exchange (ETDEWEB)

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

2014-10-01

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

Analysis of the Influence of Microcellular Injection Molding on the Environmental Impact of an Industrial Component

Directory of Open Access Journals (Sweden)

Daniel Elduque

2014-09-01

Full Text Available Microcellular injection molding is a process that offers numerous benefits due to the internal structure generated; thus, many applications are currently being developed in different fields, especially home appliances. In spite of the advantages, when changing the manufacturing process from conventional to microcellular injection molding, it is necessary to analyze its new mechanical properties and the environmental impact of the component. This paper presents a deep study of the environmental behavior of a manufactured component by both conventional and microcellular injection molding. Environmental impact will be evaluated performing a life cycle assessment. Functionality of the component will be also evaluated with samples obtained from manufactured components, to make sure that the mechanical requirements are fulfilled when using microcellular injection molding. For this purpose a special device has been developed to measure the flexural modulus. With a 16% weight reduction, the variation of flexural properties in the microcellular injected components is only 6.8%. Although the energy consumption of the microcellular injection process slightly increases, there is an overall reduction of the environmental burden of 14.9% in ReCiPe and 15% in carbon footprint. Therefore, MuCell technology can be considered as a green manufacturing technology for components working mainly under flexural load.

Ubiquitous Robotic Technology for Smart Manufacturing System.

Science.gov (United States)

Wang, Wenshan; Zhu, Xiaoxiao; Wang, Liyu; Qiu, Qiang; Cao, Qixin

2016-01-01

As the manufacturing tasks become more individualized and more flexible, the machines in smart factory are required to do variable tasks collaboratively without reprogramming. This paper for the first time discusses the similarity between smart manufacturing systems and the ubiquitous robotic systems and makes an effort on deploying ubiquitous robotic technology to the smart factory. Specifically, a component based framework is proposed in order to enable the communication and cooperation of the heterogeneous robotic devices. Further, compared to the service robotic domain, the smart manufacturing systems are often in larger size. So a hierarchical planning method was implemented to improve the planning efficiency. A test bed of smart factory is developed. It demonstrates that the proposed framework is suitable for industrial domain, and the hierarchical planning method is able to solve large problems intractable with flat methods.

Impacts of Global Manufacturing Trends on Port Development: The Case of Hong Kong1

Directory of Open Access Journals (Sweden)

Abraham Zhang

2015-03-01

Full Text Available Global manufacturing trends may have profound implications for regional port development. This paper studies Hong Kong port (HKP, which has been one of the world's busiest container ports since the 1990s. In recent years, global manufacturers have started to move away from its primary cargo base, the Chinese Pearl River Delta. This study investigates impacts of the emerging global manufacturing trends on HKP development. It is found that relocation of manufacturing to Western Guangdong benefits HKP, while other relocation destinations make HKP less attractive or even irrelevant. Based on the findings, government policies are discussed that may be formulated to support the growth of the port and wider port-related economy.

Replaceable LMFBR core components

International Nuclear Information System (INIS)

Evans, E.A.; Cunningham, G.W.

1976-01-01

Much progress has been made in understanding material and component performance in the high temperature, fast neutron environment of the LMFBR. Current data have provided strong assurance that the initial core component lifetime objectives of FFTF and CRBR can be met. At the same time, this knowledge translates directly into the need for improved core designs that utilize improved materials and advanced fuels required to meet objectives of low doubling times and extended core component lifetimes. An industrial base for the manufacture of quality core components has been developed in the US, and all procurements for the first two core equivalents for FFTF will be completed this year. However, the problem of fabricating recycled plutonium while dramatically reducing fabrication costs, minimizing personnel exposure, and protecting public health and safety must be addressed

The application of welding technology in power plant manufacture

International Nuclear Information System (INIS)

Price, A.T.; Chew, B.

1989-02-01

A strategy is presented for the application of welding technology in the manufacture of power plant. A flow chart description is adopted in the present paper to provide a general framework outlining the sequence of activities leading to manufacture. The broad chronological order of events is treated under the three headings, Component Design, Welding Development, and Implementation. Important factors that have to be considered at each of these stages are shown in subsidiary flow charts together with short notes to provide context and an aide memoire for those involved in welding technology. (author)

Development of Spray on Bag for manufacturing of large composites parts: Diffusivity analysis

Science.gov (United States)

Dempah, Maxime Joseph

Bagging materials are utilized in many composites manufacturing processes. The selection is mainly driven by cost, temperature requirements, chemical compatibility and tear properties of the bag. The air barrier properties of the bag are assumed to be adequate or in many cases are not considered at all. However, the gas barrier property of a bag is the most critical parameter, as it can negatively affect the quality of the final laminate. The barrier property is a function of the bag material, uniformity, thickness and temperature. Improved barrier properties are needed for large parts, high pressure consolidated components and structures where air stays entrapped on the part surface. The air resistance property of the film is defined as permeability and is investigated in this thesis. A model was developed to evaluate the gas transport through the film and an experimental cell was implemented to characterize various commercial films. Understanding and characterizing the transport phenomena through the film allows optimization of the bagging material for various manufacturing processes. Spray-on-Bag is a scalable alternative bagging method compared to standard films. The approach allows in-situ fabrication of the bag on large and complex geometry structures where optimization of the bag properties can be varied on a local level. An experimental setup was developed and implemented using a six axis robot and an automated spraying system. Experiments were performed on a flat surface and specimens were characterized and compared to conventional films. Air barrier properties were within range of standard film approaches showing the potential to fabricate net shape bagging structures in an automated process.

Structural mechanics research and development for main components of chinese 300 MWe PWR NPPs: from design to life management

International Nuclear Information System (INIS)

Yao Weida; Dou Yikang; Xie Yongcheng; He Yinbiao; Zhang Ming; Liang Xingyun

2005-01-01

Qinshan Nuclear Power Plant (Unit I), is a 300 MWe prototype PWR independently developed by Chinese own efforts, from design, manufacture, construction, installation, commissioning, to operation, inspection, maintenance, ageing management and lifetime assessment. Shanghai Nuclear Engineering Research and Design Institute (SNERDI) has taken up with and involved in deeply the R and D to tackle problems of this type of reactor since very beginning in early 1970s. Structural mechanics is one of the important aspects to ensure the safety and reliability for NPP components. This paper makes a summary on role of structural mechanics for component safety and reliability assessment in different stages of design, commissioning, operation, as well as lifetime assessment on this type PWR NPPs, including Qinshan-I and Chashma-I, a sister plant in Pakistan designed by SNERDI. The main contents of the paper cover design by analysis for key components of NSSS; mechanical problems relating to safety analysis; special problems relating to pressure retaining components, such as fracture mechanics, sealing analysis and its test verifications, etc.; experimental research on flow-induced vibration; seismic qualification for components; component failure diagnosis and root cause analysis; vibration qualification and diagnosis technique; component online monitoring technique; development of defect assessment; methodology of aging management and lifetime assessment for key components of NPPs, etc. (authors)

Manufacturing capability as a technological development indicator in the pharmaceutical industry

Directory of Open Access Journals (Sweden)

John Jairo Gallo Castro

2010-01-01

Full Text Available The pharmaceutical industrial has five subsectors: medicines, cosmetics, phytotherapeutics, cleaning products and medical devices. The medicine subsector consists of organisations producing, importing and selling these products. Most studies about this industry have been guided by economic interests without assessing technological aspects of production. This article was aimed at proposing a methodology for assessing and describing the medicine sector according to its technological development by using the manufacturing capability concept. The main information was taken from the Colombian Medicaments and Food Surveillance Institute’s (Instituto Nacional de Vigilancia de Medicamentos y Alimentos - INVIMA databases related to pharmaceutical plant production in Bogotá, including material transformation facilities. This study led to three characteristics being identified for defining the pharmaceutical industry’s manufacturing capability: that related to the pharmacological group to which active pharmaceutical ingredients belong, that linked to specifications regarding medicines’ sterility and that related to the technology required for manufacturing each pharmaceutical product. An analysis of these features has thus been presented and some technologies have been identified which have not been transferred or assimilated by the organisations being studied. It was found that manufacturing capability should be considered as being an indicator of the degree of technological development in these subsectors in Colombia.

