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At least 181 records · Page 10

Snow Reconciles Observed and Simulated Phase Partitioning and Increases Cloud Feedback

The surprising increase of Earth's climate sensitivity in the most recent coupled model intercomparison project (CMIP) models has been largely attributed to extratropical cloud feedback, which is thought to be driven by greater supercooled water in present-day cloud phase partitioning (CPP). Here, we report that accounting for precipitation in the Goddard Institute for Space Studies ModelE3 radiation scheme, neglected in more than 60% of CMIP6 and 90% of CMIP5 models, systematically changes its apparent CPP and substantially increases its cloud feedback, consistent with results using CMIP models. Including precipitation in the comparison with cloud–aerosol lidar and infrared pathfinder satellite observations (CALIPSO) measurements and in model radiation schemes is essential to faithfully constrain cloud amount and phase partitioning, and simulate cloud feedbacks. Our findings suggest that making radiation schemes precipitation-aware (missing in most CMIP6 models) should strengthen their positive cloud feedback and further increase their already high mean climate sensitivity.

54 ENVIRONMENTAL SCIENCES↗

Subsetted model output for aerosol-related variables from a LASSO-CACTI WRF simulation

Aerosol-related model output from a Weather Research and Forecasting (WRF) simulation from the Large-Eddy Simulation (LES) Atmospheric Radiation Measurement (ARM) Symbiotic Simulation and Observation (LASSO) deep-convection scenario for the Cloud, Aerosol, and Complex Terrain Interactions (CACTI) field campaign. The LASSO-CACTI simulations span grid spacings from 7.5 km to 100 m through the use of four nested domains, labeled d1 through d4. The simulations are of convection near the Sierras de Córdoba mountain range, roughly centered on the ARM Mobile Facility. More information can be found at https://www.arm.gov/capabilities/modeling/lasso. This version of the output is a collection of variables subsetted from the raw WRF output to reduce the file overhead for users not needing the full raw dataset. The subset files are in netCDF format with the height-based variables on the raw, model eta levels. The aerosol properties are consistent with the Thompson aerosol-aware cloud microphysics scheme where the simulated aerosol are proxies for representative “water friendly” and “ice friendly” aerosol.

54 ENVIRONMENTAL SCIENCES↗

BIOME: A scientific data archive search-and-order system using browser-aware, dynamic pages

The Oak Ridge National Laboratory's (ORNL) Distributed Active Archive Center (DAAC) is a data archive and distribution center for the National Air and Space Administration's (NASA) Earth Observing System Data and Information System (EOSDIS). Both the Earth Observing System (EOS) and EOSDIS are components of NASA's contribution to the US Global Change Research Program through its Mission to Planet Earth Program. The ORNL DAAC provides access to data used in ecological and environmental research such as global change, global warming, and terrestrial ecology. Because of its large and diverse data holdings, the challenge for the ORNL DAAC is to help users find data of interest from the hundreds of thousands of files available at the DAAC without overwhelming them. Therefore, the ORNL DAAC has developed the Biogeochemical Information Ordering Management Environment (BIOME), a customized search and order system for the World Wide Web (WWW). BIOME is a public system located at http://www-eosdis. ornl.gov/BIOME/biome.html.

CLIMATIC CHANGE↗

Communication Research in Aviation and Space Operations: Symptoms and Strategies of Crew Coordination

