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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Demonstration of How Manufacturing Innovations Challenge Conventional Structural Design

For almost 100 years, commercial aircraft have been fabricated using riveted aluminum alloy structures. Aside from refining aircraft designs for better aerodynamic efficiency, improving alloy compositions, and automating assembly steps, fuselage construction remains largely unchanged today. The intent of the lightweight metallic fuselage prototype undertaken in NASA’s Advanced Air Transport Technology project was to demonstrate innovative forming and joining processes that advance the design paradigm, i.e. achieve high-rate manufacturing and reduce assembly time/costs. Over the past decade, researchers at NASA Langley Research Center have evaluated the potential to modify the flow forming process to produce near-net shaped cylinders, integrally stiffened along the cylinder axis, for space launch vehicles. The production of integral stiffeners in a formed aluminum cylinder, the size of the Space Shuttle external tank, replaced machined thick plate and welding steps to eliminate > 500,000 pounds of machining chips and ~ 0.5 miles of welds. The flow forming method, called the Integrally Stiffened Cylinder (ISC) process, was successfully demonstrated up to the 10-foot diameter scale, which laid the groundwork for the current investigation of metallic fuselage structures. Using the ISC process as the basis for the re-design of a metallic fuselage eliminates hundreds of thousands of holes and rivets, while significantly reducing assembly time and crack initiation sites in the integral structure. However, the ISC process is not currently configured to fabricate circumferential ring frames for carrying fuselage internal pressure loads. Consequently, a trade study was performed to assess existing and advanced manufacturing processes, including additive manufacturing, forming, and welding. The approach with the lowest barriers to success, while simultaneously improving manufacturing time and cost, was to use formed ring frame segments attached to the ISC via Refill Friction Stir Spot Welding (RFSSW). The RFSSW process is five times faster than drilling, reaming, and riveting and provides similar mechanical performance. Finishing the fuselage structure with conventional windows, floor beams, and floor panels can then be accomplished using incumbent assembly methods, thereby maximizing reuse of existing infrastructure for aircraft construction. Structural analyses were performed to assess and optimize the geometric variables of integrated skin and stiffener configurations. A cost benefit and manufacturing rate analysis was also performed to compare against the current state-of-the-art for single aisle transport class aircraft. The resulting structure offers a weight reduction that rivals current graphite-epoxy composite fuselage structures. The projected manufacturing rate is close to double current metallic fuselages and six times faster than current composite manufacturing practices. The damage tolerance properties of a monocoque fuselage structure have yet to be assessed, but past integral airframe structural work has exploited geometric features to blunt or turn cracks. This concept offers promise that integrated structures can meet stringent aircraft durability specifications. An important benefit is that such aluminum fuselage structures may be inspected and repaired using established practices and existing expertise. Finally, pursuit of advanced manufacturing processes for future aluminum fuselages minimizes waste and the structure is 100% recyclable at the end-of-life for maximum sustainability.

aluminum↗
NASA NTRS1981

Structures performance, benefit, cost-study

New technology concepts and structural analysis development needs which could lead to improved life cycle cost for future high-bypass turbofans were studied. The NASA-GE energy efficient engine technology is used as a base to assess the concept benefits. Recommended programs are identified for attaining these generic structural and other beneficial technologies.

Woike, O. G.↗
NASA NTRS1983

AFB/open cycle gas turbine conceptual design study

Applications of coal fired atmospheric fluidized bed gas turbine systems in industrial cogeneration are identified. Based on site-specific conceptual designs, the potential benefits of the AFB/gas turbine system were compared with an atmospheric fluidized design steam boiler/steam turbine system. The application of these cogeneration systems at four industrial plant sites is reviewed. A performance and benefit analysis was made along with a study of the representativeness of the sites both in regard to their own industry and compared to industry as a whole. A site was selected for the conceptual design, which included detailed site definition, AFB/gas turbine and AFB/steam turbine cogeneration system designs, detailed cost estimates, and comparative performance and benefit analysis. Market and benefit analyses identified the potential market penetration for the cogeneration technologies and quantified the potential benefits.