Development of manufacturing technology and fabrication of prototype for main coolant pump

Energy Technology Data Exchange (ETDEWEB)

Chung, Koon Seok; Han, C.K.; Chei, J.M.; Chung, K.S.; Youn, M.H.; Shin, S.A.; Choi, D.J.; Kim, H.C. [HALLA Industrial Co., Ltd., Pusan (Korea)

1999-03-01

This study presents the development of the manufacturing technology for the Main Coolant Pump of the SMART. This report contains the followings; (1) Select axial type pump for the MCP (2) MCP is drived by squirrel-cage induction motor that consisted canned motor type. (3) MCP shaft has three horizontal and one vertical support bearings. (4) Design of several part of the MCP (5) Manufacturing of the performance test motor (6) Design and manufacturing of the speed sensor (7) Procedures for three-axial and five-axial M.C.T., Tig welding and Electron Beam Welding were developed. (8) Conceptional design of the MCP test facility for the performance test under operating conditions. (9) Results of standard weld test specimens according to the ASME section IX. (author). 21 refs., 35 figs., 10 tabs.

Additive Manufacturing of Wind Turbine Molds

Energy Technology Data Exchange (ETDEWEB)

Post, Brian [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Richardson, Bradley [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Lloyd, Peter [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Love, Lonnie [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Nolet, Stephen [TPI Composites, Scottsdale, AZ (United States); Hannan, James [TPI Composites, Scottsdale, AZ (United States)

2017-07-01

The objective of this project was to explore the utility of Big Area Additive Manufacturing (BAAM) for low cost manufacturing of wind turbine molds. Engineers at Oak Ridge National Laboratory (ORNL) and TPI Composites (TPI) collaborated to design and manufacture a printed mold that can be used for resin infusion of wind turbine components. Specific focus was on required material properties (operating temperatures and pressures, coefficient of thermal expansion (CTE), thermal conductivity), surface finish (accuracy and coatings) and system integration (integrated vacuum ports, and heating element). The project began with a simple proof of principle components, targeting surface coatings and material properties for printing a small section (approximately 4’ x 4’ x 2’) of a mold. Next, the second phase scaled up and integrated with the objective of capturing all of the necessary components (integrated heating to accelerate cure time, and vacuum, sealing) for resin infusion on a mold of significant size (8’ x 20’ x 6’).

Manufacturing Process Developments for Regeneratively-Cooled Channel Wall Rocket Nozzles

Science.gov (United States)

Gradl, Paul; Brandsmeier, Will

2016-01-01

Regeneratively cooled channel wall nozzles incorporate a series of integral coolant channels to contain the coolant to maintain adequate wall temperatures and expand hot gas providing engine thrust and specific impulse. NASA has been evaluating manufacturing techniques targeting large scale channel wall nozzles to support affordability of current and future liquid rocket engine nozzles and thrust chamber assemblies. The development of these large scale manufacturing techniques focus on the liner formation, channel slotting with advanced abrasive water-jet milling techniques and closeout of the coolant channels to replace or augment other cost reduction techniques being evaluated for nozzles. NASA is developing a series of channel closeout techniques including large scale additive manufacturing laser deposition and explosively bonded closeouts. A series of subscale nozzles were completed evaluating these processes. Fabrication of mechanical test and metallography samples, in addition to subscale hardware has focused on Inconel 625, 300 series stainless, aluminum alloys as well as other candidate materials. Evaluations of these techniques are demonstrating potential for significant cost reductions for large scale nozzles and chambers. Hot fire testing is planned using these techniques in the future.

APPROACHES FOR SUSTAINABLE MANUFACTURING

Institute of Scientific and Technical Information of China (English)

G(U)NTHER Seliger; SEBASTIAN Kernbaum; MARCO Zettl

2007-01-01

Sustainable development is a holistic approach harmonizing ecological, economical and socio-political needs with respect to the superior objective of enhancing human living standards. Thereby the availability of natural resources and the conservation of the ecosystems have to be considered that future generations have the possibility to meet their own needs. A long-term economical development demands the transition from a source-sink economy to a cycle economy as a result of limited resources, limited environmental capacities to absorb waste and emissions as well as increasing needs of a growing population. A reference model for sustainability in manufacturing is presented and used to illustrate sustainable approaches with respect to management, technology, process and product. Adaptation of products and components is a vital element for supporting efficient reuse of products and components. Consequently adaptation contributes to the ambitious goals of sustainability. Technological enablers for adaptation as modularity, information and communication technology are exemplarily introduced. Moreover, approaches for disseminating knowledge in sustainability are given.

Manufacturing conditioned roughness and wear of biomedical oxide ceramics for all-ceramic knee implants.

Science.gov (United States)

Turger, Anke; Köhler, Jens; Denkena, Berend; Correa, Tomas A; Becher, Christoph; Hurschler, Christof

2013-08-29

Ceramic materials are used in a growing proportion of hip joint prostheses due to their wear resistance and biocompatibility properties. However, ceramics have not been applied successfully in total knee joint endoprostheses to date. One reason for this is that with strict surface quality requirements, there are significant challenges with regard to machining. High-toughness bioceramics can only be machined by grinding and polishing processes. The aim of this study was to develop an automated process chain for the manufacturing of an all-ceramic knee implant. A five-axis machining process was developed for all-ceramic implant components. These components were used in an investigation of the influence of surface conformity on wear behavior under simplified knee joint motion. The implant components showed considerably reduced wear compared to conventional material combinations. Contact area resulting from a variety of component surface shapes, with a variety of levels of surface conformity, greatly influenced wear rate. It is possible to realize an all-ceramic knee endoprosthesis device, with a precise and affordable manufacturing process. The shape accuracy of the component surfaces, as specified by the design and achieved during the manufacturing process, has a substantial influence on the wear behavior of the prosthesis. This result, if corroborated by results with a greater sample size, is likely to influence the design parameters of such devices.

Development of contour scanning parameters to improve surface finishing of additive manufactured parts

CSIR Research Space (South Africa)

Hoosain, Shaik

2017-10-01

Full Text Available 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 have been developed to accomplish this via melting...

