Search NASA⌕ Search

SEARCH · Search NASA

Results for “design and process development”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

A Boresight Adjusment Mechanism For Use in Laser Altimeters

This paper describes the development of the Boresight Adjustment Mechanism (BAM) for the Geoscience Laser Altimeter System (GLAS) Instrument. The BAM was developed late in the integration and test phase of the GLAS instrument flight program. Thermal vacuum tests of the GLAS instrument indicated that the instrument-boresight alignment stability over temperature may be marginal. To reduce the risk that GLAS may not be able to meet the boresight alignment requirements an intensive effort was started to develop a BAM. Observatory-level testing and further evaluation of the boresight alignment data indicated that sufficient margin could be obtained utilizing existing instrument resources and therefore the BAM was never integrated onto the GLAS Instrument. However, the BAM was designed fabricated and fully qualified over a 4 month timeframe to be capable of precisely steering (less than 2 arcsec over plus or minus 300 arcsec) the output of three independent lasers to ensure the alignment between the transmit and receive paths of the GLAS instrument. The short timeline for the development of the mechanism resulted in several interesting design solutions. This paper discusses the requirement definition design, and testing processes of the BAM development effort how the design was affected by the extremely tight development schedule and the lessons learned throughout the process.

Hakun, Claef↗
NASA NTRS2004

A Boresight Adjustment Mechanism for use on Laser Altimeters

This paper describes the development of the Boresight Adjustment Mechanism (BAM) for the Geoscience Laser Altimeter System (GLAS) Instrument. The BAM was developed late in the integration and test phase of the GLAS instrument flight program. Thermal vacuum tests of the GLAS instrument indicated that the instrument boresight alignment stability over temperature may be marginal. To reduce the risk that GLAS may not be able to meet the boresight alignment requirements, an intensive effort was started to develop a BAM. Observatory-level testing and further evaluation of the boresight alignment data indicated that sufficient margin could be obtained utilizing existing instrument resources and therefore the BAM was never integrated onto the GLAS Instrument. However, the BAM was designed fabricated and fully qualified over a 4 month timeframe to be capable of precisely steering (< 1 arcsec over 300 arcsec) the output of three independent lasers to ensure the alignment between the transmit and receive paths of the GLAS instrument. The short timeline for the development of the mechanism resulted in several interesting design solutions. This paper discusses the requirement definition, design, and testing processes of the BAM development effort, how the design was affected by the extremely tight development schedule, and the lessons learned throughout the process.

Hakun, Claef↗
NASA NTRS1992

An expert system for integrated structural analysis and design optimization for aerospace structures

The results of a research study on the development of an expert system for integrated structural analysis and design optimization is presented. An Object Representation Language (ORL) was developed first in conjunction with a rule-based system. This ORL/AI shell was then used to develop expert systems to provide assistance with a variety of structural analysis and design optimization tasks, in conjunction with procedural modules for finite element structural analysis and design optimization. The main goal of the research study was to provide expertise, judgment, and reasoning capabilities in the aerospace structural design process. This will allow engineers performing structural analysis and design, even without extensive experience in the field, to develop error-free, efficient and reliable structural designs very rapidly and cost-effectively. This would not only improve the productivity of design engineers and analysts, but also significantly reduce time to completion of structural design. An extensive literature survey in the field of structural analysis, design optimization, artificial intelligence, and database management systems and their application to the structural design process was first performed. A feasibility study was then performed, and the architecture and the conceptual design for the integrated 'intelligent' structural analysis and design optimization software was then developed. An Object Representation Language (ORL), in conjunction with a rule-based system, was then developed using C++. Such an approach would improve the expressiveness for knowledge representation (especially for structural analysis and design applications), provide ability to build very large and practical expert systems, and provide an efficient way for storing knowledge. Functional specifications for the expert systems were then developed. The ORL/AI shell was then used to develop a variety of modules of expert systems for a variety of modeling, finite element analysis, and design optimization tasks in the integrated aerospace structural design process. These expert systems were developed to work in conjunction with procedural finite element structural analysis and design optimization modules (developed in-house at SAT, Inc.). The complete software, AutoDesign, so developed, can be used for integrated 'intelligent' structural analysis and design optimization. The software was beta-tested at a variety of companies, used by a range of engineers with different levels of background and expertise. Based on the feedback obtained by such users, conclusions were developed and are provided.

