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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 NTRS1997

Scale Model Icing Research Tunnel

NASA Lewis Research Center's Icing Research Tunnel (IRT) is the world's largest refrigerated wind tunnel and one of only three icing wind tunnel facilities in the United States. The IRT was constructed in the 1940's and has been operated continually since it was built. In this facility, natural icing conditions are duplicated to test the effects of inflight icing on actual aircraft components as well as on models of airplanes and helicopters. IRT tests have been used successfully to reduce flight test hours for the certification of ice-detection instrumentation and ice protection systems. To ensure that the IRT will remain the world's premier icing facility well into the next century, Lewis is making some renovations and is planning others. These improvements include modernizing the control room, replacing the fan blades with new ones to increase the test section maximum velocity to 430 mph, installing new spray bars to increase the size and uniformity of the artificial icing cloud, and replacing the facility heat exchanger. Most of the improvements will have a first-order effect on the IRT's airflow quality. To help us understand these effects and evaluate potential improvements to the flow characteristics of the IRT, we built a modular 1/10th-scale aerodynamic model of the facility. This closed-loop scale-model pilot tunnel was fabricated onsite in the various shops of Lewis' Fabrication Support Division. The tunnel's rectangular sections are composed of acrylic walls supported by an aluminum angle framework. Its turning vanes are made of tubing machined to the contour of the IRT turning vanes. The fan leg of the tunnel, which transitions from rectangular to circular and back to rectangular cross sections, is fabricated of fiberglass sections. The contraction section of the tunnel is constructed from sheet aluminum. A 12-bladed aluminum fan is coupled to a turbine powered by high-pressure air capable of driving the maximum test section velocity to 550 ft/sec (Mach 0.45). The air turbine and instrumentation are housed inside a fiberglass nacelle. Total and static pressure measurements can be taken around the loop, and velocity and flow angularity measurements can be taken with hot-wire and five-hole probes at specific locations. The Scale Model Icing Research Tunnel (SMIRT) is undergoing checkout tests to determine how its airflow characteristics compare with the IRT. Near-term uses for this scale-model tunnel include determining the aerodynamic effects of replacing the 52-yearold W-shaped heat exchanger with a flat-faced heat exchanger. SMIRT is an integral part of the improvements planned for the IRT because testing the proposed IRT improvements in a scale-model tunnel will lower costs and improve productivity.

Canacci, Victor A.↗
NASA NTRS1996

Cost Models for MMC Manufacturing Processes

Processes for the manufacture of advanced metal matrix composites are rapidly approaching maturity in the research laboratory and there is growing interest in their transition to industrial production. However, research conducted to date has almost exclusively focused on overcoming the technical barriers to producing high-quality material and little attention has been given to the economical feasibility of these laboratory approaches and process cost issues. A quantitative cost modeling (QCM) approach was developed to address these issues. QCM are cost analysis tools based on predictive process models relating process conditions to the attributes of the final product. An important attribute, of the QCM approach is the ability to predict the sensitivity of material production costs to product quality and to quantitatively explore trade-offs between cost and quality. Applications of the cost models allow more efficient direction of future MMC process technology development and a more accurate assessment of MMC market potential. Cost models were developed for two state-of-the art metal matrix composite (MMC) manufacturing processes: tape casting and plasma spray deposition. Quality and Cost models are presented for both processes and the resulting predicted quality-cost curves are presented and discussed.

Elzey, Dana M.↗
DOE OSTI2020

Techno-Economic Analysis of Biofuel Production via Catalytic Upgrading of Carbohydrates in Paper Sludge

A full-plant model was developed using correlations from a rigorous mass and energy balance and based on experimental results to determine the MFSP and its Sensitivity Analysis in the production of a hydrocarbon product from Paper Sludge. In this base case a preliminary MFSP of $5.97/GGE has been determined. This value is higher than the results reported in recent NREL reports. The difference is explained since much larger capacity plants are considered in those reports, and because we are not considering the production of co-products that bring the fuel costs down. The obtained model is being used to guide the next steps in our laboratory work since the team is now aware of which are the more sensitive process parameters "impacting" the MFSP of the final product.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Modeling Flexible Generator Operating Regions via Chance- constrained Stochastic Unit Commitment