Technology transfer and international development: Materials and manufacturing technology

Science.gov (United States)

1982-01-01

Policy oriented studies on technological development in several relatively advanced developing countries were conducted. Priority sectors defined in terms of technological sophistication, capital intensity, value added, and export potential were studied in Brazil, Venezuela, Israel, and Korea. The development of technological policy alternatives for the sponsoring country is assessed. Much emphasis is placed on understanding the dynamics of the sectors through structured interviews with a large sample of firms in the leading manufacturing and materials processing sectors.

Consequences for designer and manufacturer of mechanical components due to future requirements in Europe

International Nuclear Information System (INIS)

Hans-Joachim, Frank

2001-01-01

In the frame of European harmonization, a lot of changes on requirements for designer and manufacturer of mechanical components have been performed. Differed organizations are involved in preparing future requirements for nuclear application. On one side the French German cooperation on the development of EPR. At the origin of this project was the common decision in 1989 of Framatome and Siemens to cooperate through NPI, to design the Nuclear Island, which meets the future needs of utilities. EDF and a group of the main German Utilities joined this cooperation in 1991 and since then they have been totally involved to the progress of the work. In addition, all the process was backed up to the end by the strong cooperation between the French and the German. Safety Authorities, which have a long lasting cooperation to define common requirements, which have to be applied to future Nuclear Power Plants. Furthermore an organization has been set up to elaborate common codes related to the EPR design, at the level of the French design and construction rules (RCC) or the German KTA safety standards, the so-called EPR technical codes (ETC). On the other side, the European utilities co-operate on a much broader basis for the establishment of European Utilities Requirements (EUR). These requirements are prepared by a group of European utilities that represent the major European electricity generating companies that are determined to keep the nuclear option open. The technical requirements specified in the EUR document define the boundaries in which future plants need to be designed in order to be acceptable for the needs of the utilities and in order to fulfill the basic requirements of competitive power generation costs and licensability in all countries represented in the EUR group. All the new requirements have to be applied by designer and manufacturer. Siemens /SNP act as a designer of a lot of various vessels and tanks, heat exchangers and other items of process

Role of Ontologies for CPS Implementation in Manufacturing

Directory of Open Access Journals (Sweden)

Garetti Marco

2015-12-01

Full Text Available Cyber Physical Systems are an evolution of embedded systems featuring a tight combination of collaborating computational elements that control physical entities. CPSs promise a great potential of innovation in many areas including manufacturing and production. This is because we obtain a very powerful, flexible, modular infrastructure allowing easy (re configurability and fast ramp-up of manufacturing applications by building a manufacturing system with modular mechatronic components (for machining, transportation and storage and embedded intelligence, by integrating them into a system, through a network connection. However, when building such kind of architectures, the way to supply the needed domain knowledge to real manufacturing applications arises as a problem to solve. In fact, a CPS based architecture for manufacturing is made of smart but independent manufacturing components without any knowledge of the role they have to play together in the real world of manufacturing applications. Ontologies can supply such kind of knowledge, playing a very important role in CPS for manufacturing. The paper deals with this intriguing theme, also presenting an implementation of this approach in a research project for the open automation of manufacturing systems, in which the power of CPS is complemented by the support of an ontology of the manufacturing domain.

Selective Laser Melting of Hot Gas Turbine Components: Materials, Design and Manufacturing Aspects

DEFF Research Database (Denmark)

Goutianos, Stergios

2017-01-01

are built additively to nearly net shape. This allows the fabrication of arbitrary complex geometries that cannot be made by conventional manufacturing techniques. However, despite the powerful capabilities of SLM, a number of issues (e.g. part orientation, support structures, internal stresses), have......Selective Laser Melting (SLM) allows the design and manufacturing of novel parts and structures with improved performance e.g. by incorporating complex and more efficient cooling schemes in hot gas turbine parts. In contrast to conventional manufacturing of removing material, with SLM parts...... to be considered in order to manufacture cost-effective and high quality parts at an industrial scale. These issues are discussed in the present work from an engineering point of view with the aim to provide simple quidelines to produce high quality SLM parts....

Virtual Manufacturing Techniques Designed and Applied to Manufacturing Activities in the Manufacturing Integration and Technology Branch

Science.gov (United States)

Shearrow, Charles A.

1999-01-01

One of the identified goals of EM3 is to implement virtual manufacturing by the time the year 2000 has ended. To realize this goal of a true virtual manufacturing enterprise the initial development of a machinability database and the infrastructure must be completed. This will consist of the containment of the existing EM-NET problems and developing machine, tooling, and common materials databases. To integrate the virtual manufacturing enterprise with normal day to day operations the development of a parallel virtual manufacturing machinability database, virtual manufacturing database, virtual manufacturing paradigm, implementation/integration procedure, and testable verification models must be constructed. Common and virtual machinability databases will include the four distinct areas of machine tools, available tooling, common machine tool loads, and a materials database. The machine tools database will include the machine envelope, special machine attachments, tooling capacity, location within NASA-JSC or with a contractor, and availability/scheduling. The tooling database will include available standard tooling, custom in-house tooling, tool properties, and availability. The common materials database will include materials thickness ranges, strengths, types, and their availability. The virtual manufacturing databases will consist of virtual machines and virtual tooling directly related to the common and machinability databases. The items to be completed are the design and construction of the machinability databases, virtual manufacturing paradigm for NASA-JSC, implementation timeline, VNC model of one bridge mill and troubleshoot existing software and hardware problems with EN4NET. The final step of this virtual manufacturing project will be to integrate other production sites into the databases bringing JSC's EM3 into a position of becoming a clearing house for NASA's digital manufacturing needs creating a true virtual manufacturing enterprise.

Implementation of quality assurance in the manufacture of radiation measuring instruments

International Nuclear Information System (INIS)

Erath, W.; Maushart, R.

1993-01-01

Contrary to a general belief, quality assurance in an instrument manufacturing plant comprises considerably more than the testing of instruments and components. Quality assurance programs according to the ISO 9000 standards are part of the general quality policy of a company, comprising management, manufacturing, sales, and service. A description of the quality assurance research and development is given, and the practical execution with regard to calibration of contamination monitors is pointed out in detail. (orig.) [de

Structure and relationships within global manufacturing virtual networks

Directory of Open Access Journals (Sweden)

José Ramón Vilana

2009-04-01

Full Text Available Global Manufacturing Virtual Networks (GMVNs are dynamically changing organizations formed by Original Equipment Manufacturers (OEMs, Contract Manufacturers (CMs, turn-key and component suppliers, R+D centres and distributors. These networks establish a new type of vertical and horizontal relations between independent companies or even competitors where it is not needed to maintain internal manufacturing resources but to manage and share the network resources. The fluid relations that exist within the GMVNs allow them a very permeable organization easy to connect and disconnect from one to each other as well as to choose a set of partners with specific attributes. The result is a highly flexible system characterized by low barriers to entry and exit, geographic flexibility, low costs, rapid technological diffusion, high diversification through contract manufacturers and exceptional economies of scale. Anyhow, there are three major drawbacks in the GMVNs that should be considered at the beginning of this type of collaborations: 1 the risk of contract manufacturers to develop their own end-products in competition with their customers; 2 the technology transfer between competitors OEMs through other members of the GMVN and 3 the lose of process expertise by the OEMs the more they outsource manufacturing processes to the network.

