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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 181 records · Page 10

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NASA NTRS1986

Flat-plate solar array project. Volume 3: Silicon sheet: Wafers and ribbons

The primary objective of the Silicon Sheet Task of the Flat-Plate Solar Array (FSA) Project was the development of one or more low cost technologies for producing silicon sheet suitable for processing into cost-competitive solar cells. Silicon sheet refers to high purity crystalline silicon of size and thickness for fabrication into solar cells. Areas covered in the project were ingot growth and casting, wafering, ribbon growth, and other sheet technologies. The task made and fostered significant improvements in silicon sheet including processing of both ingot and ribbon technologies. An additional important outcome was the vastly improved understanding of the characteristics associated with high quality sheet, and the control of the parameters required for higher efficiency solar cells. Although significant sheet cost reductions were made, the technology advancements required to meet the task cost goals were not achieved.

Briglio, A.↗

NASA NTRS2014

High-Speed On-Board Data Processing for Science Instruments

A new development of on-board data processing platform has been in progress at NASA Langley Research Center since April, 2012, and the overall review of such work is presented in this paper. The project is called High-Speed On-Board Data Processing for Science Instruments (HOPS) and focuses on a high-speed scalable data processing platform for three particular National Research Council's Decadal Survey missions such as Active Sensing of CO2 Emissions over Nights, Days, and Seasons (ASCENDS), Aerosol-Cloud-Ecosystems (ACE), and Doppler Aerosol Wind Lidar (DAWN) 3-D Winds. HOPS utilizes advanced general purpose computing with Field Programmable Gate Array (FPGA) based algorithm implementation techniques. The significance of HOPS is to enable high speed on-board data processing for current and future science missions with its reconfigurable and scalable data processing platform. A single HOPS processing board is expected to provide approximately 66 times faster data processing speed for ASCENDS, more than 70% reduction in both power and weight, and about two orders of cost reduction compared to the state-of-the-art (SOA) on-board data processing system. Such benchmark predictions are based on the data when HOPS was originally proposed in August, 2011. The details of these improvement measures are also presented. The two facets of HOPS development are identifying the most computationally intensive algorithm segments of each mission and implementing them in a FPGA-based data processing board. A general introduction of such facets is also the purpose of this paper.

Beyon, Jeffrey Y.↗

DOE OSTI2025

Low Cost High-Performance HRE-Free 3-in-1 Electric Drive Unit

The project team completed work to expand upon American Axle & Manufacturing’s (AAM) baseline technology and develop a high-speed, AC induction electric drive unit (EDU) with total direct-oil-cooling and integrated power electronics. The project accelerated advancements in EDU technology by allowing AAM to build upon the progress made in developing the underlying baseline technologies. The following seven improvements to AAM’s baseline technology were implemented in this research and development program: 1) Increased speed (30k RPM) AC induction motor, 2) Silver-sintering of discrete silicon carbide (SiC) metal-oxide-semiconductor field-effect transistors (MOSFET) to heat sinks, 3) Electrically insulated rotor bars, 4) Optimized lamination steel, 5) EDU-integrated 650VDC inverter package, 6) Over-molded stator with molded liners, and 7) 650VDC power-dense stator design. The successful development of the technology resulted in a meaningful cost reduction for EDU systems in the market. Coupled with falling battery system costs, lower EDU costs will likely accelerate the market acceptance and related production scaling of battery electric vehicles. The objective of this project was to research, develop, and test a Heavy Rare Earth (HRE)-free 3-In-1 electric drive unit (EDU) that has class leading power density and cost. The key technologies to be developed were anticipated to meet or exceed the Department of Energy (DOE) targets of a cost ≤ $\$$7/kilowatt (kW), power density ≥ 12 kW/liter, and operating voltage ≥ 600 VDC.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS1981

The small community solar thermal power experiment. Parabolic dish technology for industrial process heat application

Aspects of incorporating a thermal energy transport system (ETS) into a field of parabolic dish collectors for industrial process heat (IPH) applications were investigated. Specific objectives are to: (1) verify the mathematical optimization of pipe diameters and insulation thicknesses calculated by a computer code; (2) verify the cost model for pipe network costs using conventional pipe network construction; (3) develop a design and the associated production costs for incorporating risers and downcomers on a low cost concentrator (LCC); (4) investigate the cost reduction of using unconventional pipe construction technology. The pipe network design and costs for a particular IPH application, specifically solar thermally enhanced oil recovery (STEOR) are analyzed. The application involves the hybrid operation of a solar powered steam generator in conjunction with a steam generator using fossil fuels to generate STEOR steam for wells. It is concluded that the STEOR application provides a baseline pipe network geometry used for optimization studies of pipe diameter and insulation thickness, and for development of comparative cost data, and operating parameters for the design of riser/downcomer modifications to the low cost concentrator.

