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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

The Cost of Scaling Up in Large-Format Additive Manufacturing

Additive manufacturing (AM) of large objects has, over the last decade, required the scaling of existing material extrusion processes. The current generation of large-scale printers are primarily gantry robots with high-throughput extrusion systems. With workspaces approaching 50 m 3 , these printers have pushed the boundaries of achievable print volume while allowing the utilization of low-cost feedstocks, such as cementitious materials and polymer pellets, like those used in injection molding. Continued workspace expansion requires an examination of the inherent trade-offs, which impact capital and operational costs. Here, in this work, the authors examine these trade-offs to determine fundamental scaling laws for existing system architectures, survey the state of the art for alternative system configurations, and pose recommendations for future system designers to continue the evolution of large-scale AM systems.

3D printing↗
NASA NTRS2016

A Structured, Model-Based Systems Engineering Methodology for Operations System Design

Two widely accepted techniques for lowering the cost and risk of developing systems are (1) the use of a defined systems engineering (SE) process or methodology and (2) the reuse of existing (previously built) system components. The first technique is represented, for example, in materials published by NASA (e.g., NASA Systems Engineering Handbook) or by professional societies such as INCOSE (International Council on Systems Engineering). Well-formed SE techniques provide value by establishing the proper scope of the system (e.g., requirements), and by identifying and resolving problems relatively early in project lifecycles, when fixes are less expensive. The second technique (reuse) is applied most commonly to hardware and software; it seeks to avoid replicating design and implementation costs while also reducing risk by placing proven capabilities into operational use. In this paper, we outline a methodology combining these two techniques and extending reuse beyond hardware and software to foundational aspects of a Mission Operation System’s (MOS) design. We describe the system design artifacts that result (e.g., requirements, design documentation), as well as the reusable patterns and elements of the design, and their interrelationships. This approach is enabled by model-based systems engineering (MBSE) techniques and tools and is currently available in SysML form as a plug-in to MagicDraw. Additionally, usage of a rigorous MBSE approach allows for training materials and tutorials to be packaged within the overall model itself. The results of such an approach include decreased cost and risk during the design phase, improved ability of the MOS development team to investigate trade spaces and identify impacts to important flight-ground trade studies. Such results extend into decreased costs and risk in later phases due to improved design, decreased need for late fixes or development of "glue-ware" or scripts to fill unanticipated gaps in functionality, and improved ability to identify and plan testing and other validation activities. Finally, lower operational costs can be expected, both due to improved quality of the MOS, increased ease of maintaining updated knowledge of system configuration, and the fact that training and procedural materials are also updated at the same time as accepted system changes.

Bindschadler, Duane L.↗
DOE OSTI2025

GreenThrift: Optimizing Carbon and Cost for Flexible Residential Loads

Reducing buildings’ carbon emissions is an important sustainability challenge. While scheduling flexible building loads has been previously used for a variety of grid and energy optimizations, carbon footprint reduction using such flexible loads poses new challenges since such methods need to balance both energy and carbon costs while also reducing user inconvenience from delaying such loads. This paper highlights the potential conflict between electricity prices and carbon emissions and the resulting trade-offs in carbon-aware and cost-aware load scheduling. To address this trade-off, we propose GreenThrift, a home automation system that leverages the scheduling capabilities of smart appliances and knowledge of future carbon intensity and cost to reduce both the carbon emissions and costs of flexible energy loads. At the heart of GreenThrift is an optimization technique that automatically computes schedules based on user configurations and preferences. We evaluate the effectiveness of GreenThrift using real-world carbon intensity data, electricity prices, and load traces from multiple locations and across different scenarios and objectives. Our results show that GreenThrift can replicate the offline optimal and retains 97% of the savings when optimizing the carbon emissions. Moreover, we show how GreenThrift can balance the conflict between carbon and cost and retain 95.3% and 85.5% of the potential carbon and cost savings, respectively.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS1993

Cost model relationships between textile manufacturing processes and design details for transport fuselage elements

Textile manufacturing processes offer potential cost and weight advantages over traditional composite materials and processes for transport fuselage elements. In the current study, design cost modeling relationships between textile processes and element design details were developed. Such relationships are expected to help future aircraft designers to make timely decisions on the effect of design details and overall configurations on textile fabrication costs. The fundamental advantage of a design cost model is to insure that the element design is cost effective for the intended process. Trade studies on the effects of processing parameters also help to optimize the manufacturing steps for a particular structural element. Two methods of analyzing design detail/process cost relationships developed for the design cost model were pursued in the current study. The first makes use of existing databases and alternative cost modeling methods (e.g. detailed estimating). The second compares design cost model predictions with data collected during the fabrication of seven foot circumferential frames for ATCAS crown test panels. The process used in this case involves 2D dry braiding and resin transfer molding of curved 'J' cross section frame members having design details characteristic of the baseline ATCAS crown design.