Manufacturing at Nanoscale: Top-Down, Bottom-up and System Engineering

International Nuclear Information System (INIS)

Zhang Xiang; Sun Cheng; Fang, Nicholas

2004-01-01

The current nano-technology revolution is facing several major challenges: to manufacture nanodevices below 20 nm, to fabricate three-dimensional complex nano-structures, and to heterogeneously integrate multiple functionalities. To tackle these grand challenges, the Center for Scalable and Integrated NAno-Manufacturing (SINAM), a NSF Nanoscale Science and Engineering Center, set its goal to establish a new manufacturing paradigm that integrates an array of new nano-manufacturing technologies, including the plasmonic imaging lithography and ultramolding imprint lithography aiming toward critical resolution of 1-10 nm and the hybrid top-down and bottom-up technologies to achieve massively parallel integration of heterogeneous nanoscale components into higher-order structures and devices. Furthermore, SINAM will develop system engineering strategies to scale-up the nano-manufacturing technologies. SINAMs integrated research and education platform will shed light to a broad range of potential applications in computing, telecommunication, photonics, biotechnology, health care, and national security

Justification and manufacturing quality assurance for the use of hot Isostatically pressed, reactor coolant system components in PWR plant

International Nuclear Information System (INIS)

Sulley, J. L.; Hookham, I. D.

2008-01-01

This paper presents an overview of the work undertaken by Rolls-Royce to introduce Hot Isostatically Pressed (HIP) components into Pressurised Water Reactor plant. It presents the work from a design justification and manufacturing quality assurance perspective, rather than from a pure metallurgical perspective, although some metallurgical and mechanical property comparisons with the traditional forged material are presented. Although the HIP process is not new, it was new in its application to Rolls-Royce designed nuclear reactor plant. In order to satisfy the regulatory requirement of 'Proven Engineering Practices' with regard to the introduction of new material processes, and to provide a robust manufacturing substantiation leg of a multi-legged safety case, Rolls-Royce has implemented an evolving, staged approach, starting with HIP bonding of solid valve seats into small bore valve pressure boundaries. This was followed by powder HIP consolidation of leak-limited, thin-walled toroids, and has culminated in the powder HIP consolidation of components, such as steam generator headers, large bore valves and pipe sections. The paper provides an overview of each of these stages and the approach taken with respect to justification. The paper describes the benefits that Rolls-Royce has realised so far through the introduction of HIPed components, and improvements planned for the future. Structural integrity benefits are described, such as improved grain structure, mechanical properties, and ultrasonic inspection. Project-based benefits are also described, such as provision of an alternative strategic sourcing route, cost and lead-time reduction. A full description is provided of key quality assurance steps applied to the process to ensure a high quality product is delivered commensurate with a high integrity nuclear application. 2008 Rolls-Royce plc. (authors)

Manufacturing of large and integral-type steel forgings for nuclear steam supply system components

International Nuclear Information System (INIS)

Kawaguchi, S.; Tsukada, H.; Suzuki, K.; Sato, I.; Onodera, S.

1986-01-01

Forgings for the reactor pressure vessel (RPV) of the pressurized heavy water reactor (PHWR) 700 MWe, which is composed of seven major parts and nozzles totaling about 965 tons, were successfully developed. These forgings are: 1. Flanges: an outside diameter of 8440 mm and a weight of 238 tons max, requiring an ingot of 570 tons. 2. Shells and torus: an outside diameter of about 8000 mm with large height. 3. Cover dome: a diameter of 6800 mm and a thickness of 460 mm, requiring a blank forging before forming of 8000 mm in diameter and 550 m thick. The material designation is 20Mn-Mo-Ni 5 5 (equivalent to SA508, Class 3). In this paper, the manufacturing of and the properties of such large and integral forgings are discussed, including an overview of manufacturing processes for ultralarge-sized forgings over the last two decades

Overview of the Photovoltaic Manufacturing Technology (PVMaT) project

International Nuclear Information System (INIS)

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

1993-08-01

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

Implementation of hierarchical design for manufacture rules in manufacturing processes

OpenAIRE

Parvez, Masud

2008-01-01

In order to shorten the product development cycle time, minimise overall cost and smooth transition into production, early consideration of manufacturing processes is important. Design for Manufacture (DFM) is the practice of designing products with manufacturing issues using an intelligent system, which translates 3D solid models into manufacturable features. Many existing and potential applications, particularly in the field of manufacturing, require various aspects of features technology. ...

Chemistry, manufacturing and controls in passive transdermal drug delivery systems.

Science.gov (United States)

Goswami, Tarun; Audett, Jay

2015-01-01

Transdermal drug delivery systems (TDDS) are used for the delivery of the drugs through the skin into the systemic circulation by applying them to the intact skin. The development of TDDS is a complex and multidisciplinary affair which involves identification of suitable drug, excipients and various other components. There have been numerous problems reported with respect to TDDS quality and performance. These problems can be reduced by appropriately addressing chemistry, manufacturing and controls requirements, which would thereby result in development of robust TDDS product and processes. This article provides recommendations on the chemistry, manufacturing and controls focusing on the unique technical aspects of TDDS.

Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives.

Science.gov (United States)

Gonzalez-Gutierrez, Joamin; Cano, Santiago; Schuschnigg, Stephan; Kukla, Christian; Sapkota, Janak; Holzer, Clemens

2018-05-18

Additive manufacturing (AM) is the fabrication of real three-dimensional objects from metals, ceramics, or plastics by adding material, usually as layers. There are several variants of AM; among them material extrusion (ME) is one of the most versatile and widely used. In MEAM, molten or viscous materials are pushed through an orifice and are selectively deposited as strands to form stacked layers and subsequently a three-dimensional object. The commonly used materials for MEAM are thermoplastic polymers and particulate composites; however, recently innovative formulations of highly-filled polymers (HP) with metals or ceramics have also been made available. MEAM with HP is an indirect process, which uses sacrificial polymeric binders to shape metallic and ceramic components. After removing the binder, the powder particles are fused together in a conventional sintering step. In this review the different types of MEAM techniques and relevant industrial approaches for the fabrication of metallic and ceramic components are described. The composition of certain HP binder systems and powders are presented; the methods of compounding and filament making HP are explained; the stages of shaping, debinding, and sintering are discussed; and finally a comparison of the parts produced via MEAM-HP with those produced via other manufacturing techniques is presented.

Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives

Science.gov (United States)

Cano, Santiago

2018-01-01

Additive manufacturing (AM) is the fabrication of real three-dimensional objects from metals, ceramics, or plastics by adding material, usually as layers. There are several variants of AM; among them material extrusion (ME) is one of the most versatile and widely used. In MEAM, molten or viscous materials are pushed through an orifice and are selectively deposited as strands to form stacked layers and subsequently a three-dimensional object. The commonly used materials for MEAM are thermoplastic polymers and particulate composites; however, recently innovative formulations of highly-filled polymers (HP) with metals or ceramics have also been made available. MEAM with HP is an indirect process, which uses sacrificial polymeric binders to shape metallic and ceramic components. After removing the binder, the powder particles are fused together in a conventional sintering step. In this review the different types of MEAM techniques and relevant industrial approaches for the fabrication of metallic and ceramic components are described. The composition of certain HP binder systems and powders are presented; the methods of compounding and filament making HP are explained; the stages of shaping, debinding, and sintering are discussed; and finally a comparison of the parts produced via MEAM-HP with those produced via other manufacturing techniques is presented. PMID:29783705

Axial strain localization of CuCrZr tubes during manufacturing of ITER-like mono-block W/Cu components using HIP

International Nuclear Information System (INIS)

Zhao, S.X.; Peng, L.J.; Li, Q.; Wang, W.J.; Wei, R.; Qin, S.G.; Shi, Y.L.; Chang, S.P.; Xu, Y.; Liu, G.H.; Wang, T.J.; Luo, G.-N.