Polzien, R. E.↗

NASA NTRS2015

Iodine Propulsion Advantages for Low Cost Mission Applications and the Iodine Satellite (ISAT) Technology Demonstration

The NASA Marshall Space Flight Center Science and Technology Office is continuously exploring technology options to increase performance or reduce cost and risk to future NASA missions including science and exploration. Electric propulsion is a prevalent technology known to reduce mission costs by reduction in launch costs and spacecraft mass through increased post launch propulsion performance. The exploration of alternative propellants for electric propulsion continues to be of interest to the community. Iodine testing has demonstrated comparable performance to xenon. However, iodine has a higher storage density resulting in higher ΔV capability for volume constrained systems. Iodine's unique properties also allow for unpressurized storage yet sublimation with minimal power requirements to produce required gas flow rates. These characteristics make iodine an ideal propellant for secondary spacecraft. A range of mission have been evaluated with a focus on low-cost applications. Results highlight the potential for significant cost reduction over state of the art. Based on the potential, NASA has been developing the iodine Satellite for a near-term iodine Hall propulsion technology demonstration. Mission applications and progress of the iodine Satellite project are presented.

Dankanich, John W.↗

NASA NTRS2022

Approaches To Humans-Mars Both Safe and Affordable

The fundamental differences regarding the Moon vs. Mars for humans include far longer missions and greater resources required for Mars. In humans-Mars planning, thus far the extant technologies and approaches have not enabled missions which are both fully safe/healthy for humans and affordable. Cost reductions are required to afford health and safety and to reduce their costs. This report suggests and examines a wide spectrum of approaches to improve the affordability of humans-Mars approaches to ensure human safety and health during long distance space exploration and pioneering-on-the-way to colonization with humans-Mars as the exemplar

Dennis M. Bushnell↗

NASA NTRS1981

Advanced materials and fabrication processes for supersonic cruise aircraft

Research and development programs to develop high-strength aluminum alloys and low-cost materials and fabrication techniques for titanium alloys are being conducted. Thirteen aluminum alloy compositions are being evaluated. A section of a production component was fabricated using superplastic forming and diffusion bonding (SPF/DB) and fabrication studies are being conducted on three low temperature forming beta titanium alloys. Cost studies indicate substantial structural cost reduction potentials resulting from the use of both aluminum alloys and low-cost titanium fabrication techniques. Lowest overall costs are indicated for a composite/aluminum or composite titanium structure.

Guess, M. K.↗

NASA NTRS1982

Estimating acreage by double sampling using LANDSAT data

Double sampling techniques employing LANDSAT data for estimating the acreage of corn and soybeans was investigated and evaluated. The evaluation was based on estimated costs and correlations between two existing procedures having differing cost/variance characteristics, and included consideration of their individual merits when coupled with a fictional 'perfect' procedure of zero bias and variance. Two features of the analysis are: (1) the simultaneous estimation of two or more crops; and (2) the imposition of linear cost constraints among two or more types of resource. A reasonably realistic operational scenario was postulated. The costs were estimated from current experience with the measurement procedures involved, and the correlations were estimated from a set of 39 LACIE-type sample segments located in the U.S. Corn Belt. For a fixed variance of the estimate, double sampling with the two existing LANDSAT measurement procedures can result in a 25% or 50% cost reduction. Double sampling which included the fictional perfect procedure results in a more cost effective combination when it is used with the lower cost/higher variance representative of the existing procedures.

Pont, F.↗

NASA NTRS1983

New approaches to planetary exploration - Spacecraft and information systems design

Approaches are recommended for use by the NASA Solar System Exploration Committee (SSEC) in lowering the costs of planetary missions. The inclusion of off-the-shelf hardware, i.e., configurations currently in use for earth orbits and constructed on a nearly assembly-line basis, is suggested. Alterations would be necessary for the thermal control, power supply, telecommunications equipment, and attitude sensing in order to be serviceable as a planetary observer spacecraft. New technology can be developed only when cost reduction for the entire mission would be realized. The employment of lower-cost boost motors, or even integrated boost motors, for the transfer out of earth orbit is indicated, as is the development of instruments that do not redundantly gather the same data as previous planetary missions. Missions under consideration include a Mars geoscience climatology Orbiter, a lunar geoscience Orbiter, a near-earth asteroid rendezvous, a Mars aeronomy Orbiter, and a Venus atmospheric probe.