Here, we introduce a novel chance-constrained stochastic unit commitment model to address uncertainty in renewables' production uncertainty in power systems operation. For most thermal generators,underlying technical constraints that are universally treated as "hard" by deterministic unit commitment models are in fact based on engineering judgments, such that system operators can periodically request operation outside these limits in non-nominal situations, e.g., to ensure reliability. We incorporate this practical consideration into a chance-constrained stochastic unit commitment model, specifically by in-frequently allowing minor deviations from the minimum and maximum thermal generator power output levels. We demonstrate that an extensive form of our model is computationally tractable for medium-sized power systems given modest numbers of scenarios for renewables' production. We show that the model is able to potentially save significant annual production costs by allowing infrequent and controlled violation of the traditionally hard bounds imposed on thermal generator production limits. Finally, we conduct a sensitivity analysis of optimal solutions to our model under two restricted regimes and observe similar qualitative results.

42 ENGINEERING↗
DOE OSTI2020

Research note: LED lighting – A global enterprise

There is considerable focus on technology manufacturing locations and the value in funding innovation when upstream products are not manufactured within a domestic economy. Light-emitting diodes (LEDs) are such an upstream product. Here, we evaluate the value added along the supply chain of luminaires, a product that utilizes LEDs, using bottom-up cost modelling. Coupling the results with analysis of shipping cost and time, this analysis examines how advances in LEDs can incentivize LED luminaire adoption leading to the potential for significant domestic manufacturing effects even if the upstream products are produced in other economies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1977

Space-based solar power conversion and delivery systems study. Volume 5: Economic analysis

Space-based solar power conversion and delivery systems are studied along with a variety of economic and programmatic issues relevant to their development and deployment. The costs, uncertainties and risks associated with the current photovoltaic Satellite Solar Power System (SSPS) configuration, and issues affecting the development of an economically viable SSPS development program are addressed. In particular, the desirability of low earth orbit (LEO) and geosynchronous (GEO) test satellites is examined and critical technology areas are identified. The development of SSPS unit production (nth item), and operation and maintenance cost models suitable for incorporation into a risk assessment (Monte Carlo) model (RAM) are reported. The RAM was then used to evaluate the current SSPS configuration expected costs and cost-risk associated with this configuration. By examining differential costs and cost-risk as a function of postulated technology developments, the critical technologies, that is, those which drive costs and/or cost-risk, are identified. It is shown that the key technology area deals with productivity in space, that is, the ability to fabricate and assemble large structures in space, not, as might be expected, with some hardware component technology.

Source record↗
DOE OSTI2025

Mobilizing mine lands for biobased decarbonization strategies

Over 163 000 ha of mine lands in Pennsylvania (PA) have the potential to produce willow as a feedstock for renewable energy generation. Each year these lands could produce between 454 000 and 907 000 dry Mg of willow, which can be a feedstock for bioenergy (i.e., biopower) with carbon capture and sequestration (BECCS) or sustainable aviation fuel (SAF) production. We used a spatially explicit model to explore cost-minimized allocation of willow biomass from abandoned mine lands (AML) to be used for BECCS or SAF production and to abate carbon dioxide. The results suggest that between 454 000 and 907 000 dry Mg of biomass can be produced on AML in PA at costs from $94 to $250 per dry Mg. This AML willow biomass could be combined with other available biomass and aggregated to ten facilities to produce 17.9 TWh of power; alternatively, it could produce 958 million liters of jet fuel, 638 million liters of renewable diesel, and 1.289 billion liters of naphtha, along with 0.735 TWh of electricity. From this analysis, in PA, under the BECCS pathway, up to 36 million Mg per year of CO2 could be abated at costs of up to $134 per Mg; under the SAF pathway, up to 17.5 million Mg per year of CO2 could be abated at costs up to $150 per Mg of CO2. The use of mine land willow as a supplemental feedstock for SAF and BECCS would need strong incentive programs if costs of production are to be comparable with production on agricultural land.