Dickinson, T. W.↗
DOE OSTI2024

Community Solar Consolidated Billing: An Exploration of Implementation and Alternatives

The report presents an analysis of the considerations, costs, and benefits surrounding the implementation of utility consolidated billing in community solar programs while also exploring alternatives to achieve similar benefits in its absence. Consolidated billing simplifies the billing process for customers by combining all charges and credits associated with electricity service and community solar subscriptions into a single bill. The potential benefits of consolidated billing implementation include increased transparency, improved customer experience, and ultimately increased retention rates and decreased subscriber acquisition costs. Currently, community solar subscribers often receive two separate bills - one from the utility and one from a third-party community solar provider - potentially causing confusion. Consolidated billing seeks to resolve this by offering a unified bill, which, while beneficial to numerous stakeholders, presents administrative, technical, and financial hurdles that utilities and program administrators must address.

14 SOLAR ENERGY↗
DOE OSTI2025

Community Solar Consolidated Billing: An Exploration of Implementation and Alternatives [Slides]

This presentation is an abridged version of the report it is based on that presents an analysis of the considerations, costs, and benefits surrounding the implementation of utility consolidated billing in community solar programs while also exploring alternatives to achieve similar benefits in its absence. Consolidated billing simplifies the billing process for customers by combining all charges and credits associated with electricity service and community solar subscriptions into a single bill. The potential benefits of consolidated billing implementation include increased transparency, improved customer experience, and ultimately increased retention rates and decreased subscriber acquisition costs. Currently, community solar subscribers often receive two separate bills - one from the utility and one from a third-party community solar provider - potentially causing confusion. Consolidated billing seeks to resolve this by offering a unified bill, which, while beneficial to numerous stakeholders, presents administrative, technical, and financial hurdles that utilities and program administrators must address.

14 SOLAR ENERGY↗
NASA NTRS2002

Sensor Web Architectural Concepts and Implementation Challenges - An Heuristic Approach

There is a significant interest in the Earth Science remote sensing community to increase the number of observations. The obvious reasons for such a push is to improve the temporal and surface coverage of measurements. However, there is little analysis available in terms of benefits, costs and optimized set of sensors needed to make these necessary observations. In reality, this is a complex problem that should be carefully studied and balanced over many boundaries. For example, the question of technology maturity versus users desire to obtain additional measurements is non congruent. This is further complicated by the limitations of the laws of physics and the economic conditions. With the advent of advance technology, it is anticipated that the cost of the spacecraft technology will become more affordable. However, the specialized detector subsystems, and the precision flying techniques may still require substantial innovation, development time and cost. Additionally, the space deployment scheme should also be given a careful attention because of a high expense. Nonetheless, it is important to carefully examine the science priorities and steer the development efforts that can commensurate with the tangible requirements. This paper outlines a possible set of architectural concepts, operational scenarios and potential benefits of one scheme versus another. It further makes some suggestions where one can draw some boundary conditions to incrementally solve this predicament.

Habib, Shahid↗
NASA NTRS2002

Sensor Web and Intelligent Sensors for Earth Science Applications

There is a significant interest in the Earth Science remote sensing community in substantially increasing the number of observations relative to the current frequency of collection. The obvious reason for such a push is to improve the temporal and surface coverage of measurements. However, there is little analysis available in terms of benefits, costs and optimized set of sensors needed to make these necessary observations. This is a complex problem that should be carefully studied and balanced over many boundaries. For example, the question of technology maturity versus users' desire for obtaining additional measurements is noncongruent. This is further complicated by the limitations of the laws of physics and the economic conditions. With the advent of advanced technology, it is anticipated that developments in spacecraft technology will enable advanced capabilities to become more affordable. However, specialized detector subsystems, and precision flying techniques may still require substantial innovation, development time and cost. Additionally, the space deployment scheme should also be given careful attention because of the high associated expense. Nonetheless, it is important to carefully examine the science priorities and steer the development efforts that can commensurate with the tangible requirements. This presentation will focus on a possible set of architectural concepts beneficial for future Earth science studies and research its and potential benefits.