Diaz, A. V.↗

DOE OSTI2024

Screening aqueous organic redox couples for spontaneous hydrogen generation on catalysts

Two low-cost redox couples with near neutral or alkaline pH - 7,8-dihydroxyphenazine-2-sulfonic acid (DHPS) and chrome chelated ethylenediaminetetraacetic acid (Cr-EDTA) with ammonia – are identified to generate hydrogen evolution spontaneously on Pt/C catalysts. Cr-EDTA redox couple has two times higher hydrogen evolution rate than that of DHPS, and the charged Cr-EDTA molecules are fully utilized to generate hydrogen gas, while ~ 50% of DHPS molecules are utilized to produce hydrogen spontaneously on Pt/C catalysts. The Cr-EDTA electrolyte enables cost reduction by allowing cheap raw material of Cr and corrosion resistant alloy instead of costly superalloy for catalytic reactor systems. Furthermore, the Cr-EDTA with ammonia as a negolyte for flow batteries was validated to suppress hydrogen evolution side reaction, reach 99% of coulombic efficiency in flow cell operation paired with Fe(CN)6 redox couple near neutral pH.

08 HYDROGEN↗

NASA NTRS1982

Cost estimates for flat plate and concentrator collector arrays

The current module and installation costs for the U.S. National Photovoltaic Program's grid-connected systems are significantly higher than required for economic viability of this alternative. Attention is accordingly given to the prospects for installed module cost reductions in flat plate, linear focus Fresnel concentrator, and point focus Fresnel concentrator candidate systems. Cost projections indicate that all three systems would meet near-term and midterm goals, provided that module costs of $2.80/W(p) and $0.70/W(p), respectively, are met. The point focus Fresnel system emerges as the most viable for the near term.

Shimada, K.↗

NASA NTRS1998

Simple Automatic File Exchange (SAFE) to Support Low-Cost Spacecraft Operation via the Internet

Various issues associated with Simple Automatic File Exchange (SAFE) are presented in viewgraph form. Specific topics include: 1) Packet telemetry, Internet IP networks and cost reduction; 2) Basic functions and technical features of SAFE; 3) Project goals, including low-cost satellite transmission to data centers to be distributed via an Internet; 4) Operations with a replicated file protocol; 5) File exchange operation; 6) Ground stations as gateways; 7) Lessons learned from demonstrations and tests with SAFE; and 8) Feedback and future initiatives.

Baker, Paul↗

NASA NTRS1991

Designing for Cost

Designing for cost is a state of mind. Of course, a lot of technical knowledge is required and the use of appropriate tools will improve the process. Unfortunately, the extensive use of weight based cost estimating relationships has generated a perception in the aerospace community that the primary way to reduce cost is to reduce weight. Wrong! Based upon an approximation of an industry accepted formula, the PRICE H (tm) production-production equation, Dean demonstrated theoretically that the optimal trajectory for cost reduction is predominantly in the direction of system complexity reduction, not system weight reduction. Thus the phrase "keep it simple" is a primary state of mind required for reducing cost throughout the design process.

Dean, Edwin B.↗

NASA NTRS2012

Update on Multi-Variable Parametric Cost Models for Ground and Space Telescopes

Parametric cost models can be used by designers and project managers to perform relative cost comparisons between major architectural cost drivers and allow high-level design trades; enable cost-benefit analysis for technology development investment; and, provide a basis for estimating total project cost between related concepts. This paper reports on recent revisions and improvements to our ground telescope cost model and refinements of our understanding of space telescope cost models. One interesting observation is that while space telescopes are 50X to 100X more expensive than ground telescopes, their respective scaling relationships are similar. Another interesting speculation is that the role of technology development may be different between ground and space telescopes. For ground telescopes, the data indicates that technology development tends to reduce cost by approximately 50% every 20 years. But for space telescopes, there appears to be no such cost reduction because we do not tend to re-fly similar systems. Thus, instead of reducing cost, 20 years of technology development may be required to enable a doubling of space telescope capability. Other findings include: mass should not be used to estimate cost; spacecraft and science instrument costs account for approximately 50% of total mission cost; and, integration and testing accounts for only about 10% of total mission cost.