The day-to-day operators of today's aerospace systems work under increasing pressures to accomplish more with less. They work in operational systems which are complex, technology-based, and high-risk; in which incidents and accidents have far-reaching and costly consequences. For these and other reasons, there is concern that the safety net formerly built upon redundant systems and abundant resources may become overburdened. Although we know that human ingenuity can overcome incredible odds, human nature can also fail in unpredictable ways. Over the last 20 years, a large percentage of aviation accidents and incidents have been attributed to human errors rather than hardware or environmental factors alone. A class of errors have been identified which are not due to a lack of individual, technical competencies. Rather, they are due to the failure of teams to utilize readily available resources or information in a timely fashion. These insights began a training revolution in the aviation industry called Cockpit Resource Management, which later became known as Crew Resource Management (CRM) as its concepts and applications extended to teams beyond the flightdeck. Then, as now, communication has been a cornerstone in CRM training since crew coordination and resource management largely resides within information transfer processes--both within flightcrews, and between flightcrews and the ground operations teams that support them. The research I will describe takes its roots in CRM history as we began to study communication processes in order to discover symptoms of crew coordination problems, as well as strategies of effective crew management. On the one hand, communication is often the means or the tool by which team members manage their resources, solve problems, maintain situational awareness and procedural discipline. Conversely, it is the lack of planning and resource management, loss of vigilance and situational awareness, and non-standard communications that are implicated in accidents and incidents. NASA/Ames Crew Factors researchers have been developing a model of effective crew coordination in order to understand the sources of performance breakdowns, and to develop effective solutions and interventions. Because communication is a primary mechanism by which information is received and transmitted, and because it is observable behavior, we focus on these group processes in order to identify patterns of communication that distinguish effective from less effective crew performance. Since a prime objective is to develop training recommendations for enhancing communication skills, we interpret our findings in the context of relevant task and environmental conditions, role and procedural constraints, and the normal real-time parameters of flight operations. Another research objective is to consider how communication and coordination can be enhanced through design. For example, flight deck and hardware design as well as procedural and software design may greatly influence the efficiency with which crews communicate and coordinate their work. In addition, teams and tasks may be designed, organized, and trained so that team interactions with each other are based upon appropriately shared knowledge, procedures and situation awareness. In short, we are interested in enhancing communication practices through (1) the training of specific communication skills, and (2) the design of equipment, tasks, procedures, and teams that optimize smooth, unambiguous communication processes. Two examples of communication research will be described; one in aviation and one in space operations. The first example is a high-fidelity full mission simulation study which investigates the affect of flightdeck automation on crew coordination and communication (contrasting crew performance in the DC-9 vs. MD88). Additional information is contained in the original extended abstract.

Kanki, Barbara G.↗

Overcoming the Technical Challenges of Coordinating Distributed Load Resources at Scale (Final Report)

Significant recent research has investigated the potential for loads to provide balancing services to the grid. However, this research has not addressed key issues that may arise when such schemes are applied at scale including: 1. Distribution Network Issues. Coordination of large numbers of loads could result in power flows that violate distribution network constraints; 2. Stability Issues. Certain strategies to control loads can exhibit nonlinearity in the form of period-adding bifurcations and chaos. Other control strategies can potentially synchronize the behavior of large numbers of loads. In both cases, the outcome can be power oscillations and instability; 3. Communication Network Issues. Bidirectional low-latency communication channels between a central controller (or several distributed controllers) and each resource are expensive and likely not necessary for effective coordination. Our research questions were: What network, stability, and communication issues might arise in practice when we coordinate large aggregations of loads? How can we coordinate loads to achieve performance objectives in a cost effective manner while avoiding these issues? The ultimate technical goal of the project was the development of network-aware, communication-constrained, non-disruptive load control strategies with stability guarantees that achieve the performance requirements of typical balancing services at a sufficiently low cost to enable the load aggregator and customer to profit. The overall goal was to establish credibility for load control at scale and contribute to U.S. energy security and environmental goals. The team succeeded in answering these research questions and developing these control strategies. The overall approach was based on the development of three testing environments: a simulation testbed, an experimental testbed (20 physical model houses with window-box air conditioners) coupled with the simulation testbed, and a field testbed (100 actual homes in Austin, TX) coupled with the simulation testbed, which enabled controller testing, identification of issues, controller development, and controller validation. The resulting controller was used to demonstrate fast timescale grid balancing (frequency regulation) by aggregations of physical and virtual air conditioners, with sufficient quality to participate in the electricity market. Cost benefit analysis showed overall benefits to the participating households, load aggregators, and the grid, especially if the control technology was integrated directly into existing programmable communicating thermostats. The project provides a variety of wider benefits. Our technology transfer and outreach activities lead us to choose an open-source licensing commercialization pathway, enabling the project results to be available to researchers, industry, and the public. Furthermore, new grid balancing technologies will increase grid flexibility and will enable higher penetrations of intermittent renewable energy resources, such as wind and solar, to be connected to the grid, reducing its environmental impact, and mitigating climate change to the benefit of society.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Technology 2000, volume 2