2014-01-01

Highlights: • Axial cracking and denting of CuCrZr tubes were observed. • Annealing the as-received tubes can alleviate cracking. • Denting results in the formation bonding flaws at the Cu/CuCrZr interfaces. - Abstract: Two forms of axial strain localization of CuCrZr tubes, i.e., cracking and denting, were observed during the manufacturing of ITER-like mono-block W/Cu components for EAST employing hot isostatic pressing (HIP). Microscopic investigations indicate that the occurrence of axial strain localization correlates to the heavily deformed Cu grains and elongated Cr-rich precipitates as well as highly anisotropic microstructures, which impair the circumferential ductility. Annealing the as-received tubes at 600 °C alleviates cracking due to partial recrystallization of Cu grains. However, the annealed tubes are still sensitive to wall thinning (caused by non-uniform polishing or tube bending), which results in denting. Denting may cause bonding flaws at CuCrZr/Cu interfaces and the underlying mechanisms are discussed. To some extent, denting seems do not affect the high heat flux performance of components. In this paper, we demonstrate that testing only the axial mechanical properties is not enough for manufacturers who use HIP or hot radial pressing technologies, especially for those anisotropic tubes

Development of HT-PEMFC components and stack for CHP unit

Energy Technology Data Exchange (ETDEWEB)

Jensen, Jens Oluf; Li, Q. (Technical Univ. of Denmark, Dept. of Chemistry, Kgs. Lyngby (Denmark)); Terkelsen, C.; Rudbech, H.C.; Steenberg, T. (Danish Power System Aps, Charlottenlund (Denmark)); Thibault de Rycke (IRD Fuel Cell A/S, Svendborg (Denmark))

2009-10-15

The aim of the project has been to further develop components for an all Danish high temperature PEM fuel cells stack for application in combined heat and power units (CHP units). The final product aimed at was a 1.5-2 kW stack for operation at 150-200 deg. C. The project follows the previous PSO project 4760, 'High Temperature PEM Fuel Cell'. The project has addressed the HT-PEM fuel cells form a components point of view and the materials here for. The main areas were polymer and membrane development, electrode and MEA development (MEA = membrane electrode assembly, i.e. the cells.) and stack development. The membrane development begins with the polymer. The polymerization technique was improved significantly in two ways. Better understanding of the process and the critical issues has led to more reproducible results with repeated high molecular weights. The molecular weight is decisive for the membrane strength and durability. The process was also scaled up to 100-200 g polymer pr. batch in a new polymerization facility build during the project. It is dimensioned for larger batches too, but this was not verified during the project. The polymer cannot be purchased in the right quality for fuel cell membranes and it is important that it manufacture is not a limiting factor at the present state. Experiments with other membrane casting techniques were also made. The traditional PBI doped with phosphoric acid is still the state of art membrane for the HT-PEM fuel cells, but progress was also made with modified membranes. Different variants of PBI were synthesized and tested. Electrodes have been manufactured by a spray technique in contrast to the previously applied tape casting. The hand held spray gun previously led to an improvement of the electrodes, but the reproducibility was limited. Subsequently the construction of a semi automated spray machine was started and results like of the best hand sprayed electrodes were obtained. A viable way of MEA rim

Developing a Model Component

Science.gov (United States)

Fields, Christina M.

2013-01-01

The Spaceport Command and Control System (SCCS) Simulation Computer Software Configuration Item (CSCI) is responsible for providing simulations to support test and verification of SCCS hardware and software. The Universal Coolant Transporter System (UCTS) was a Space Shuttle Orbiter support piece of the Ground Servicing Equipment (GSE). The initial purpose of the UCTS was to provide two support services to the Space Shuttle Orbiter immediately after landing at the Shuttle Landing Facility. The UCTS is designed with the capability of servicing future space vehicles; including all Space Station Requirements necessary for the MPLM Modules. The Simulation uses GSE Models to stand in for the actual systems to support testing of SCCS systems during their development. As an intern at Kennedy Space Center (KSC), my assignment was to develop a model component for the UCTS. I was given a fluid component (dryer) to model in Simulink. I completed training for UNIX and Simulink. The dryer is a Catch All replaceable core type filter-dryer. The filter-dryer provides maximum protection for the thermostatic expansion valve and solenoid valve from dirt that may be in the system. The filter-dryer also protects the valves from freezing up. I researched fluid dynamics to understand the function of my component. The filter-dryer was modeled by determining affects it has on the pressure and velocity of the system. I used Bernoulli's Equation to calculate the pressure and velocity differential through the dryer. I created my filter-dryer model in Simulink and wrote the test script to test the component. I completed component testing and captured test data. The finalized model was sent for peer review for any improvements. I participated in Simulation meetings and was involved in the subsystem design process and team collaborations. I gained valuable work experience and insight into a career path as an engineer.

Characterization of CuCrZr and CuCrZr/SS junction strength for different blanket components manufacturing conditions

International Nuclear Information System (INIS)

Gillia, O.; Briottet, L.; Chu, I.; Lemoine, P.; Bucci, P.; Peacock, A.

2007-01-01

Full text of publication follows: This work describes studies on the strength of CuCrZr/SS joint for different manufacturing conditions foreseen for the fabrication of blanket components. In the meantime, as junction strength is expected to be strongly related to CuCrZr property, investigation on the properties of the CuCrZr itself after the different manufacturing conditions is also presented. The initial manufacturing conditions retained were made of a HIP treatment combined with a fast cooling plus a subsequent ageing treatment. For security reasons, the HIP quenching operation was not possible. It is too severe for the HIP vessel. A supplementary solutioning cycle has then been inserted to the heat treatment process just after the HIP-bonding treatment in order to have a sufficient fast cooling of the CuCrZr. The manufacturing conditions thus comprise a HIP cycle (simulated for mono-material samples), a separate solutioning cycle with controlled cooling rate and an ageing treatment. The influence of solutioning temperature has been addressed (1040 deg. C or 980 deg. C) as well as that of the cooling rate after solutioning (70 deg. C/min to water quench), the ageing temperature (480 deg. C or 560 deg. C) and the HIP temperature (1040 deg. C or 980 deg. C). Test results show that the ageing temperature is very important for keeping high strength of material whereas elongation properties are not very sensible to the manufacturing conditions. 1040 deg. C HIP or solutioning temperature gives better strength properties, as well as a higher cooling rate after solutioning. Concerning samples with junctions, it appears that CT test is more selective than other tests since tensile test does not give rupture at joint and KCU test eliminates a route without classifying other routes. A minimum value of J Q for CT test is given, but as confined plasticity requirement is not satisfied for the sample geometry, this value should only be used concomitantly with the same testing

Theorizing about technological development of manufacturing companies

DEFF Research Database (Denmark)

Matthiesen, Rikke Vestergaard

2012-01-01

The aim of the paper is to apply metatriangulation and theory building to strengthen our theorizing on technological development of manufacturing firms. AMT literature is reviewed and by means of bracketing, the paper identifies a set of problematic assumptions embedded within traditional AMT...... research. A case study is used to emphasize how a process perspective enriches the traditional structural perspective. Finally, through first attempts at theory building, a set of propositions is suggested in order to overcome long-standing problems found in AMT research....