Stahl, H. Philip↗

DOE OSTI2025

ROTA-CAP™: An Intensified Carbon Capture System Using Rotating Packed Beds (Final Scientific/Technical Report)

GTI Energy and Carbon Clean Solutions Limited successfully designed, constructed, and operated an integrated ROTA-CAP carbon capture skid. ROTA-CAP™ is a process intensification technology, applied for post-combustion carbon capture, which utilizes the centrifugal forces generated from rotation of rotating packed beds as well as advanced solvents to achieve increased mass transfer rates 1-2 orders of magnitude higher than conventional columns while substantially decreasing footprint. The test skid, which consisted of a dual stage RPB absorber with external interstage cooling and a single stage RPB regenerator, was operated at capacities up to 0.5 tonne/day of CO 2 capture with flue gas concentrations ranging from 4% to 22% CO 2 by vol. CO 2 removal rates greater than 95% were achieved, with CO 2 product purity also exceeding 95% by vol. Over 1,600 hours of operation were accumulated throughout the project, including over 1,000 hours of operation of the with real flue gas containing at least 9.8% CO 2 by vol. The skid was operated continuously for 24 hours per day and 7 days per week over the course of 7 long-term test campaigns, with the campaigns ranging from approximately 2-4 weeks per campaign. A techno-economic analysis was performed, and a cost of capture of $\$$41.18/tonne CO 2 was calculated for the ROTA-CAP process, compared to $\$$45.75/tonne for a Cansolv-based process. These results show a cost reduction of approximately 10% compared to the Cansolv-based process. Although this still exceeds the target cost of capture of $\$$30/tonne specified for this project, GTI expects that the cost of capture can be further reduced through further optimization of the design and technology. GTI also performed an engineering design review to determine the scale-up potential of the technology, with the results of the preliminary assessment indicating that it appears to be feasible to scale up the RPB technology to 4,000 TPD. It was also determined that both horizontal and vertical rotor orientations are feasible, though there are mechanical advantages to the vertical orientation.

20 FOSSIL-FUELED POWER PLANTS↗

NASA NTRS1999

Subsurface Microsensors for Assisted Recertification of TPS (SmarTPS)

Commercialization of a competitive reusable launch vehicle (RLV) is a primary goal for both NASA and the U.S. aerospace industry. To expedite achievement of this goal, the Bantam-X Technology Program is funding development of innovative technologies to lower costs for access to space. Ground operations is one area where significant cost reduction is required. For the Shuttle fleet, ground operations account for over 80% of the life cycle costs, and TPS recertification accounts for 27% of the operation costs ($4.5M per flight). Bantam Task TPS-7, Subsurface Microsensors for Assisted Recertification of TPS (SmarTPS), is a joint effort between NASA centers and industry partners to develop rapid remote detection and scanning technology for inspection of TPS and detection of subsurface defects. This short paper will provide a general overview of the SmarTPS concept.

Pallix, Joan B.↗

NASA NTRS1973

Space program payload costs and their possible reduction

The possible ways by which NASA payload costs might be reduced in the future were studied. The major historical reasons for payload costs being as they were, and if there are technologies (hard and soft), or criteria for technology advances, that could significantly reduce total costs of payloads were examined. Payload costs are placed in historical context. Some historical cost breakdowns for unmanned NASA payloads are presented to suggest where future cost reductions could be most significant. Space programs of NOAA, DoD and COMSAT are then examined to ascertain if payload reductions have been brought about by the operational (as opposed to developmental) nature of such programs, economies of scale, the ability to rely on previously developed technology, or by differing management structures and attitudes. The potential impact was investigated of NASA aircraft-type management on spacecraft program costs, and some examples relating previous costs associated with aircraft costs on the one hand and manned and unmanned costs on the other are included.

Vanvleck, E. M.↗

DOE OSTI2024

Adaptive Framework for Maintenance Scheduling Based on Dynamic Preventive Intervals and Remaining Useful Life Estimation

Data-based prognostic methods exploit sensor data to forecast the remaining useful life (RUL) of industrial settings to optimize the scheduling of maintenance actions. However, implementing sensors may not be cost-effective or practical for all components. Traditional preventive approaches are not based on sensor data; however, they schedule maintenance at equally spaced intervals, which is not a cost-effective approach since the distribution of the time between failures changes with the degradation state of other parts or changes in working conditions. This study introduces a novel framework comprising two maintenance scheduling strategies. In the absence of sensor data, we propose a novel dynamic preventive policy that adjusts intervention intervals based on the most recent failure data. When sensor data are available, a method for RUL prediction, designated k-LSTM-GFT, is enhanced to dynamically account for RUL prediction uncertainty. The results demonstrate that dynamic preventive maintenance can yield cost reductions of up to 51.8% compared to conventional approaches. The predictive approach optimizes the exploitation of RUL, achieving costs that are only 3–5% higher than the minimum cost achievable while ensuring the safety of critical systems since all of the failures are avoided.

Nunes, Pedro (ORCID:0000000180012172)↗