Technology 2000 was the first major industrial conference and exposition spotlighting NASA technology and technology transfer. It's purpose was, and continues to be, to increase awareness of existing NASA-developed technologies that are available for immediate use in the development of new products and processes, and to lay the groundwork for the effective utilization of emerging technologies. Included are sessions on: computer technology and software engineering; human factors engineering and life sciences; materials science; sensors and measurement technology; artificial intelligence; environmental technology; optics and communications; and superconductivity.

Source record↗

Calibration approach and range of observed sap flow influences transpiration estimates from thermal dissipation sensors

Calibrating thermal dissipation (TD) sap flow sensors has become increasingly important to accurately estimate whole-tree transpiration, but it is unclear how the calibration approach itself influences the resulting coefficients and estimates. Here, we compare the two most common calibration approaches, gravimetric and potometric, using TD sensors inserted into Eucalyptus benthamii tree stems. The gravimetric approach uses an excised stem segment devoid of branches and leaves and pushes water through the stem using gravity, a positive force. The potometric approach uses a severed stem containing an intact canopy placed upright in a reservoir where water is pulled through the stem via transpiration, a negative force. We hypothesized that the positive pressure associated with gravimetric calibration would overestimate conductive sapwood area relative to that estimated from potometric calibration and that coefficients from these different approaches would result in different estimates of transpiration when applied to intact trees. We also predicted that calibrations could improve transpiration estimates by targeting the range of observed sap flow rates (i.e., K values) in intact trees. Conductive sapwood area was higher under gravimetric calibrations and resulting estimates of transpiration were lower compared to potometric calibrations. Segmented calibration curves, which fit two separate curves for the relationship between sap flux density (Fd) and sap flux index (K) based on the range of sap flow rates observed in intact trees, increased transpiration estimates from both gravimetric and potometric coefficients and diminished the magnitude of difference in transpiration estimates between approaches. Researchers should be aware that calibration approach and range of observed sap flow profoundly influences transpiration estimates from TD sensors and this likely applies to calibrations of other heat-based sap flow sensors.

54 ENVIRONMENTAL SCIENCES↗

Influence of Nanoconfinement and Elevated Temperatures on Geocolloid-Facilitated Transport of Energy related Contaminants

Fossil fuels obtained using hydraulic fracturing and nuclear energy are deemed crucial for meeting the current and future energy demands of the United States. The utilization of these resources, especially fossil fuels from hydraulic fracturing, has increased rapidly within the last decade. However, with the increasing levels of hydraulic fracturing activities, the occurrence and fate of chemicals used in these processes in the geosystem, as well as the potential consequences of their interactions with environment and geosystems (e.g. mineral-based geocolloids and geosurfaces), have been increasingly recognized as issues warranting consideration owing to the toxic nature of these chemicals. Scientific results originated from this project has brought better understandings on how such contaminants can preferentially or adversely interact with geosystems and how geocolloids can facilitate their transport by realistically mimicking geological conditions and environments in the laboratory level for the first time. Based on such knowledge, it may eventually lead to the development of mitigation strategies for reducing and minimizing the transport and wide distribution of contaminants and pollutants. This aspect is important for the society to ensure that energy-related contaminants do not find their way to waterbodies that are used as drinking water or irrigation. The project is also anticipated to increase public awareness about potential adverse effects of energy systems on the geosphere and environment and may motivate society to consider better mitigation strategies to prevent such occurrences.