Source record↗
DOE OSTI2025

Modular System for Direct Conversion of Methane into Methanol via Photocatalysis

In this project, the Recipient’s objective is to develop a liquid phase photocatalytic process for direct conversion of methane into methanol. The specific objectives are to: Develop a bifunctional catalyst using a semiconductor photocatalyst architecture to facilitate methane activation to directly convert methane into methanol. Develop a scalable reactor design to maximize mass transfer and methanol selectivity using an optimized photocatalyst. Develop a conceptual process design for a modular system for flare gas utilization. Conduct comprehensive techno-economic and commercial market assessments to position the technology for commercialization.

03 NATURAL GAS↗
NASA NTRS1981

A Module Experimental Process System Development Unit (MEPSDU)

Design work for a photovoltaic module, fabricated using single crystal silicon dendritic web sheet material, resulted in the identification of surface treatment to the module glass superstrate which improved module efficiencies. A final solar module environmental test, a simulated hailstone impact test, was conducted on full size module superstrates to verify that the module's tempered glass superstrate can withstand specified hailstone impacts near the corners and edges of the module. Process sequence design work on the metallization process selective, liquid dopant investigation, dry processing, and antireflective/photoresist application technique tasks, and optimum thickness for Ti/Pd are discussed. A noncontact cleaning method for raw web cleaning was identified and antireflective and photoresist coatings for the dendritic webs were selected. The design of a cell string conveyor, an interconnect feed system, rolling ultrasonic spot bonding heat, and the identification of the optimal commercially available programmable control system are also discussed. An economic analysis to assess cost goals of the process sequence is also given.

Source record↗
NASA NTRS2006

Managing Analysis Models in the Design Process

Design of large, complex space systems depends on significant model-based support for exploration of the design space. Integrated models predict system performance in mission-relevant terms given design descriptions and multiple physics-based numerical models. Both the design activities and the modeling activities warrant explicit process definitions and active process management to protect the project from excessive risk. Software and systems engineering processes have been formalized and similar formal process activities are under development for design engineering and integrated modeling. JPL is establishing a modeling process to define development and application of such system-level models.

design↗
DOE OSTI2026

Extremized nonlinear and linearized responses in soft metamaterials enabled by gradient-based design and grayscale digital light processing

In this study, we develop a gradient-based design approach that exploits grayscale digital light processing (DLP) 3D printing for extremizing the nonlinear and linearized response of soft metamaterials — materials that harness engineered geometric instabilities to undergo large and programmable changes in configuration. Grayscale DLP approaches modulate local mechanical properties at the pixel scale by tuning the light intensity within a single grayscale image, unlocking an exceptionally large design space. To effectively navigate this space, we develop smooth mappings between local light intensity values and global quantities of interest that characterize the behavior of soft metamaterials. Enabling these smooth mappings are robust and differentiable nonlinear finite element simulations powered by a trust region solver. A PDE-constrained optimization problem is then solved to invert these mappings and produce light intensity distributions that endow the printed part with varying stiffness and flexibility in distinctive regions. It is shown that optimizing the distribution of soft and stiff phases throughout a metamaterial structure results in markedly different buckling and self-contact configurations to drive extremized nonlinear compression and linearized vibration responses. Optimized light intensity distributions are translated to grayscale images and directly used to print soft metamaterial samples, showing remarkable agreement between the buckling and self-contact response in simulated and measured deformed configurations.

Additive manufacturing↗
NASA NTRS2015

Application of Additively Manufactured Components in Rocket Engine Turbopumps

The use of additive manufacturing technology has the potential to revolutionize the development of turbopump components in liquid rocket engines. When designing turbomachinery with the additive process there are several benefits and risks that are leveraged relative to a traditional development cycle. This topic explores the details and development of a 90,000 RPM Liquid Hydrogen Turbopump from which 90% of the parts were derived from the additive process. This turbopump was designed, developed and will be tested later this year at Marshall Space Flight Center.

Calvert, Marty, Jr.↗
NASA NTRS1980

Silicon web process development

A barrier crucible design which consistently maintains melt stability over long periods of time was successfully tested and used in long growth runs. The pellet feeder for melt replenishment was operated continuously for growth runs of up to 17 hours. The liquid level sensor comprising a laser/sensor system was operated, performed well, and meets the requirements for maintaining liquid level height during growth and melt replenishment. An automated feedback loop connecting the feed mechanism and the liquid level sensing system was designed and constructed and operated successfully for 3.5 hours demonstrating the feasibility of semi-automated dendritic web growth. The sensitivity of the cost of sheet, to variations in capital equipment cost and recycling dendrites was calculated and it was shown that these factors have relatively little impact on sheet cost. Dendrites from web which had gone all the way through the solar cell fabrication process, when melted and grown into web, produce crystals which show no degradation in cell efficiency. Material quality remains high and cells made from web grown at the start, during, and the end of a run from a replenished melt show comparable efficiencies.