Wahlstrom, Mallory [Pennsylvania State University]↗
NASA NTRS1991

COSTMODL: An automated software development cost estimation tool

The cost of developing computer software continues to consume an increasing portion of many organizations' total budgets, both in the public and private sector. As this trend develops, the capability to produce reliable estimates of the effort and schedule required to develop a candidate software product takes on increasing importance. The COSTMODL program was developed to provide an in-house capability to perform development cost estimates for NASA software projects. COSTMODL is an automated software development cost estimation tool which incorporates five cost estimation algorithms including the latest models for the Ada language and incrementally developed products. The principal characteristic which sets COSTMODL apart from other software cost estimation programs is its capacity to be completely customized to a particular environment. The estimation equations can be recalibrated to reflect the programmer productivity characteristics demonstrated by the user's organization, and the set of significant factors which effect software development costs can be customized to reflect any unique properties of the user's development environment. Careful use of a capability such as COSTMODL can significantly reduce the risk of cost overruns and failed projects.

Roush, George B.↗
DOE OSTI2025

Benchmark of numerical modeling approaches on the systematic performance evaluation of wave energy converters

Different numerical modeling methods have been developed and applied to evaluate a variety of performance indicators of wave energy converters (WECs), including the power performance, structural loads, levelized cost of energy, etc. Based on the modeling fidelity, the commonly used numerical modeling approaches can be classified as linear modeling, weakly nonlinear modeling and fully nonlinear modeling approaches. Each method differs in accuracy and computational efficiency, making them suitable for different stages of WEC design. However, the selection of modeling approach could significantly impact evaluation outcomes. For instance, simplified linear models may underestimate structural loads or overestimate energy production in some operational conditions, potentially leading to less cost-effective designs. Given the widespread utilization of these models, it is essential to understand the uncertainties brought by them in performance evaluations. This work is dedicated to benchmarking different linear-potential-flow-based numerical models for evaluating the systematic performance of WECs. Three representative numerical modeling approaches are considered in this work, including linear frequency-domain modeling, statistically linearized spectral-domain modeling and Cummins equation-based nonlinear time-domain modeling. A generic point absorber WEC is considered as the research reference in this work, and different sea sites are taken into account. The numerical models are utilized to predict critical performance indicators, including power performance, the annual energy production, the capacity factor, the levelized cost of energy and the PTO fatigue loads. By comparing the results, this work identifies the uncertainties associated with different modeling approaches in evaluating WEC performance.

Fatigue↗
NASA NTRS2001

A Winning Cast

Howmet Research Corporation was the first to commercialize an innovative cast metal technology developed at Auburn University, Auburn, Alabama. With funding assistance from NASA's Marshall Space Flight Center, Auburn University's Solidification Design Center (a NASA Commercial Space Center), developed accurate nickel-based superalloy data for casting molten metals. Through a contract agreement, Howmet used the data to develop computer model predictions of molten metals and molding materials in cast metal manufacturing. Howmet Metal Mold (HMM), part of Howmet Corporation Specialty Products, of Whitehall, Michigan, utilizes metal molds to manufacture net shape castings in various alloys and amorphous metal (metallic glass). By implementing the thermophysical property data from by Auburn researchers, Howmet employs its newly developed computer model predictions to offer customers high-quality, low-cost, products with significantly improved mechanical properties. Components fabricated with this new process replace components originally made from forgings or billet. Compared with products manufactured through traditional casting methods, Howmet's computer-modeled castings come out on top.