(Nano)Confinement↗

Synthetic Vision Displays for Planetary and Lunar Lander Vehicles

Aviation research has demonstrated that Synthetic Vision (SV) technology can substantially enhance situation awareness, reduce pilot workload, improve aviation safety, and promote flight path control precision. SV, and related flight deck technologies are currently being extended for application in planetary exploration vehicles. SV, in particular, holds significant potential for many planetary missions since the SV presentation provides a computer-generated view for the flight crew of the terrain and other significant environmental characteristics independent of the outside visibility conditions, window locations, or vehicle attributes. SV allows unconstrained control of the computer-generated scene lighting, terrain coloring, and virtual camera angles which may provide invaluable visual cues to pilots/astronauts, not available from other vision technologies. In addition, important vehicle state information may be conformally displayed on the view such as forward and down velocities, altitude, and fuel remaining to enhance trajectory control and vehicle system status. The paper accompanies a conference demonstration that introduced a prototype NASA Synthetic Vision system for lunar lander spacecraft. The paper will describe technical challenges and potential solutions to SV applications for the lunar landing mission, including the requirements for high-resolution lunar terrain maps, accurate positioning and orientation, and lunar cockpit display concepts to support projected mission challenges.

Arthur, Jarvis J., III↗

Cultural Resource Management Plan for Brookhaven National Laboratory

The Cultural Resource Management Plan (CRMP) for Brookhaven National Laboratory (BNL) provides an organized guide that describes or references the facets and interrelationships of cultural resources at BNL. Management strategies included within this CRMP are designed to adequately identify the cultural resources that BNL and DOE consider significant and to acknowledge associated management actions. A principal objective of the CRMP is to reduce the need for additional regulatory documents and to serve as the basis for a formal agreement between the DOE and the New York State Historic Preservation Officer (NYSHPO). The BNL CRMP is designed to be a “living document.” Each section includes identified gaps in the management plan, with proposed goals and actions for addressing each gap. The plan will be periodically revised to incorporate new documentation. The current (2023) update incorporates new findings and/or updated text based on completed or ongoing projects related to cultural resources at BNL since inception of the last updated CRMP in 2013. Historically, Brookhaven National Laboratory had little need for cultural resource management because many of its buildings were less than 50 years old. Most of the features that are potentially eligible for inclusion in the National Register of Historic Places were protected simply by avoiding the features. Compliance with cultural resource laws and regulations has included archeological surveys, such as those associated with the 1977 Final Environmental Impact Statement for Brookhaven National Laboratory and the 1978 Final Environmental Impact Statement for the Proton-Proton Storage Accelerator Facility (ISABELLE). In 1979, World War I trenches associated with the former Camp Upton and located near ISABELLE were determined to be eligible for inclusion in the National Register of Historic Places; however, many of these trenches had been destroyed by construction work. In 1991, the NYSHPO provided BNL with a letter indicating that only three structures and features were likely to be eligible for inclusion in the National Register of Historic Places. Between 1991 and 1999, little work associated with cultural resource management was accomplished. Beginning in 1999, awareness for the need of a program to manage cultural resources grew out of the realization that over half of the buildings at BNL were either 50 years old or were reaching that age and were, therefore, subject to the requirements in Section 106 of the National Historic Preservation Act. This fact, concomitant with the decontamination and decommissioning of the Brookhaven Graphite Research Reactor (BGRR) and the subsequent determination of BGRR’s eligibility for listing as an historical site, fueled the need for developing and implementing a more structured program for managing cultural resources at BNL.