Habib, Shahid↗
NASA NTRS2006

Should We Enhance the Observing Systems or Improve Coordination Among the Operating Agencies: What is Needed the Most for Security--A Philosophical Discussion

As an integrated observing strategy, the concept of sensorweb for Earth observations is appealing in many aspects. For instance, by increasing the spatial and temporal coverage of observations from space and other vantage points, one can eventually aid in increasing the accuracy of the atmospheric models which are precursor to hurricane track prediction, volcanic eruption forecast, and trajectory path of transcontinental transport of dust, harmful nuclear and chemical plumes. In reality, there is little analysis available in terms of benefits, costs and optimized set of sensors needed to make these necessary observations. This is a complex problem that must be carefully studied and balanced over many boundaries such as science, defense, early warning, security, and surveillance. Simplistically, the sensorweb concept from the technological point of view alone has a great appeal in the defense, early warning and security applications. In fact, it can be relatively less expensive in per unit cost as opposed to building and deploying it for the scientific use. However, overall observing approach should not be singled out and aligned somewhat orthogonally to serve a particular need. On the other hand, the sensorweb should be designed and deployed to serve multiple subject areas and customers simultaneously; and can behave as directed measuring systems for both science and operational entities. Sensorweb can be designed to act as expert systems, and/or also provide a dedicated integrated surveillance network. Today, there is no system in the world that is fully integrated in terms of reporting timely multiple hazards warnings, computing the loss of life and property damage estimates, and is also designed to cater to everyone's needs. It is not an easier problem to undertake and more so is not practically solvable. At this time due to some recent events in the world, the scientific community, social scientists, and operational agencies are more cognizant and getting together to address such colossal problems. Increasing our knowledge of the home planet, via amplified set of observations, is certainly a right step in a right direction. Furthermore, this is a pre-requisite in understanding multiple hazard phenomenas. This paper examines various sensorweb options and observing architectures that can be useful specifically in addressing some of these complex issues. The ultimate goal is to serve the society by providing potential natural hazards information to the decision makers in the most expeditious manner so they can prepare themselves to mitigate potential risks to human life, livestock and property.

Habib, Shahid↗
NASA NTRS2006

Applying Advanced and Existing Sensors in Dealing with Potential Natural Disasters

As an integrated observing strategy, the concept of sensorweb for Earth observations is appealing in many aspects. For instance, by increasing the spatial and temporal coverage of observations from space and other vantage points, one can eventually aid in increasing the accuracy of the atmospheric models which are precursor to hurricane track prediction, volcanic eruption forecast, and trajectory path of transcontinental transport of dust, harmful nuclear and chemical plumes. In reality, there is little analysis available in terms of benefits, costs and optimized set of sensors needed to make these necessary observations. This is a complex problem that must be carefully studied and balanced over many boundaries such as science, defense, early warning, security, and surveillance. Simplistically, the sensorweb concept from the technological point of view alone has a great appeal in the defense, early warning and security applications. In fact, it can be relatively less expensive in per unit cost as opposed to building and deploying it for the scientific use. However, overall observing approach should not be singled out and aligned somewhat orthogonally to serve a particular need. On the other hand, the sensorweb should be designed and deployed to serve multiple subject areas and customers simultaneously; and can behave as directed measuring systems for both science and operational entities. Sensorweb can be designed to act as expert systems, and/or also provide a dedicated integrated surveillance network. Today, there is no system in the world that is fully integrated in terms of reporting timely multiple hazards warnings, computing the loss of life and property damage estimates, and is also designed to cater to everyone s needs. It is not an easier problem to undertake and more so is not practically solvable. At this time due to some recent events in the world, the scientific community, social scientists, and operational agencies are more cognizant and getting together to address such colossal problems. Increasing our knowledge of the home planet, via amplified set of observations, is certainly a right step in a right direction. Furthermore, this is a prerequisite in understanding multiple hazard phenomena's. This paper examines various sensorweb options and observing architectures that can be useful specifically in addressing some of these complex issues. The ultimate goal is to serve the society by providing potential natural hazards information to the decision makers in the most expeditious manner so they can prepare themselves to mitigate potential risks to human life, livestock and property.

