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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS1971

Technology for low cost solid rocket boosters.

A review of low cost large solid rocket motors developed at the Lewis Research Center is given. An estimate is made of the total cost reduction obtainable by incorporating this new technology package into the rocket motor design. The propellant, case material, insulation, nozzle ablatives, and thrust vector control are discussed. The effect of the new technology on motor cost is calculated for a typical expandable 260-in. booster application. Included in the cost analysis is the influence of motor performance variations due to specific impulse and weight changes. It is found for this application that motor costs may be reduced by up to 30% and that the economic attractiveness of future large solid rocket motors will be improved when the new technology is implemented.

Ciepluch, C.↗
NASA NTRS1974

Low-cost, air mass 2 solar simulator

A low cost air mass 2 solar simulator for testing flat-plate solar collectors was developed and operated at Lewis. Total cost was less than $10,800/sq m ($1000/sq ft). It consists of an array of 143 tungsten-halogen 300-watt lamps, each having integral dichroic coated reflectors. A second array of 143 respective hexagonal-shaped plastic Fresnel lenses are located approximately 1 focal length from the lamps. The simulator will produce a uniform collimated beam covering an area of 1.2 by 1.2m(4 by 4 ft). Design features, construction details, and component costs are given, as well as measured results on a 12-lamp prototype.

Yass, K.↗
NASA NTRS1978

Process for utilizing low-cost graphite substrates for polycrystalline solar cells

Low cost polycrystalline silicon solar cells supported on substrates were prepared by depositing successive layers of polycrystalline silicon containing appropriate dopants over supporting substrates of a member selected from the group consisting of metallurgical grade polycrystalline silicon, graphite and steel coated with a diffusion barrier of silica, borosilicate, phosphosilicate, or mixtures thereof such that p-n junction devices were formed which effectively convert solar energy to electrical energy. To improve the conversion efficiency of the polycrystalline silicon solar cells, the crystallite size in the silicon was substantially increased by melting and solidifying a base layer of polycrystalline silicon before depositing the layers which form the p-n junction.

Chu, T. L.↗
NASA NTRS1985

Iron rich low cost superalloys

An iron-rich low-cost superalloy was developed. The alloy, when processed by conventional chill casting, has physical and mechanical properties that compare favorably with existing nickel and cobalt based superalloys while containing significantly lower amounts of strategic elements. Studies were also made on the properties of Cr(20)-Mn(10)-C(3.4)-Fe(bal.), a eutectic alloy processed by chill casting and directional solidification which produced an aligned microstructure consisting of M7C3 fibers in a gamma-Fe matrix. Thermal expansion of the M7C3 (M = Fe, Cr, Mn) carbide lattice was measured up to 800 C and found to be highly anisotropic, with the a-axis being the predominant mode of expansion. Repetitive impact sliding wear experiments performed with the Fe rich eutectic alloy showed that the directionally solidified microstructure greatly improved the alloy's wear resistance as compared to the chill cast microstructure and conventional nickel base superalloys. Studies on the molybdenum cementite phase prove that the crystal structure of the xi phase is not orthorhombic. The crystal structure of the xi phase is made up of octahedra building elements consisting of four Mo and two Fe atoms and trigonal prisms consisting of four Fe and two Mo atoms. The voids are occupied by carbon atoms. The previous chemical formula for the molybdenum cementite MoFe2C is now clearly seen to be Mo12Fe22C10.

Wayne, S. F.↗
NASA NTRS2015

Low Cost, Upper Stage-Class Propulsion

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

Vickers, John↗
DOE OSTI2021

Low cost scroll compressor or vacuum pump

A low cost scroll device and methods of manufacturing the same are described. The scroll device includes, for example, a drive pin hole and bearing bores machined into a scroll of the scroll device from the same side as the involute of the scroll; idler shaft assemblies with no more than one bearing in the orbiting scroll for mechanically coupling the orbiting scroll to the fixed scroll; and an epoxy coating applied using a process that requires assembly of the scroll device only once.

Mesward, Joshua R.↗
DOE OSTI2024

Evaluating consumer 3D printing nozzles as a low cost alternative for mesophase pitch-derived carbon fiber production

Synthetic fibers, such as Kevlar fibers, SiC fibers, and carbon fibers, are essential components for constructing high performance structures. Whether for engineering, sports, energy storage (batteries and supercapacitors), or aerospace applications, fiber microstructure plays a critical role in fiber properties and functionalities. However, studying fiber nozzle configurations and spinning parameters to achieve the desired microstructure remains challenging, costly, and time consuming. Here, mesophase pitch-derived fibers were used as an example to demonstrate that low cost, commercially available 3D printer nozzles can “print” fibers. Four different nozzles were used to “print” fibers and the effects of their features on fiber properties were observed and compared to other lab spun and commercial pitch- derived CF. A longer orifice length resulted in higher modulus fiber whereas a larger draw-down ratio yielded a stronger fiber. Furthermore, the findings provide a new opportunity for 3D printer hardware application and open up opportunities for developing low-cost fibers.