54 ENVIRONMENTAL SCIENCES↗

FAIR to WISE (F2W) v1.0.0

FAIR to WISE (F2W) is an iterative, large-language model (LLM) driven pipeline that turns unstructured research PDFs into structured, queryable knowledge graphs (KGs). Core features include schema-driven extraction to a LinkML model; full provenance capture; ontology-grounded enrichment (e.g., chemical validation and ChEBI lookup); graph construction to JSON-LD with stable IDs; and KG-RAG question answering with evidence-aware retrieval. The system is engineered for reproducibility and accessibility (open-source Ollama models, temperature=0, NVTX/Nsight profiling) with robust QA (relation verification, deduplication, and deterministic outputs). Primary uses are literature-to-KG automation, knowledge-grounded Q&A, and experimental steering support. We demonstrate the approach in organic photovoltaics, where the pipeline ingests papers, builds a domain KG, and evaluates answers against expert competency questions to guide experimental planning and interpretation. Compared with off-the-shelf LLMs and ad-hoc NLP tools, F2W addresses ontology gaps and reduces hallucination risk by grounding responses in extracted evidence and enforcing schema constraints; it also offers deterministic, provenance-linked outputs and open, cost-aware deployment. Evidence-aware ranking further improves answer quality over pure vector search.

Abramov, David [Lawrence Berkeley National Laborat↗

Polar Cloud Microphysics and Surface Energy Budget from AWARE (Final Technical Report)

This was a collaborative project between the Scripps Institution of Oceanography at the University of California San Diego (SIO), Byrd Polar and Climate Research Center at The Ohio State University (BPCRC), The Department of Meteorology and Atmospheric Science at The Pennsylvania State University (Penn State), and Brookhaven National Laboratory (BNL). The project’s over-arching objectives involved maximizing the scientific potential of the ARM West Antarctic Radiation Experiment (AWARE) data set, in two respects: (1) application of polar-optimized climate models to test the most current and comprehensive cloud microphysical parameterizations; and (2) analysis of the most advanced ARM Mobile Facility sensors (e.g., cloud radar, spectroradiometer, and aerosol observing system data) to advance understanding of Antarctic cloud microphysical and radiative properties, particularly on a climatological basis with emphasis on contrasts with the high Arctic. The team’s efforts have resulted in 16 peer-review publications, in addition to an overview of the AWARE campaign in the Bulletin of the American Meteorological Society. Our emphasis throughout this program was to go beyond the traditional “case study” approach to model evaluation, in which a “classical” or otherwise well-characterized surface-atmosphere-cloud system of short duration is simulated by several climate models. Instead, we attempted analysis of longer time series in the AWARE data, both climatologically and with models. We have numerous successful results from both AWARE locations: The main AMF-2 deployment at McMurdo Station on Ross Island (13 months duration), and the extended facility at the West Antarctic Ice Sheet (WAIS) Divide Ice Camp (40 days during austral summer 2015-16).

54 ENVIRONMENTAL SCIENCES↗

An overview of the evolving jurisdictional scope of the U.S. Clean Water Act for hydrologists

Abstract The Clean Water Act (CWA) is the primary federal mechanism by which the physical, chemical, and biological integrity of streams, lakes, and wetlands are protected in the United States. The CWA has evolved considerably since its initial passage in 1948, including explicit expansions and contractions of jurisdictional scope through a series of legislative actions, court decisions, and agency rules. Here, we provide a practical summary of the CWA's evolution, detailing the major updates or revisions and their circumstances. Additionally, we identify the jurisdictional scope of the law for rivers and streams, lakes, and wetlands based on the language used and implementation by the agencies during the same time period. While the rulemaking process commonly uses language that will be abstract to many hydrologists, understanding the on‐the‐ground implications, quantifying regulatory (un)certainties, and assessing the magnitude of changes through time is important to understanding the implications of environmental regulation development, litigation, and enforcement. Thus, we translate the enforcement norms and definitions into quantitative estimates for Clean Water Act scope in the Wabash River Basin (Illinois, Indiana, and Ohio, USA) as a demonstration of the spatial consequences of changing regulatory language. This article is categorized under: Engineering Water > Planning Water Human Water > Water Governance Water and Life > Conservation, Management, and Awareness

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Uncertainty-Guided Prediction Horizon of Phase-Resolved Ocean Wave Forecasting Under Data Sparsity: Experimental and Numerical Evaluation