Metschan, Stephen L.↗
NASA NTRS2002

Optimization Shield Materials Trade Study for Lunar/Gateway Mission

The great cost of added radiation shielding is a potential limiting factor in many deep space missions. For this enabling technology, we are developing tools for optimized shield design over multi-segmented missions involving multiple work and living areas in the transport and duty phase of various space missions. The total shield mass over all pieces of equipment and habitats is optimized subject to career dose and dose rate constraints. Preliminary studies of deep space missions indicate that for long duration space missions, improved shield materials will be required. The details of this new method and its impact on space missions and other technologies will be discussed. This study will provide a vital tool for evaluating Gateway designs in their usage context. Providing protection against the hazards of space radiation is one of the challenges to the Gateway infrastructure designs. We will use the mission optimization software to scope the impact of Gateway operations on human exposures and the effectiveness of alternate shielding materials on Gateway infrastructure designs. It is being proposed to use Moon and the Lagrange points as the hub for deep space missions. This study will provide a guide to the effectiveness of multifunctional materials in preparation to more detailed geometry studies in progress.

Tripathi, R. K.↗
DOE OSTI2020

Ultra-Light Hybrid Composite Door Design, Manufacturing and Demonstration

New Corporate Average Fuel Economy regulations require improved fuel efficiency of the future vehicle fleet. Weight reduction is key to achieving these targets. Replacing metallic body and chassis components with carbon fiber-reinforced composites offers the most weight reduction potential at up to 70%. Introduction of the BMW i3 and i8 in 2014 required mass production processes to meet 20,000+ units per year. Preforming with High Pressure Resin Transfer Molding has been implemented and meets rate, cost, and performance requirements. We will advance these technologies to develop an ultra-light driver’s side door for the vehicle with production rates of 40,000 units annually per plant in Detroit, Michigan. This project sought to employ a comprehensive systems approach for designing, manufacturing, and demonstrating an ultra-light hybrid composite automotive door. Composite structural components are integrated with other functional systems to reduce part count and full-system weight by a minimum of 42.5%. The approach will be demonstrated on a driver’s- side front door and will consider all fit, functional, safety, and cost requirements. These concepts will be evaluated using structural and crash simulations and linked to a manufacturing feasibility study, resulting in producible designs of an integrated door system. A cost model will evaluate part of the cost for the various designs and will ensure the cost target of less than $5 per pound of weight saved is met. Hybrid composites consisting of carbon, glass, and metal components will be included in our trade-off studies to satisfy these cost and performance goals.

02 PETROLEUM↗
DOE OSTI2023

Feasibility Analysis for the Use of Retrofitted Air-Conditioners Using Thermal Energy Storage (TES) for High Ambient Temperature (HAT) Countries

In high ambient temperature (HAT) countries, summer temperatures exceed 35℃, degrading the performance of air-conditioning systems and straining power grids. In this paper, a feasibility analysis was conducted to investigate potential savings during the peak using latent Thermal Energy Storage (TES) at near room phase-change temperatures, replacing condensers, thus, minimizing temperature lifts. Weather data, building loads, and baseline air-conditioning systems data were gathered for Dubai. A transient vapor-compression model in Modelica was used to compare the COP, total power input and cooling capacity of the air-conditioner at peak hours when ambient temperatures range between 35 – 45 ⁰C versus the TES-Phase-Change Material (PCM) melting temperatures from 22 – 28⁰C. The results indicate that the TES-PCM can enhance the system COP at the peak by a factor 1.4 and 2 for during for outdoor temperatures of 35 – 40⁰C, and 40 – 45⁰C, respectively. Lower melting temperature PCMs were able to reduce the required power input by 30-50%, with more savings occurring at higher temperature days. On the other hand, higher temperature PCMs enhancements were minimal especially at outdoor ambient temperatures ranging between 35 – 40⁰C. Improvements to the cooling capacity range from 8 – 18 % for the outdoor temperature range of 35 – 45 ⁰C. An economic analysis was conducted to find the potential saving in utility costs for 30%, 60%, and 90% of the space cooling demands of Dubai, and find the trade-off points between utility savings and cost of PCM-TES implementation. If the peak loads are to be shifted by 6 hours daily, the percentage utility savings for the city is 18%. Using estimated costs of the PCM-TES, ranging from $200-500/kWh, the daily load shifting hours were estimated to range from 4 hours at the lowest cost systems to 2.5 hours at the highest costs.