Drug development and manufacturing

Science.gov (United States)

Warner, Benjamin P.; McCleskey, T. Mark; Burrell, Anthony K.

2015-10-13

X-ray fluorescence (XRF) spectrometry has been used for detecting binding events and measuring binding selectivities between chemicals and receptors. XRF may also be used for estimating the therapeutic index of a chemical, for estimating the binding selectivity of a chemical versus chemical analogs, for measuring post-translational modifications of proteins, and for drug manufacturing.

Development of Advanced In-Cylinder Components and Tribological Systems for Low Heat Rejection Diesel Engines

Science.gov (United States)

Yonushonis, T. M.; Wiczynski, P. D.; Myers, M. R.; Anderson, D. D.; McDonald, A. C.; Weber, H. G.; Richardson, D. E.; Stafford, R. J.; Naylor, M. G.

1999-01-01

In-cylinder components and tribological system concepts were designed, fabricated and tested at conditions anticipated for a 55% thermal efficiency heavy duty diesel engine for the year 2000 and beyond. A Cummins L10 single cylinder research engine was used to evaluate a spherical joint piston and connecting rod with 19.3 MPa (2800 psi) peak cylinder pressure capability, a thermal fatigue resistant insulated cylinder head, radial combustion seal cylinder liners, a highly compliant steel top compression ring, a variable geometry turbocharger, and a microwave heated particulate trap. Components successfully demonstrated in the final test included spherical joint connecting rod with a fiber reinforced piston, high conformability steel top rings with wear resistant coatings, ceramic exhaust ports with strategic oil cooling and radial combustion seal cylinder liner with cooling jacket transfer fins. A Cummins 6B diesel was used to develop the analytical methods, materials, manufacturing technology and engine components for lighter weight diesel engines without sacrificing performance or durability. A 6B diesel engine was built and tested to calibrate analytical models for the aluminum cylinder head and aluminum block.

THE IMPACT OF GLOBAL COMPETITION ON THE STATE OF MANUFACTURING IN UKRAINE AND DEVELOPED COUNTRIES

Directory of Open Access Journals (Sweden)

Kateryna Shatnenko

2017-11-01

Full Text Available At the end of the 20th century, the economic structure was changed fundamentally in some countries. It was mostly related to the growth of global competition. One of the consequences of this process was the decline in manufacturing production in developed countries and in the post-Soviet countries. The purpose of this article is to define the meaning and consequences of the decline in manufacturing production in developed countries and in post-Soviet countries on the example of Ukraine. Methodology. This study is based on some general theoretical approaches such as analysis and synthesis, induction and deduction, etc. Also, statistical analysis was used for discovering some economic trends. Structural analysis was helpful for examining shifts in economic structure. Correlation between different facts, which is crucial for the understanding of the transformation of manufacturing, was identified by applying the systems approach. The aim of the article is to reveal the impact of global competition on the state of manufacturing and to define the manufacturing development trend. Results of this research showed that the decline in the rate of profit causes the transformation of economic structure. Global competition made the production of some goods in developed countries less profitable due to the relatively high costs. The ability to transfer labour-intensive production to developing countries transformed economic structure in developed countries. It was the reason for a sharp decline in manufacturing production, which caused some economic and social problems. Post-Soviet countries had serious economic and social problems too. Liberalization of trade made these countries face with global competition. This competition revealed extremely weak competitive positions of a great range of products. There was a massive decline in manufacturing production in Ukraine. This study proves that the transformation of manufacturing is far from the end. First of all

The 'Pole Nucleaire Bourgogne' for developing the nuclear components industry

International Nuclear Information System (INIS)

Kottmann, G.

2012-01-01

The 'Pole Nucleaire Bourgogne' (PNB) is a high-technology and heavy industries cluster in Burgundy with an international calling. It aims at innovating, educating and federating in order to place the French nuclear industry in a leading position. PNB gathers 76 small-, and medium-sized enterprises, most of them operating in the metal sector, in design and in the control/measuring sector. The aim of PNB is to make enterprises work and cooperate on specific topics according to their sectors of activities and their skills. PNB has identified 3 domains of strategical innovations: -) ecological manufacturing and durability of heavy components, -) controls for high performance components, and -) maintenance and dismantling techniques in hostile environments. The various industry sectors represented in PNB allows a cross-fertilization between high-tech industries (aeronautics, energy, transportation)

Advanced Manufacturing Technologies

Science.gov (United States)

Fikes, John

2016-01-01

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

Individual, team and organizational antecedents of explorative and exploitative innovation in manufacturing firms

NARCIS (Netherlands)

de Visser, Matthias

2013-01-01

Innovation is crucial for the long-term survival and growth of organizations. Many manufacturing companies face intense pressures to innovate and develop new products that meet customer requirements. A central component of success in new product development is the maintenance of a balance between

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

Energy Technology Data Exchange (ETDEWEB)

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.

The Tore Supra toroidal pump limiter: experience feedback of HHF elements series manufacture

Energy Technology Data Exchange (ETDEWEB)

Cordier, J.J.; Bayetti, P.; Chappuis, P.; Durocher, A.; Escourbiac, F.; Grosman, A.; Lipa, M.; Mitteau, R.; Schlosser, J.; Van Houtte, D

2003-07-01

Since 1992, reliable High Heat Flux PFCs based on copper alloy heat sink structures and a CFC armour, have been developed. The final result is an actively cooled high heat flux element that is capable of removing up to 10 MW.m{sup -2} in stationary operating conditions. About 600 of these high performance individual components have then been manufactured and assembled in order to equip a Toroidal Pump Limiter (TPL). The final deliveries was successfully achieved end of 2001. The paper deals with the experience feedback built-up along the four years duration of the TPL components manufacture. We will show where issues were encountered, how solutions were found to achieve the fabrication of components and will highlight what are the main technical lessons to be learned: acceptance criteria, choice of materials, margins of processes. Finally a proposal of an alternative optimised design is presented, fruit of the experience gained from this up to now, unique series manufacture of actively cooled plasma facing HHF components. We believe that such experience will certainly be of use to ITER as well as to Wendelstein 7-X as far as PFC is concerned. (authors)

Flexural Properties of PLA Components Under Various Test Condition Manufactured by 3D Printer

Science.gov (United States)

Jaya Christiyan, K. G.; Chandrasekhar, U.; Venkateswarlu, K.