Duncan, C. S.↗
NASA NTRS2018

Aeronautics Autonomy Testbed Capability (AATC) Team Developed Concepts

In 2015, the National Aeronautics and Space Administration (NASA) formed a multi-center, interdisciplinary team of engineers from three different aeronautics research centers who were tasked with improving NASA autonomy research capabilities. This group was subsequently named the Aeronautics Autonomy Testbed Capability (AATC) team. To aid in confronting the autonomy research directive, NASA contracted IDEO, a design firm, to provide consultants and guides to educate NASA engineers through the practice of design thinking, which is an unconventional method for aerospace design processes. The team then began learning about autonomy research challenges by conducting interviews with a diverse group of researchers and pilots, military personnel and civilians, experts and amateurs. Part of this design thinking process involved developing ideas for products or programs known as concepts that could enable real world fulfillment of the most important latent needs identified through analysis of the interviews. The concepts are intended to be sacrificial, intermediate steps in the design thinking process and are presented in this report to record the efforts of the AATC group. Descriptions are provided in present tense to allow for further ideation and imagining the concept as reality as was attempted during the teams discussions and interviews. This does not indicate that the concepts are actually in practice within NASA though there may be similar existing programs independent of AATC. These concepts were primarily created at two distinct stages during the design thinking process. After the initial interviews, there was a workshop for concept development and the resulting ideas are shown in this work as from the First Round. As part of succeeding interviews, the team members presented the First Round concepts to refine the understanding of existing research needs. This knowledge was then used to generate an additional set of concepts denoted as the Second Round. Some concepts were created by a single person in a few minutes while others were refined by the entire team over several weeks. Thus, certain ideas are more detailed than others but those from the second round are not necessarily more comprehensive than the first round concepts. Primarily, as reported here in the Second Round section, the designs serve to encompass more of the high level end user research needs which were not necessarily known to the team during the prior workshop. In the figures provided throughout this report, illustrations are often provided to represent a concept. Nearly all of the images are informal sketches or renderings and this casualness should, hopefully, not be held to negate the potential insights available within the concepts.

Smith, Phillip J.↗
NASA NTRS1984

General Electric composite ring-disk flywheel: Recent and potential developments

Recent developments of the General Electric hybrid rotor design are described. The relation of the hybrid rotor design to flywheel designs that are especially suitable for spacecraft applications is discussed. Potential performance gains that can be achieved in such rotor designs by applying latest developments in materials, processing, and design methodology are projected. Indications are that substantial improvements can be obtained.

Coppa, A. P.↗
NASA NTRS2019

Development of an Additively Manufactured Capacitive Humidity Sensor for the International Space Station

The ability to measure humidity on the International Space Station and other long-duration spaceflight missions is a crucial part of the onboard systems. For example, the Environmental Control and Life Support System (ECLSS) needs to know the amount of humidity in the air to make decisions about whether it should spend power to run the dehumidifier systems to attempt to reclaim that water. Other issues can arise if the humidity reaches too high of levels and condensation builds up on electrical components. With that in mind, it is vital that the spacecraft keeps spare sensors on board or has the ability to manufacture new sensors on demand. An additively manufactured sensor would be additionally beneficial because it would save space onboard that would normally be taken up by spares, save money from costly resupply missions, and allow the sensor to be constantly updated with the most effective design. This Technical Memorandum outlines a development process carried out to design, manufacture, and test an additively manufactured humidity sensor.

Chang, K. T.↗
NASA NTRS2020

Design and Implementation of a Scenario Development Process for a 2040 Trajectory-Based Operations Simulation

The National Aeronautics and Space Administration (NASA) is supporting research to transition from a legacy, air traffic management (ATM) system to Trajectory-Based Operations (TBO) environment targeting the 2035-2045 timeframe by creating simulation scenarios for current and future studies. TBO in the National Airspace System (NAS) focuses on modernizing the current operating paradigm to increase efficiency, predictability, resilience, and flexibility while migrating toward greater operational autonomy across the airspace. These simulation scenarios offer a wide dissemination and use of system-level constraints and aircraft state/intent data, routine use of data communications to request complex trajectory modifications and to receive clearances, and aircraft that are flying on 4-D trajectories with flexibility when desired, but structure where required. This report describes the end-to-end development of scenarios for the NASA Langley Research Center simulation environment to represent a 2040 Trajectory-Based Operations airspace for air transport operations research.