25 ENERGY STORAGE↗
DOE OSTI2024

Autonomous online optimization of a closed-circuit reverse osmosis system

As freshwater becomes increasingly scarce, many industrial and municipal water utilities look at premise-scale water treatment and reuse to meet water demand. Closed-circuit reverse osmosis (CCRO) has been proposed as a promising process design to do so. This sequencing batch process enables operation at higher brine salinity levels by means of a recycle flow. Optimal operation requires that the maximum salinity level at the membrane surface represents an optimal trade-off between brine disposal costs and energy efficiency. This maximum salinity level may change over time as the feed water composition changes and electricity markets fluctuate. In this article, we present the results of the experimental evaluation of an automatic technique for continuous online optimization, known as extremum seeking control. This technique has a long history in the process control community but has received little traction so far in the water industry. We modify this technique to enable its use for online optimization of CCRO, specifically to account for its sequential batch operation. We challenge the optimization schemes through several experimental tests and illustrate the advantages and drawbacks of extremum-seeking control.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

WOMBAT (Windfarm Operations and Maintenance cost-Benefit Analysis Tool) WISDEM® [SWR-21-68]

The windfarm operations and maintenance cost-benefit analysis tool (WOMBAT) is software to simulate the operations and maintenance phase of either onshore or offshore windfarms. WOMBAT is a medium-fidelity tool that is designed to model turbine, cable, and substation failures at the subassembly level, but is flexible enough that individual component or asset-level modeling can also be performed. WOMBAT enables users to model technological improvements, the use of a wide range of service equipment from drone repairs and remote resets to heavy lift vessels and crawler cranes, to analyze cost trends with varying trade-offs in conjunction with energy production, availability and a growing range of metrics. This library provides a tool to simulate the operation and maintenance phase (O&M) of distributed, land-based, and offshore windfarms using a discrete event simulation framework. WOMBAT is written around the SimPy discrete event simulation framework. Additionally, this is supported using a flexible and modular object-oriented code base, which enables the modeling of arbitrarily large (or small) windfarms with as many or as few failure and maintenance tasks that can be encoded. Please note that this is still heavily under development, so you may find some functionality to be incomplete at the current moment, but rest assured the functionality is expanding. With that said, it would be greatly appreciated for issues or PRs to be submitted for any improvements at all, from fixing typos (guaranteed to be a few) to features to testing. Also available at: https://pypi.org/project/wombat/

Cooperman, Aubryn↗
DOE OSTI2023

Hybrid Solar System (Final Scientific/Technical Report)