Accurate short-term wave forecasting is critical for the safe and efficient operation of marine structures that rely on real-time, phase-resolved ocean wave information for control and monitoring purposes (e.g., digital twins). These systems often depend on environmental sensors (e.g., waverider buoys, wave-sensing LIDAR). Challenges arise when upstream sensor data are missing, sparse, or phase-shifted due to drift. This study investigates the performance of two machine learning models, time-series dense encoder (TiDE) and long short-term memory (LSTM), for forecasting phase-resolved ocean surface elevations under varying degrees of data degradation. We introduce the τ-trimming algorithm, which adapts the prediction horizon based on uncertainty thresholds derived from historical forecasts. Numerical wave tank (NWT) and wave basin experiments are used to benchmark model performance under short- and long-term data masking, spatially coarse sensor grids, and upstream phase shifts. Results show under a 50% probability of upstream data loss, the τ-trimmed TiDE model achieves a 46% reduction in error at the most upstream target, compared to 22% for LSTM. Furthermore, phase misalignment in upstream data introduces a near-linear increase in forecast error. Under moderate model settings, a ±3 s misalignment increases the mean absolute error by approximately 0.5 m, while the same error is accumulated at ±4 s using the more conservative approach. These findings inform the design of resilient, uncertainty-aware wave forecasting systems suited for realistic offshore sensing environments.

42 ENGINEERING↗

Region and cloud regime dependence of parametric sensitivity in E3SM atmosphere model

Abstract The Department of Energy (DOE)’s Energy Exascale Earth System Model (E3SM), including its atmosphere model (EAM), has many relatively new features. In a previous study we conducted a systematic parametric sensitivity analysis for EAM based on short, perturbed parameter ensemble (PPE) simulations, mainly focusing on global mean climate features and metrics. While parameter values in global climate models are generally invariant in space and time, model response to parameters perturbation may vary by regions and climate regimes, which motivates the need to better understand the EAM model behaviors and physics at regional scale and process level. In this study, using the same set of PPE simulations and a similar sensitivity analysis framework, we identify parameters that cause largest sensitivities over different regions and compare model responses in fast atmospheric processes to the parameters across different cloud regimes for several important cloud-related fidelity metrics. We find that cloud forcing has opposite response to some parameters over mid-latitude vs. tropical land. We also analyze how the parametric sensitivity varies as stratocumulus transitions to shallow convection and to deep convection over ocean. Low cloud forcing and shortwave cloud forcing in the subtropical eastern Pacific are most sensitive to the parameters controlling the width of the probability density function (PDF) of the subgrid vertical velocity ( w’ ) ( gamma ) and the damping of the w’ skewness ( c8 ) near the coast but become more sensitive to the parameter affecting the damping of the w’ variance ( c1 ) further offshore. Detailed interpretation of the spatial dependence of parametric sensitivity is provided. We also investigate how the parametric sensitivity evolves with prediction duration. This study improves our process-level understanding of cloud physics and parameterization and provides insights for developing more advanced regime-aware parameterization schemes in global climate model.

54 ENVIRONMENTAL SCIENCES↗

An Investigation of LES Wall Modeling for Rayleigh–Bénard Convection via Interpretable and Physics-Aware Feedforward Neural Networks with DNS

Abstract The traditional approach of using the Monin–Obukhov similarity theory (MOST) to model near-surface processes in large-eddy simulations (LESs) can lead to significant errors in natural convection. In this study, we propose an alternative approach based on feedforward neural networks (FNNs) trained on output from direct numerical simulation (DNS). To evaluate the performance, we conduct both a priori and a posteriori tests. In the a priori (offline) tests, we compare the statistics of the surface shear stress and heat flux, computed from filtered DNS input variables, to the stress and flux obtained from the filtered DNS. Additionally, we investigate the importance of various input features using the Shapley additive explanations value and the conditional average of the filter grid cells. In the a posteriori (online) tests, we implement the trained models in the System for Atmospheric Modeling (SAM) LES and compare the LES-generated surface shear stress and heat flux with those in the DNS. Our findings reveal that vertical velocity, a traditionally overlooked flow quantity, is one of the most important input features for determining the wall fluxes. Increasing the number of input features improves the a priori test results but does not always improve the model performance in the a posteriori tests because of the differences in input variables between the LES and DNS. Last, we show that physics-aware FNN models trained with logarithmic and scaled parameters can well extrapolate to more intense convection scenarios than in the training dataset, whereas those trained with primitive flow quantities cannot. Significance Statement The traditional near-surface turbulence model, based on a shear-dominated boundary layer flow, does not represent near-surface turbulence in natural convection. Using a feedforward neural network (FNN), we can construct a more accurate model that better represents the near-surface turbulence in various flows and reveals previously overlooked controlling factors and process interactions. Our study shows that the FNN-generated models outperform the traditional model and highlight the importance of the near-surface vertical velocity. Furthermore, the physics-aware FNN models exhibit the potential to extrapolate to convective flows of various intensities beyond the range of the training dataset, suggesting their broader applicability for more accurate modeling of near-surface turbulence.