Trajectory-Based Operations↗
DOE OSTI2022

Design and analysis of a ten-turbine floating wind farm with shared mooring lines

This paper discusses the development and analysis of a novel design for a 10-turbine floating wind farm with shared mooring lines. Shared mooring lines tether adjacent floating platforms together, reducing the number of anchors required but increasing system complexity. We present a systematic, multistage design process for shared mooring systems, involving linearized analysis of array layout options, quasi-static mooring line optimization, and design refinement based on coupled dynamic loads analysis. The design developed from this process is thought to represent one of the most advantageous shared-mooring configurations for this scale of floating wind array. It features perpendicular anchor line pairs and allows shared, multiline anchors, making it an example of a shared-mooring-and-anchor array. Comparing the performance and cost characteristics of the shared-mooring design with more conventional three-line individual mooring systems shows equivalent dynamic response characteristics and stationkeeping system cost savings of 25% when using shared mooring lines and shared anchors. The design is also advantageous in the case of a mooring line failure, with offsets and redundancy characteristics similar to four-line individual mooring systems.

17 WIND ENERGY↗
NASA NTRS2019

Aircraft Conceptual Structural Design Using the AMMIT Structural Analysis Tool

Aircraft conceptual structural design is the process of developing and refining an idea for an aircraft into a feasible structural design. The process typically involves multiple evaluations of a single configuration and can require designers to examine thousands of concepts. Standard approaches to conducting structural analyses in this phase are either based on the use of historical or empirical data or often require significant expertise in structural analysis to perform these rapid assessments. The AMMIT structural analysis tool includes structural line models and handbook methods wrapped in a simple to use interface that can enable rapid, physics-based structural designs without requiring extensive structural expertise. The objectives of the present paper are to introduce AMMIT, describe the methods used in AMMIT, and present the results of the validation effort. Validation of the AMMIT methodology was performed on nine aircraft to determine the accuracy of the methods, highlight features of AMMIT, and guide future development of the methodology. Results of the validation effort indicated that AMMIT provides a prediction of primary structural weight for each aircraft with an acceptable level of error during the preliminary design phase with a minimal expenditure of computational resources.

Horvath, Bryce L.↗
NASA NTRS2000

Modeling of Solid Waste Processing Options in BIO-Plex

BIO-Plex is a ground-based test bed currently under development by NASA for testing technologies and practices that may be utilized in future long-term life support missions. All aspects of such an Advanced Life Support (ALS) System must be considered to confidently construct a reliable system, which will not only allow the crew to survive in harsh environments, but allow the crew time to perform meaningful research. Effective handling of solid wastes is a critical aspect of the system, especially when recovery of resources contained in the waste is required. This is particularly important for ALS Systems configurations that include a Biomass Production Chamber. In these cases, significant amounts of inedible biomass waste may be produced, which can ultimately serve as a repository of necessary resources for sustaining life, notably carbon, water, and plant nutrients. Numerous biological and physicochemical solid waste processing options have been considered. Biological options include composting, aerobic digestion, and anaerobic digestion. Physicochemical options include pyrolysis, SCWO (supercritical water oxidation), various incineration configurations, microwave incineration, magnetically assisted gasification, and low temperature plasma reaction. Modeling of these options is a necessary step to assist in the design process. A previously developed top-level model of BIO-Plex implemented in MATLAB Simulink (r) for the use of systems analysis and design has been adopted for this analysis. Presently, this model only considered incineration for solid waste processing. Present work, reported here, includes the expansion of this model to include a wider array of solid waste processing options selected from the above options, bearing in mind potential, near term solid waste treatment systems. Furthermore, a trade study has also been performed among these solid waste processing technologies in an effort to determine the ideal technology for long-term life support missions.

Rodriguez, Luis F.↗
NASA NTRS1983

Development and fabrication of a high current, fast recovery power diode

A high voltage (VR = 1200 V), high current (IF = 150 A), fast recovery ( 700 ns) and low forward voltage drop ( 1.5 V) silicon rectifier was designed and the process developed for its fabrication. For maximum purity, uniformity and material characteristic stability, neutron transmutation n-type doped float zone silicon is used. The design features a hexagonal chip for maximum area utilization of space available in the DO-8 diode package, PIN diffused junction structure with deep diffused D(+) anode and a shallow high concentration n(+) cathode. With the high temperature glass passivated positive bevel mesa junction termination, the achieved blocking voltage is close to the theoretical limit of the starting material. Gold diffusion is used to control the lifetime and the resulting effect on switching speed and forward voltage tradeoff. For solder reflow assembly, trimetal (Al-Ti-Ni) contacts are used. The required major device electrical characteristics were achieved. Due to the tradeoff nature of forward voltage drop and reverse recovery time, a compromise was reached for these values.

Berman, A. H.↗