Habib, Shahid↗
NASA NTRS2006

Acquiring Comprehensive Observations using an Integrated Sensorweb for Early Warning

As an integrated observing strategy, the concept of sensorweb for Earth observations is appealing in many aspects. For instance, by increasing the spatial and temporal coverage of observations from space and other vantage points, one can eventually aid in increasing the accuracy of the atmospheric models which are precursor to hurricane track prediction, volcanic eruption forecast, and trajectory path of transcontinental transport of dust, harmful nuclear and chemical plumes. In reality, there is little analysis'available in terms of benefits, costs and optimized set of sensors needed to make these necessary observations. This is a complex problem that must be carefully studied and balanced over many boundaries such as science, defense, early warning security, and surveillance. Simplistically, the sensorweb concept from the technological point of view alone has a great appeal in the defense, early warning and security applications. In fact, it can be relatively less expensive in per unit cost as opposed to building and deploying it for the scientific use. However, overall observing approach should not be singled out and aligned somewhat . orthogonally to serve a particular need. On the other hand, the sensorweb should be designed and deployed to serve multiple subject areas and customers simultaneously; and can behave as directed measuring systems for both science and operational entities. Sensorweb can be designed to act as expert systems, and/or also provide a dedicated integrated surveillance network. Today, there is no system in the world that is fully integrated in terms of reporting timely multiple hazards warnings, computing the lass of life and property damage estimates, and is also designed to cater to everyone's needs. It is not an easier problem to undertake and more so is not practically solvable. At this time due to some recent events in the world, the scientific community, social scientists, and operational agencies are more cognizant and getting together to address such colossal problems. Increasing our knowledge of the home planet, via amplified set of observations, is certainly a right step in a right direction. Furthermore, this is a pre-requisite in understanding multiple hazard phenomena's. This paper examines various sensorweb options and observing architectures that can be useful specifically in addressing some of these complex issues. The ultimate goal is to serve the society by providing potential natural hazards information to the decision makers in the most expeditious manner so they can prepare themselves to mitigate potential risks to human life, livestock and property.

Habib, Shahid↗
NASA NTRS2006

Acquiring Comprehensive Observations using an integrated Sensorweb for Early Warning

As an integrated observing strategy, the concept of sensorweb for Earth observations is appealing in many aspects. For instance, by increasing the spatial and temporal coverage of observations from space and other vantage points, one can eventually aid in increasing the accuracy of the atmospheric models which are precursor to hurricane track prediction, volcanic eruption forecast, and trajectory path of transcontinental transport of dust, harmful nuclear and chemical plumes. In reality, there is little analysis'available in terms of benefits, costs and optimized set of sensors needed to make these necessary observations. This is a complex problem that must be carefully studied and balanced over many boundaries such as science, defense, early warning, security, and surveillance. Simplistically, the sensorweb concept from the technological point of view alone has a great appeal in the defense, early warning and security applications. In fact, it can be relatively less expensive in per unit cost as opposed to building and deploying it for the scientific use. However, overall observing approach should not be singled out and aligned somewhat orthogonally to serve a particular need. On the other hand, the sensorweb should be designed and deployed to serve multiple subject areas and customers simultaneously; and can behave as directed measuring systems for both science and operational entities. Sensorweb can be designed to act as expert systems, and/or also provide a dedicated integrated surveillance network. Today, there is no system in the world that is fully integrated in terms of reporting timely multiple hazards warnings, computing the loss of life and property damage estimates, and is also designed to cater to everyone's needs. It is not an easier problem to undertake and more so is not practically solvable. At this time due to some recent events in the world, the scientific community, social scientists, and operational agencies are more cognizant and getting together to address such colossal problems. Increasing our knowledge of the home planet, via amplified set of observations, is certainly a right step in a right direction. Furthermore, this is a pre-requisite in understanding multiple hazard phenomena's. This paper examines various sensorweb options and observing architectures that can be useful specifically in addressing some of these complex issues. The ultimate goal is to serve the society by providing potential natural hazards information to the decision makers in the most expeditious manner so they can prepare themselves to mitigate potential risks to human life, livestock and property.