36 MATERIALS SCIENCE↗
NASA NTRS1997

Ultra-Low-Cost Room Temperature SiC Thin Films

The research group at CSU has conducted theoretical and experimental research on 'Ultra-Low-Cost Room Temperature SiC Thin Films. The effectiveness of a ultra-low-cost room temperature thin film SiC growth technique on Silicon and Germanium substrates and structures with applications to space solar sells, ThermoPhotoVoltaic (TPV) cells and microelectronic and optoelectronic devices was investigated and the main result of this effort are summarized.

Faur, Maria↗
NASA NTRS1979

The REFSAT approach to low-cost GPS terminals

A concept utilizing a geostationary reference satellite (REFSAT) that broadcasts navigation aiding signals to low cost civil user terminals which employ the constellation of 24 NAVSTAR Global Positioning System (GPS) satellites for position determination is described. The signal acquisition, tracking and position fixing properties of such low cost, dual channel, L-band, civil user receiver designed to receive both GPS navigation and REFSAT navigation aiding signals is presented. REFSAT reduces the cost of user equipment.

Sennott, J. W.↗
NASA NTRS2017

NASA's Advanced Solar Sail Propulsion System for Low-Cost Deep Space Exploration and Science Missions that Use High Performance Rollable Composite Booms

Several low-cost solar sail technology demonstrator missions are under development in the United States. However, the mass saving derived benefits that composites can offer to such a mass critical spacecraft architecture have not been realized yet. This is due to the lack of suitable composite booms that can fit inside CubeSat platforms and ultimately be readily scalable to much larger sizes, where they can fully optimize their use. With this aim, a new effort focused at developing scalable rollable composite booms for solar sails and other deployable structures has begun. Seven meter booms used to deploy a 90 m2 class solar sail that can fit inside a 6U CubeSat have already been developed. The NASA road map to low-cost solar sail capability demonstration envisioned, consists of increasing the size of these composite booms to enable sailcrafts with a reflective area of up to 2000 m2 housed aboard small satellite platforms. This paper presents a solar sail system initially conceived to serve as a risk reduction alternative to Near Earth Asteroid (NEA) Scout's baseline design but that has recently been slightly redesigned and proposed for follow-on missions. The features of the booms and various deployment mechanisms for the booms and sail, as well as ground support equipment used during testing, are introduced. The results of structural analyses predict the performance of the system under microgravity conditions. Finally, the results of the functional and environmental testing campaign carried out are shown.

Fernandez, Juan M.↗
NASA NTRS1981

Low cost concentrator

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

Bedard, R. J., Jr.↗
NASA NTRS1976

Organizing for low cost space operations - Status and plans

Design features of the Space Transportation System (vehicle reuse, low cost expendable components, simple payload interfaces, standard support systems) must be matched by economical operational methods to achieve low operating and payload costs. Users will be responsible for their own payloads and will be charged according to the services they require. Efficient use of manpower, simple documentation, simplified test, checkout, and flight planning are firm goals, together with flexibility for quick response to varying user needs. Status of the Shuttle hardware, plans for establishing low cost procedures, and the policy for user charges are discussed.

Lee, C.↗
DOE OSTI2026

Hydrogen Detection via a Low-Cost Prototype Fiber-Optic Sensing System

The developed low-cost prototype sensing system successfully detects hydrogen concentrations across a wide range, demonstrating immediate feasibility for commercial deployment. Utilizing fiber-optic technology, the system delivers stable, reproducible performance from parts-per-million levels up to 100% pure H2 environments. Environmental and chemical cross-sensitivity evaluations confirm robust selectivity against methane and temperature changes, establishing its readiness for near-term commercialization.

fiber-optic H2 sensor↗
NASA NTRS2003

Efficient, Low-Cost Fan System Research for General Aviation and Commuter Aircraft

This document reports research investigations into efficient, low-cost fan system concepts for high bypass turbofans for future general aviation and commuter aircraft. The research specifically addressed lower pressure ratio fans for good propulsive efficiencies in the 200 to 400 knot flight speed regime. Aerodynamic design analyses yielded predicted efficiency in area of 91 to 92 percent (adiabatic). Low-cost manufacturing studies yielded an aluminum blisk rotor and investment cast stator having lowest cost. Structural design analyses yielded a design having excellent vibratory characteristics and the ability to pass One- and Four-pound bird strikes satisfactorily. The low speed and low pressure fans of the study are estimated to have 24 to 30 EPNdB lower community noise levels than larger, high pressure ratio transonic fans.