2018-06-01

Rapid Prototyping (RP) technologies have emerged as a fabrication method to obtain engineering components in the resent past. Desktop 3D printing, also referred as an additive layer manufacturing technology is a powerful method of RP technique that can fabricate 3 dimensional engineering components. In this method, 3D digital data is converted into real product. In the present investigation, Polylactic Acid (PLA) was considered as a starting material. Flexural strength of PLA material was evaluated using 3-point bend test, as per ASTM D790 standard. Specimens with flat (0°) and vertical (90°) orientation were considered. Moreover, layer thicknesses of 0.2, 0.25, and 0.3 mm were considered. To fabricate these specimens, printing speed of 38 and 52 mm/s was maintained. Nozzle diameter of 0.4 mm with 40 % of infill density were used. Based on the experimental results, it was observed that 0° orientation, 38 mm/s printing speed, and 0.2 mm layer thickness resulted maximum flexural strength, as compared to all other specimens. The improved flexural strength was due to the lower layer thickness (0.2 mm) specimens, as compared with other specimens made of 0.25 and 0.30 mm layer thicknesses. It was concluded that flexural strength properties were greatly influenced by lower the layer thickness, printing speed, and orientation.

Experience in the manufacture of nuclear equipment in India

International Nuclear Information System (INIS)

Challappa, S.; Murthy, G.S.K.; Mehta, S.K.; Kakodkar, A.; Natarajan, A.

1977-01-01

Department of Atomic Energy with its programme for achieving self-sufficiency was involved in engineering, manufacture, inspection, performance testing and quality surveillance of major precision and critical equipment such as reactor vessels, shields, fuelling machines, coolant channel components etc. etc. high pressure equipment for Heavy Water Plants, specialized components for Fuel Complex, major equipment for Cyclotron Project and various research projects. These had to be manufactured at various shops in the country depending upon the availability of machines. The relative importance of various important parameters associated with the manufacture of this equipment were assessed in a separate R and D programme. This has helped in re-designing in some areas to suit the manufacture under Indian conditions. Assessment of any marginal variations that take place during manufacture was also possible because of the availability of data of this kind. Critical components and equipment are tested for their performance under simulated conditions before shipments. B.A.R.C. has contributed immensely in achieving the self-sufficiency and also for designs for future plants

Additively manufactured custom load-bearing implantable devices: grounds for caution

Directory of Open Access Journals (Sweden)

Elisabetta M Zanetti

2017-08-01

Full Text Available Background Additive manufacturing technologies are being enthusiastically adopted by the orthopaedic community since they are providing new perspectives and new possibilities. First applications were finalised for educational purposes, pre-operative planning, and design of surgical guides; recent applications also encompass the production of implantable devices where 3D printing can bring substantial benefits such as customization, optimization, and manufacturing of very complex geometries. The conceptual smoothness of the whole process may lead to the idea that any medical practitioner can use a 3D printer and her/his imagination to design and produce novel products for personal or commercial use. Aims Outlining how the whole process presents more than one critical aspects, still demanding further research in order to allow a safe application of this technology for fully-custom design, in particular confining attention to orthopaedic/orthodontic prostheses defined as components responding mainly to a structural function. Methods Current knowledge of mechanical properties of additively manufactured components has been examined along with reasons why the behaviour of these components might differ from traditionally manufactured components. The structural information still missing for mechanical design is outlined. Results Mechanical properties of additively manufactured components are not completely known, and especially fatigue limit needs to be examined further. Conclusion At the present stage, with reference to load-bearing implants subjected to many loading cycles, the indication of custom-made additively manufactured medical devices should be restricted to the cases with no viable alternative.

Methods of measuring residual stresses in components

International Nuclear Information System (INIS)

Rossini, N.S.; Dassisti, M.; Benyounis, K.Y.; Olabi, A.G.

2012-01-01

Highlights: ► Defining the different methods of measuring residual stresses in manufactured components. ► Comprehensive study on the hole drilling, neutron diffraction and other techniques. ► Evaluating advantage and disadvantage of each method. ► Advising the reader with the appropriate method to use. -- Abstract: Residual stresses occur in many manufactured structures and components. Large number of investigations have been carried out to study this phenomenon and its effect on the mechanical characteristics of these components. Over the years, different methods have been developed to measure residual stress for different types of components in order to obtain reliable assessment. The various specific methods have evolved over several decades and their practical applications have greatly benefited from the development of complementary technologies, notably in material cutting, full-field deformation measurement techniques, numerical methods and computing power. These complementary technologies have stimulated advances not only in measurement accuracy and reliability, but also in range of application; much greater detail in residual stresses measurement is now available. This paper aims to classify the different residual stresses measurement methods and to provide an overview of some of the recent advances in this area to help researchers on selecting their techniques among destructive, semi destructive and non-destructive techniques depends on their application and the availabilities of those techniques. For each method scope, physical limitation, advantages and disadvantages are summarized. In the end this paper indicates some promising directions for future developments.

Mechanical properties of sheet metal components with local reinforcement produced by additive manufacturing

Science.gov (United States)

Ünsal, Ismail; Hama-Saleh, R.; Sviridov, Alexander; Bambach, Markus; Weisheit, A.; Schleifenbaum, J. H.

2018-05-01

New technological challenges like electro-mobility pose an increasing demand for cost-efficient processes for the production of product variants. This demand opens the possibility to combine established die-based manufacturing methods and innovative, dieless technologies like additive manufacturing [1, 2]. In this context, additive manufacturing technologies allow for the weight-efficient local reinforcement of parts before and after forming, enabling manufacturers to produce product variants from series parts [3]. Previous work by the authors shows that the optimal shape of the reinforcing structure can be determined using sizing optimization. Sheet metal parts can then be reinforced using laser metal deposition. The material used is a pearlite-reduced, micro-alloyed steel (ZE 630). The aim of this paper is to determine the effect of the additive manufacturing process on the material behavior and the mechanical properties of the base material and the resulting composite material. The parameters of the AM process are optimized to reach similar material properties in the base material and the build-up volume. A metallographic analysis of the parts is presented, where the additive layers, the base material and also the bonding between the additive layers and the base material are analyzed. The paper shows the feasibility of the approach and details the resulting mechanical properties and performance.

A systematic approach for component-based software development

NARCIS (Netherlands)

Guareis de farias, Cléver; van Sinderen, Marten J.; Ferreira Pires, Luis

2000-01-01

Component-based software development enables the construction of software artefacts by assembling prefabricated, configurable and independently evolving building blocks, called software components. This paper presents an approach for the development of component-based software artefacts. This

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing

Science.gov (United States)

Grady, Joseph E.; Halbig, Michael C.; Singh, Mrityunjay

2015-01-01

In a NASA Aeronautics Research Institute (NARI) sponsored program entitled "A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing", evaluation of emerging materials and additive manufacturing technologies was carried out. These technologies may enable fully non-metallic gas turbine engines in the future. This paper highlights the results of engine system trade studies which were carried out to estimate reduction in engine emissions and fuel burn enabled due to advanced materials and manufacturing processes. A number of key engine components were identified in which advanced materials and additive manufacturing processes would provide the most significant benefits to engine operation. In addition, feasibility of using additive manufacturing technologies to fabricate gas turbine engine components from polymer and ceramic matrix composite were demonstrated. A wide variety of prototype components (inlet guide vanes (IGV), acoustic liners, engine access door) were additively manufactured using high temperature polymer materials. Ceramic matrix composite components included first stage nozzle segments and high pressure turbine nozzle segments for a cooled doublet vane. In addition, IGVs and acoustic liners were tested in simulated engine conditions in test rigs. The test results are reported and discussed in detail.