Habib, Shahid↗
DOE OSTI2026

Scalable Upcycling of Spent Lithium-Ion Battery Anodic Graphite to Electronic-Grade Graphene

Recycling processes for lithium-ion batteries (LIBs) are imperative to support the sustainable growth of global energy storage systems. This study introduces a scalable method for the upcycling of spent graphite anodes from LIBs to produce electronic-grade graphene nanoplatelets. In addition to comprehensive materials characterization, the electronic quality of the upcycled graphene is demonstrated by formulating it into a screen printing ink that achieves high-resolution patterning and thin-film electrical conductivity exceeding 104 S m−1. This screen printing ink is also used to print planar micro-supercapacitors with exceptional areal capacitance (1.78 mF cm−2), areal energy density (0.247 µWh cm−2), and cycling stability (> 10 000 cycles). Life cycle assessment (LCA) and techno-economic analysis (TEA) highlight the environmental benefits and cost reductions attainable through upcycling of graphite from LIBs. By capturing economic value from spent LIBs, this work fosters a sustainable battery supply chain and provides an abundant and geographically distributed raw material for electronic-grade graphene.

energy storage↗
NASA NTRS2006

Processing of Space Resources to Enable the Vision for Space Exploration

The NASA human exploration program as directed by the Vision for Exploration (G.W. Bush, Jan. 14,2004) includes developing methods to process materials on the Moon and beyond to enable safe and affordable human exploration. Processing space resources was first popularized (O Neill 1976) as a technically viable, economically feasible means to build city sized habitats and multi GWatt solar power satellites in Earth/Moon space. Although NASA studies found the concepts to be technically reasonable in the post Apollo era (AMES 1979), the front end costs the limits of national or corporate investment. In the last decade analysis of space on has shown it to be economically justifiable even on a relatively small mission or commercial scenario basis. The Mars Reference Mission analysis (JSC 1997) demonstrated that production of return propellant on Mars can enable an order of magnitude decrease in the costs of human Mars missions. Analysis (by M. Duke 2003) shows that production of propellant on the Moon for the Earth based satellite industries can be commercially viable after a human lunar base is established. Similar economic analysis (Rapp 2005) also shows large cost benefits for lunar propellant production for Mars missions and for the use of lunar materials for the production of photovoltaic power (Freundlich 2005). Recent technologies could enable much smaller initial costs, to achieve mass, energy, and life support self sufficiency, than were achievable in the 1970s. If the Exploration Vision program is executed with a front end emphasis on space resources, it could provide a path for human self reliance beyond Earth orbit. This path can lead to an open, non-zero-sum, future for humanity with safer human competition with limitless growth potential. This paper discusses extension of the analysis for space resource utilization, to determine the minimum systems necessary for human self sufficiency and growth off Earth. Such a approach can provide a more compelling and comprehensive path to space resource utilization.

Curreri, Peter A.↗
NASA NTRS1973

Feasibility study of an Integrated Program for Aerospace vehicle Design (IPAD) Volume 7: IPAD benefits and impact

The potential benefits, impact and spinoff of IPAD technology are described. The benefits are projected from a flowtime and labor cost analysis of the design process and a study of the flowtime and labor cost savings being experienced with existing integrated systems. Benefits in terms of designer productivity, company effectiveness, and IPAD as a national resource are developed. A description is given of the potential impact of information handling as an IPAD technology, upon task and organization structure and people who use IPAD. Spinoff of IPAD technology to nonaerospace industries is discussed. The results of a personal survey made of aerospace, nonaerospace, government and university sources are given.