Source record↗
DOE OSTI2020

Land Use in Computable General Equilibrium Models

Constant Elasticity of Transformation (CET) functions are widely used to allocate land across uses in Computable General Equilibrium (CGE) models. These models fail to maintain area of land in balance. Several ways have been used or offered to fix this problem. This paper first examines the extent to which the CET approach may generate imbalances in area of land and identifies determinants of such imbalances. It then evaluates the merits, properties, and welfare impacts of the available approaches that restore area of land in balance. We show that heterogeneity in land prices (land rents) is the main source of imbalance in area of land, not the curvature of the CET function. Furthermore, we show that the available approaches that restore area of land in balance either introduce ad hoc adjustments in land allocation or undermine the conventional welfare assessments of the CET results and ignore the opportunity costs of land transformation. The CGE models which applied stochastic productivity distribution functions to allocate land among uses maintain area of land in balance, but they suffer from important limitations and ignore costs of land transformation.

Taheripour, Farzad↗
DOE OSTI2023

Integrated Sustainable Product Design With Warranty and End-of-Use Considerations

The concept of integrated sustainable product design has recently emerged, aiming to incorporate downstream life cycle performance into the initial product design to enhance sustainability. Various sustainable product design tools based on life cycle assessment or quality function deployment have been established while the impact of reliability on circular practices has received limited attention. Recognizing the critical role of product reliability in post-design performance, this paper develops a product design optimization model that considers the warranty performance and the effect of end-of-use options. The model takes into account the effect of uncertain operating conditions on product reliability. Two optimization goals including the minimization of expected unit life cycle cost and environmental impact are achieved by the model. To demonstrate the benefits of the integrated approach, the model is applied to an electric motor design problem. The results highlight that integrating end-of-use options in the early design phase leads to adjustments in component selection and reliability design. Moreover, the circular utilization of used products enables cost savings throughout the product’s life cycle and contributes to environmental impact reduction. Finally, the study analyzes the effects of operating conditions, warranty policies, and take-back prices for used products on design decisions, providing valuable insights for product designers.

Integrated design↗
DOE OSTI2023

Field validation of isotropic analytical models for simulating fabric shades

Fabric roller shades are common shading materials used in commercial and residential buildings. Accurately characterizing and modeling shades helps practitioners select the appropriate product and its control strategy based on climate and occupants' priorities, such as visual comfort and view to outdoors. Previous studies established a generalized method for modeling complex fenestration systems using data-driven tabulated bidirectional scattering distribution functions. However, deploying such a method at scale to all fabric shading products on the market is too costly and time-consuming. Analytical models that are based on a limited set of measurements (e.g., normal-normal and normal-hemispherical visible transmittance and reflectance, and directional cut-off angles) can be used to model the wide variety of shading products on the market. This study evaluates the performance of two isotropic analytical models, Roos-Wienold and Modified-Kotey, for modeling fabric roller shades, with a focus on the model's ability to predict occupant visual comfort. The performance evaluation was conducted through laboratory and field measurements and simulations. The results showed that both models are sufficient for predicting vertical illuminance at seated eye-level. Roos-Wienold model was able to predict binary visual comfort classification (glare/no-glare) under a wide range of luminance conditions, while Modified-Kotey model did not perform as well under high-contrast low-adaptation conditions. Both models are insufficient in predicting visual comfort at a four-point scale (e.g., imperceptible, perceptible, disturbing, intolerable). The two isotropic models become less accurate when the fabric exhibits high anisotropy.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Coupled CVD and Float Zone Reactor for Lower Cost, Higher Efficiency Si Boules (Final Technical Report)

This project modeled a new type of photovoltaic (PV) Si production reactor with the promise to reduce the cost, increase the efficiency, and reduce the energy required to manufacture Si wafers. The production of photovoltaic (PV) grade Si is well established, based on the pulling of single crystalline Si boules from polycrystalline Si created from trichlorosilane using the Siemens process. However, these processes are very energy intensive, and manufacturing of PV Si occurs almost entirely in China. To disrupt this paradigm and on-shore production of this critical material and provide benefits to the public, a substantial technological leap is required to move past incumbent technology. This study evaluated a new float zone chemical vapor deposition (Fz-CVD) concept in which trichlorosilane (TCS), the feedstock for polysilicon in the Siemens process, is injected directly into a float zone crystallizer to continuously deposit the feed rod for the boule pulling process through a combination of multiphysics modeling and technoeconomic analysis.