54 ENVIRONMENTAL SCIENCES↗

Facilitating International Collaboration on Climate Change Research

The Chinese American Oceanic and Atmospheric Association (COAA) organized the 8th COAA International Conference on Atmosphere, Ocean, and Climate Change (ICAOCC), which was held at the Nanjing University of Information Science and Technology (NUIST) campus in Nanjing, China during July 10-12, 2019. The conference was locally hosted by NUIST and co-sponsored by Nanjing University. This international conference provided a platform for weather and climate experts in the international oceanic and atmospheric sciences community to communicate their research, share ideas and experiences, inspire new research strategies and identify opportunities for future collaborations. It also provided a great opportunity for students and young scholars to forge professional relationships and be more aware of cutting-edge research areas through their interactions with experts and senior professionals.

54 ENVIRONMENTAL SCIENCES↗

A manufacturing database of advanced materials used in spacecraft structures

Cost savings opportunities over the life cycle of a product are highest in the early exploratory phase when different design alternatives are evaluated not only for their performance characteristics but also their methods of fabrication which really control the ultimate manufacturing costs of the product. In the past, Design-To-Cost methodologies for spacecraft design concentrated on the sizing and weight issues more than anything else at the early so-called 'Vehicle Level' (Ref: DOD/NASA Advanced Composites Design Guide). Given the impact of manufacturing cost, the objective of this study is to identify the principal cost drivers for each materials technology and propose a quantitative approach to incorporating these cost drivers into the family of optimization tools used by the Vehicle Analysis Branch of NASA LaRC to assess various conceptual vehicle designs. The advanced materials being considered include aluminum-lithium alloys, thermoplastic graphite-polyether etherketone composites, graphite-bismaleimide composites, graphite- polyimide composites, and carbon-carbon composites. Two conventional materials are added to the study to serve as baseline materials against which the other materials are compared. These two conventional materials are aircraft aluminum alloys series 2000 and series 7000, and graphite-epoxy composites T-300/934. The following information is available in the database. For each material type, the mechanical, physical, thermal, and environmental properties are first listed. Next the principal manufacturing processes are described. Whenever possible, guidelines for optimum processing conditions for specific applications are provided. Finally, six categories of cost drivers are discussed. They include, design features affecting processing, tooling, materials, fabrication, joining/assembly, and quality assurance issues. It should be emphasized that this database is not an exhaustive database. Its primary use is to make the vehicle designer aware of some of the most important aspects of manufacturing associated with his/her choice of the structural materials. The other objective of this study is to propose a quantitative method to determine a Manufacturing Complexity Factor (MCF) for each material being contemplated. This MCF is derived on the basis of the six cost drivers mentioned above plus a Technology Readiness Factor which is very closely related to the Technology Readiness Level (TRL) as defined in the Access To Space final report. Short of any manufacturing information, our MCF is equivalent to the inverse of TRL. As more manufacturing information is available, our MCF is a better representation (than TRL) of the fabrication processes involved. The most likely application for MCF is in cost modeling for trade studies. On-going work is being pursued to expand the potential applications of MCF.

Bao, Han P.↗