Hansen, S. D.↗
DOE OSTI2026

Performance assessment of 3D printed multi-material energy absorber for automotive bumper: pedestrian lower extremity protection

Designing an energy absorber for automotive bumpers involves balancing low-speed and high-speed impacts to ensure safety, reduce repair costs, and meet regulatory standards. Here, this study explores a novel design using multi-material 3D printing and structural optimization to fabricate a lightweight and cost-efficient energy absorber. The design effectively dissipates energy in low-speed collisions and minimizes force transmission in high-speed pedestrain impacts, helping to meet both safety and performance requirements. The energy absorber design combines 20% carbon fiber-reinforced acrylonitrile butadiene styrene (CF-ABS) and thermoplastic polyurethane (TPU) for optimal stiffness and flexibility. It uses 3D-printed lattice structures optimized through finite element simulations to help meet both low-speed and high-speed impact requirements. Full-scale energy absorbers were 3D-printed using optimized CF-ABS/TPU blends and tested under high-speed impact using the Flexible Pedestrian Legform Impactor (Flex-PLI). For fair comparison, a baseline bumper with a traditional triangular lattice structure, also 3D-printed from the same CF-ABS/TPU materials, was similarly tested. Interestingly, both the optimized and baseline 3D-printed energy absorbers showed nearly identical performance, successfully meeting injury limits. Their performances were also benchmarked against an injection-molded energy absorber. While both 3D-printed and injection-molded designs met injury limits, the 3D-printed absorber exhibited a higher tibia bending moment, indicating an opportunity for further optimization. A Techno-Economic Analysis compared the costs of producing energy absorbers using traditional manufacturing and 3D printing. The analysis highlighted that 3D printing offers cost benefits for low to medium production volumes, with the total cost per energy absorber at ∼ $\$$74, compared to traditional methods that become economical beyond 2000 units.

Additive manufacturing↗
DOE OSTI2022

Roadmap for Deployment of Modularized Hydrothermal Liquefaction: Understanding the Impacts of Industry Learning, Optimal Plant Scale, and Delivery Costs on Biofuel Pricing

Hydrothermal liquefaction (HTL) is a promising technology for converting abundant organic wastes into fuels. Previous techno-economic analyses (TEAs) of HTL have been used to estimate the minimum fuel selling price (MFSP) of biofuel products, but these analyses often assume a bespoke plant design where each plant operates under unique process conditions and neglect transportation costs. However, transportation costs must be included in realistic TEAs, and further, a mass-produced fixed-scale modular plant design approach may be more effective than case-by-case plant design, provided that there is sufficient market capacity to benefit from modularization. This study estimates fuel price behavior in the presence of transportation costs and benefits stemming from modular plant design. This analysis indicates that a modular process capable of handling 60 dry tons per day (DTPD) is optimal, resulting in a ~25% reduction in MFSP (from $4.70/GGE, fully upgraded) at complete market feedstock utilization compared with case-by-case design. The associated cost reductions are attributable to learning benefits and modularization. Several HTL deployment “roadmaps” are then explored, with each roadmap consisting of different periods of case-by-case design followed by adoption of a modularized approach. A period of nonmodular industry growth up to market saturation of ~7% followed by implementation of modular plant design strikes a balance between the investment risk and learned cost reductions associated with modular plant design. However, if bespoke plants built during this period of nonmodular growth saturate more than 23% of available feedstock, learned cost reductions are significantly diminished. Here, this study points to the potential benefits of modularized and decentralized waste-to-energy processes when the modularization follows an optimal deployment strategy.

09 BIOMASS FUELS↗
NASA NTRS1992

National Launch System comparative economic analysis

Results are presented from an analysis of economic benefits (or losses), in the form of the life cycle cost savings, resulting from the development of the National Launch System (NLS) family of launch vehicles. The analysis was carried out by comparing various NLS-based architectures with the current Shuttle/Titan IV fleet. The basic methodology behind this NLS analysis was to develop a set of annual payload requirements for the Space Station Freedom and LEO, to design launch vehicle architectures around these requirements, and to perform life-cycle cost analyses on all of the architectures. A SEI requirement was included. Launch failure costs were estimated and combined with the relative reliability assumptions to measure the effects of losses. Based on the analysis, a Shuttle/NLS architecture evolving into a pressurized-logistics-carrier/NLS architecture appears to offer the best long-term cost benefit.

Prince, A.↗