14 SOLAR ENERGY↗
DOE OSTI2025

A Demand Bidding Model for Multi-Product Industrial Plants

The growing contribution of renewable energy sources has increased volatility and uncertainty in electricity markets, challenging traditional grid operation paradigms. Demand bidding (DB), a market participation model where (large) electricity users communicate their willingness to pay for electricity to the grid operator, was shown in previous work to enhance grid stability and lower generation cost. We present a DB model for multi-product industrial plants, based on an extended optimal power flow problem where the plant dynamics are represented using autoregressive with extra inputs (ARX) models. We compare DB to price-based demand-side management, showing that, under certain assumptions, the two approaches are equivalent, while DB provides more transparency and predictability to the grid operator. A case study based on an industrial air separation unit is discussed.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

A System-Level Cost Modeling Framework for Design for Remanufacturing: A Case Study of an Agricultural Machine Transmission

Remanufacturing offers significant environmental and economic benefits by restoring end-of-life products to as-new conditions. Although extensive research has been conducted on the topic, the adoption of remanufacturing practices remains limited across various industries. A primary barrier to broader implementation is the substantial upfront investment required, which necessitates reliable cost modeling to justify potential future savings. Most existing models treat components independently and ignore inter-component dependencies. We develop a probabilistic, system-level cost modeling framework that integrates reliability, reusability, and a dependency matrix to capture cascading effects across components over multiple life cycles. Our model identifies those critical components that maximize remanufacturing benefits across a product's many lives. A toy example and an industry case study (John Deere PowrQuad transmission subassembly) illustrate how design alternatives affect cumulative cost. Using a Monte Carlo simulation (MCS) to perform life cycle cost analysis on the system with different design changes, we show the normalized average cost savings after three remanufacturing cycles. Accounting for dependencies meaningfully alters cost projections and ignoring them underestimates accumulated cost by up to 20% in our examples. Furthermore, the results of our study confirm that accounting for component interdependencies is necessary to produce cost estimates that meet industry standards.

Life Cycle Analysis and Design↗
DOE OSTI2024

Scalable and Highly-Efficient Microbial Electrochemical Reactor for Hydrogen Generation from Wastes

The overall goal of this project was to develop a scalable and highly efficient hybrid microbial electrochemical reactor for hydrogen recovery from waste streams at a cost of less than $\$$2/kg H₂. The specific objectives were: (1) to design and fabricate a scalable and highly efficient microbial electrochemical cell (MEC) reactor, and (2) to determine the techno-economic feasibility of the system for H₂ generation from organic-rich waste streams. We achieved the first objective by (a) developing low-cost electrode materials, (b) synthesizing a highly efficient cathode catalyst in a scalable manner, (c) evaluating and validating the developed electrode material and catalyst in MEC reactors, and (d) designing and fabricating a larger reactor that incorporates (a) to (c). We met the second objective by (a) identifying the impacts of wastewater composition and operational conditions on H₂ production, and (b) developing a cost-performance model that identified critical parameters affecting the system's performance and cost, providing a pathway for further improvement.

08 HYDROGEN↗
NASA NTRS2019

Blind Validation Study of Parametric Cost Estimation Tool SEER-H for NASA Space Missions

One of the primary parametric cost modeling tools used by NASA and the aerospace industry to estimate the development and production cost of future spacecraft hardware is SEER-H by Galorath. To date, no independent validation of this tool for cost estimation of space missions has been reported in the literature. In the present validation study, cost estimators used SEER-H to estimate the cost of twelve different past NASA science missions. The estimators were prevented from knowing the actual cost of the missions in an effort to minimize cognitive biases. The point estimates of SEER-H had an average error of 23%, median error of -0.3%, and a standard deviation of 43%. Nine of the twelve mission's actual costs fell within the 80% confidence interval of SEER's probabilistic estimates. Several factors independent of SEER that may have affected the accuracy of the results have been identified and are discussed; these include: uncertainty in the technical data used for the estimates, the methods used to estimate uncertainty in spacecraft component mass and numbers of prototypes, and the experience of the estimators.

SEER-H↗