Lean Manufacturing Auto Cluster at Chennai

Science.gov (United States)

Bhaskaran, E.

2012-10-01

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

An Integrated Environment for Batch Process Development - From Recipe to Manufacture

DEFF Research Database (Denmark)

Batch process development involves the process of converting a chemical synthesis into an optimum, safe, robust, and economical process for manufacturing the chemical of desired quality at the ultimate desired scale. In this paper we describe a strategy for developing a set of integrated decision...

Space storable propulsion components development

Science.gov (United States)

Hagler, R., Jr.

1982-01-01

The current development status of components to control the flow of propellants (liquid fluorine and hydrazine) in a demonstration space storable propulsion system is discussed. The criteria which determined the designs for the pressure regulator, explosive-actuated valves, propellant shutoff valve, latching solenoid-actuated valve and propellant filter are presented. The test philosophy that was followed during component development is outlined. The results from compatibility demonstrations for reusable connectors, flange seals, and CRES/Ti-6Al4V transition tubes and the evaluations of processes for welding (hand-held TIG, automated TIG, and EB), cleaning for fluorine service, and decontamination after fluorine exposure are described.

Potential criticality accident at the General Electric Nuclear Fuel and Component Manufacturing Facility, May 29, 1991

International Nuclear Information System (INIS)

1991-08-01

At the General Electric Nuclear Fuel and Component Manufacturing facility, located near Wilmington, North Carolina, on May 28 and 29, 1991, approximately 150 kilograms of uranium were inadvertently transferred from safe process tanks to an unsafe tank located at the waste treatment facility, thus creating the potential for a localized criticality safety problem. The excess uranium was ultimately safely recovered when the tank contents were centrifuged to remove the uranium-bearing material. Subsequently, the US Nuclear Regulatory Commission dispatched an Incident Investigation Team to determine what happened, to identify probable causes, and to make appropriate findings and conclusions. This report describes the incident, the methodology used by the team in its investigation, and presents the team's findings and conclusions. 48 figs., 8 tabs

Development and validation of resource flexibility measures for manufacturing industry

Directory of Open Access Journals (Sweden)

Gulshan Chauhan

2014-01-01

Full Text Available Purpose: Global competition and ever changing customers demand have made manufacturing organizations to rapidly adjust to complexities, uncertainties, and changes. Therefore, flexibility in manufacturing resources is necessary to respond cost effectively and rapidly to changing production needs and requirements.  Ability of manufacturing resources to dynamically reallocate from one stage of a production process to another in response to shifting bottlenecks is recognized as resource flexibility. This paper aims to develop and validate resource flexibility measures for manufacturing industry that could be used by managers/ practitioners in assessing and improving the status of resource flexibility for the optimum utilization of resources. Design/methodology/approach: The study involves survey carried out in Indian manufacturing industry using a questionnaire to assess the status of various aspects of resource flexibility and their relationships. A questionnaire was specially designed covering various parameters of resource flexibility. Its reliability was checked by finding the value of Cronback alpha (0.8417. Relative weightage of various measures was found out by using Analytical Hierarchy Process (AHP. Pearson’s coefficient of correlation analysis was carried out to find out relationships between various parameters. Findings: From detailed review of literature on resource flexibility, 17 measures of resource flexibility and 47 variables were identified. The questionnaire included questions on all these measures and parameters. ‘Ability of machines to perform diverse set of operations’ and ability of workers to work on different machines’ emerged to be important measures with contributing weightage of 20.19% and 17.58% respectively.  All the measures were found to be significantly correlated with overall resource flexibility except ‘training of workers’, as shown by Pearson’s coefficient of correlation. This indicates that

Technical cost modelling for a novel semi-solid metal (SSM) casting processes for automotive component manufacturing

CSIR Research Space (South Africa)

Tlale, NS

2008-09-01

Full Text Available . It has been well established that over 70% of the total development cost of a product and its manufacturing process is decided during the design phase, although this phase accounts for less than 7% of the total costs. It is thus important to be able...

Water-Based Coating Simplifies Circuit Board Manufacturing

Science.gov (United States)

2008-01-01

The Structures and Materials Division at Glenn Research Center is devoted to developing advanced, high-temperature materials and processes for future aerospace propulsion and power generation systems. The Polymers Branch falls under this division, and it is involved in the development of high-performance materials, including polymers for high-temperature polymer matrix composites; nanocomposites for both high- and low-temperature applications; durable aerogels; purification and functionalization of carbon nanotubes and their use in composites; computational modeling of materials and biological systems and processes; and developing polymer-derived molecular sensors. Essentially, this branch creates high-performance materials to reduce the weight and boost performance of components for space missions and aircraft engine components. Under the leadership of chemical engineer, Dr. Michael Meador, the Polymers Branch boasts world-class laboratories, composite manufacturing facilities, testing stations, and some of the best scientists in the field.

Development of a virtual metrology for high-mix TFT-LCD manufacturing processes

International Nuclear Information System (INIS)

Chen Shan; Pan Tianhong; Jang Shishang

2010-01-01

Nowadays, TFT-LCD manufacturing has become a very complex process, in which many different products being manufactured with many different tools. The ability to predict the quality of product in such a high-mix system is critical to developing and maintaining a high yield. In this paper, a statistical method is proposed for building a virtual metrology model from a number of products using a high-mix manufacturing process. Stepwise regression is used to select 'key variables' that really affect the quality of the products. Multivariate analysis of covariance is also proposed for simultaneously applying the selected variables and product effect. This framework provides a systematic method of building a processing quality prediction system for a high-mix manufacturing process. The experimental results show that the proposed quality prognostic system can not only estimate the critical dimension accurately but also detect potentially faulty glasses.

Thermoplastic Composites Reinforced with Textile Grids: Development of a Manufacturing Chain and Experimental Characterisation

Science.gov (United States)

Böhm, R.; Hufnagl, E.; Kupfer, R.; Engler, T.; Hausding, J.; Cherif, C.; Hufenbach, W.

2013-12-01

A significant improvement in the properties of plastic components can be achieved by introducing flexible multiaxial textile grids as reinforcement. This reinforcing concept is based on the layerwise bonding of biaxially or multiaxially oriented, completely stretched filaments of high-performance fibers, e.g. glass or carbon, and thermoplastic components, using modified warp knitting techniques. Such pre-consolidated grid-like textiles are particularly suitable for use in injection moulding, since the grid geometry is very robust with respect to flow pressure and temperature on the one hand and possesses an adjustable spacing to enable a complete filling of the mould cavity on the other hand. The development of pre-consolidated textile grids and their further processing into composites form the basis for providing tailored parts with a large number of additional integrated functions like fibrous sensors or electroconductive fibres. Composites reinforced in that way allow new product groups for promising lightweight structures to be opened up in future. The article describes the manufacturing process of this new composite class and their variability regarding reinforcement and function integration. An experimentally based study of the mechanical properties is performed. For this purpose, quasi-static and highly dynamic tensile tests have been carried out as well as impact penetration experiments. The reinforcing potential of the multiaxial grids is demonstrated by means of evaluating drop tower experiments on automotive components. It has been shown that the load-adapted reinforcement enables a significant local or global improvement of the properties of plastic components depending on industrial requirements.

Component-based development of software language engineering tools