Merrill, G. L.↗
DOE OSTI2023

Classroom aerosol dispersion modeling: experimental assessment of a low-cost flow simulation tool

The purpose of this study was to assess the utility of a low-cost flow simulation tool for an indoor air modeling application by comparing its outputs with the results of a physical experiment, as well as those from a more advanced computational fluid dynamics (CFD) software package. In this study, five aerosol dispersion tests were performed in two different classrooms by releasing a CO 2 tracer gas from six student locations. Resultant steady-state concentrations were monitored at 13 locations around the periphery of the room. Subsequently, the experiments were modeled using both a low-cost tool (SolidWorks Flow Simulation) and a more sophisticated tool (STAR-CCM+). Models were evaluated based on their ability to predict the experimentally measured concentrations at the 13 monitoring locations by calculating four performance parameters commonly used in the evaluation of dispersion models: fractional mean bias (FB), normalized mean-square error (NMSE), fraction of predicted value within a factor of two (FAC2), and normalized absolute difference (NAD). The more sophisticated model performed better in 15 of the 20 possible cases (five tests at four parameters each), with parameters meeting acceptance criteria in 19 of 20 cases. However, the lower-cost tool was only slightly worse, with parameters meeting acceptance criteria in 18 of 20 cases, and it performed better than the other tool in 3 of 20 cases. Because it provides useful results at a fraction of the monetary and training cost and is already widely accessible to many institutions, such a tool may be worthwhile for many indoor aerosol dispersion applications, especially for students or researchers just beginning CFD modeling.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1979

High resolution, low cost solar cell contact development

The experimental work demonstrating the feasibility of the MIDFILM process as a low cost means of applying solar cell collector metallization as reported. Cell efficiencies of above 14% (AMl, 28 C) were achieved with fritted silver metallization. Environmental tests suggest that the metallization is slightly humidity sensitive and degradation is observed on cells with high series resistance. The major yield loss in the fabrication of cells was due to discontinuous grid lines, resulting in high series resitance. Standard lead-tin solder plated interconnections do not appear compatible with the MIDFILM contact. Copper, nickel and molybdemun base powder were investigated as low cost metallization systems. The copper based powder degraded the cell response. The nickel and molybdenum base powders oxidized when sintered in the oxidizing atmosphere necessary to ash the photoresin.

Mardesich, N.↗
NASA NTRS2022

Design of a Low-Cost, Submersible, Digital Holographic Microscope for in Situ Microbial Imaging

The methodologies for studying marine microbiology typically consist of utilizing instrumentation within a laboratory. This typically requires extracting a sample from its place of origin prior to examination, which may be days after collection. Oftentimes, the solution is to bring the lab to the ocean, which may be costly and provide further limitations for a sterile and stable laboratory environment. Here we present a low-cost, submersible, digital holographic microscope (DHM) designed to image marine microorganisms (such as bacteria and plankton) in their natural underwater environment. Our instrument eliminates the need to transport samples and allows for instantaneous data collection of microbes in-situ. The DHM achieves sub-micron spatial resolution and is paired with artificial intelligence for the detection and tracking of specimens to reduce the overall collected data. This instrument also aims to reduce the cost of manufacturing and field expenses relative to marine microbiological research. “Off the shelf” components were selected in the design process of this instrument which allows us to achieve precise results without sacrificing data quality. The DHM itself costs under one thousand dollars and features a low-cost high-resolution camera, the Arducam MT9J001. Included in the design were five main subsystems: optical, mechanical, electrical, power, and machine learning. Our on board computer and artificial intelligence consist of a Raspberry Pi 4 (8 Gb) and Google Coral USB Tensorflow accelerator. Instrument testing has successfully proven our abilities of data acquisition for at least two hours in depths of at least forty meters below sea level. Additionally, our artificial intelligence system is currently capable of tracking up to ten areas of interest in a fraction of a second with over ninety percent confidence via the neural net driven by the tensor cores on the Google Coral. Furthermore, we have demonstrated the versatility of our instrument by mounting it on an ocean-going ROV, the BlueRov2 by BlueRobotics. Our tests on the BlueRov2 exemplified the cost-effective nature of a submersible and reusable instrument that can be implemented in moderate environments and on most vessels.

Wallace, James Kent↗
NASA NTRS1979

Low-cost encapsulation materials for terrestrial solar cell modules

The paper presents the findings of material surveys intended to identify low cost materials which could be functional as encapsulants (by 1986) for terrestrial solar cell modules. Economic analyses have indicated that in order to meet the low cost goal of $2.70 per sq m, some or all of the following material technologies must be developed or advanced: (1) UV screening outer covers; (2) elastomeric acrylics; (3) weatherproofing and waterproofing of structural wood and paper products; (4) transparent UV stabilizers for the UV-sensitive transparent pottants; and (5) cost-effective utilization of silicone and fluorocarbon materials.

Cuddihy, E. F.↗