GTI Energy (GTI) teamed with the University of California at Merced (UCM) to scaleup the hybrid solar system (HSS) technology for demonstrating its performance at the US Gypsum (USG) plant in Plaster City, California. The technology integrates two-stage concentrating solar collector with matching particle thermal transport and storage (TSS) system to deliver cost-effective, and on-demand distributed high temperature industrial process heat up to 600°C with solar thermal, in this case to a gypsum kettle, to reduce its fuel use and carbon footprint. Current solar technologies, which reach these temperatures, are not distributable (towers) or cost-effective (dish). The research team developed a conceptual system design for host site retrofit, including preliminary heat balance, process flow diagram, particle to process heat exchanger and equipment placements at the site. Subsequently, parallel efforts were carried out at UCM to design, build and test a 12 m long commercial scale prototype concentrating thermal-only collector system and at GTI to design, build and test a matching 650°C capable particle TTS system. The nominal 50 kWth collector consists of a parabolic trough and three 4 m long two-stage receivers in series. Prior to on-sun testing, a 4 m long receiver was fabricated and successfully tested at 650 °C in a laboratory setting for 100 hrs of continuous operation showing less than 15% radiation loss. A 7 m wide x 17 m long parabolic trough was then installed at UCM for on-sun testing of the 12 m long receiver, and concurrently several 4 m long receivers were built. The optics of the parabolic trough were calibrated, and on-sun test were carried out on 12 m long receivers. During tests, the intense solar radiation (53x) caused the absorber tubes in the receivers to bend, reducing the overall optical efficiency. To address the bending issue, a self-consistent algorithm that includes ray tracing, thermal and deformation models was developed to perform thermal stress analysis on absorbers for parabolic solar collectors. Results obtained with this algorithm showed a dramatic rise in deformation as absorber tube length increases. A combined efficiency parameter that includes the occluded area for the mounts was developed to obtain an optimized tube length obtained. Based on the results, a length of 2.7 m for the absorber + 0.2 m for the coupler was chosen to minimize any bending and optimize optical efficiency while maintaining ease of mounting. The associated particle TTS system was designed, built and successfully tested at GTI. It includes storage, receiving and lock hoppers and piping that simulates the transfer of captured solar energy to an actual industrial furnace. Tests over 77 charge-discharge cycles demonstrated <2% particle degradation, with no problematic particle accumulations and no flow interruptions. The piping pressure drop was about 5 psi. The team also worked with Stanley Consultants (Stanley) to prepare conceptual and preliminary engineering packages to facilitate follow-on development and commercialization efforts. These include process and instrumentation diagram’s (P&ID’s), general arrangements, electrical one-line, project definitions document, equipment data sheets, schedule, and construction cost estimate for 2 MWth system. Updated HSS technology commercialization and customer engagement plans and detailed costs and evaluated market trade-offs and manufacturing.

03 NATURAL GAS↗
DOE OSTI2025

West Coast Offshore Wind Transmission Study

As a primary federal investigation of the utility of transmission to support offshore wind emergence in the Western Interconnect, the West Coast Offshore Wind Transmission study evaluates five distinct West Coast-wide transmission scenarios and trades the economic benefits and costs of six development pathways from 2035 to 2050. In this time, 33 GW of OSW generation and supporting transmission are explored within the context of 350 additional GW of generation to support 100% clean electricity. Geospatial analysis informed plausible transmission topologies and cost estimates. All pathways to intraregional or interregional coordination transmission builds showed more than $\$$14 billion in present value cost savings, with a maximum of $\$$25 billion of savings in the interregional case. These savings are primarily driven by fuel costs and increased availability of power flows enabled by new transmission networks. Key considerations of clean, dispatchable generation options, geographic disaggregation of costs, system reliability reinforcements, resilience, and community values are also presented and discussed.

17 WIND ENERGY↗
DOE OSTI2022

AssessCCUS: An Integrated Approach for Aggregating Resources to Enable Techno-Economic and Life Cycle Assessment of Carbon Management Technologies

Carbon capture, utilization, and storage (CCUS) - also sometimes known as carbon management - technologies are becoming an increasingly important part of the portfolio of technologies necessary to mitigate climate change and defossilize industrial production systems (Sick, 2021). These technologies capture carbon dioxide from industrial point sources or from the atmosphere directly and then either sequester it or use it as a carbon source in valuable products. Potential utilization pathways include, but are not limited to, concrete, fuels, and certain commodity chemicals, and sequestration pathways can include permanent geological storage or temporary storage in natural sinks ranging from forests to agricultural soil. Regardless of the pathway, assessment of the economic and environmental performance of the technologies is important for understanding their potential scalability and impact as well as developing plans to minimize life cycle costs and potential environmental trade-offs. A full discussion of potential trade-offs associated with CCUS is outside the scope of this article, but promoting assessment broadly helps to stimulate important conversations about the benefits and drawbacks of any particular technological choice.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

The Effect of the Flux Separability Approximation on Multigroup Neutron Transport

The angular dependence of flux-weighted multigroup cross sections is commonly neglected when generating multigroup libraries. The error of this flux separability approximation is typically not isolated from other error sources due to a lack of availability of library generation and corresponding solvers that cannot relax this approximation. These errors can now be isolated and quantified with the availability of a multigroup Monte Carlo transport and multigroup library-generation capability in the OpenMC Monte Carlo transport code. This work will discuss relevant details of the OpenMC implementation, provide an example case useful for detailing the type of errors one can expect from making the flux separability approximation, and end with more realistic problems which show the impact of the approximation and highlight how it can strongly arise from an energy-dependent resonance absorption effect. Since the angle-dependence is intrinsically linked to the energy group structure, these examples also show that relaxing the flux separability approximation with angle-dependent cross sections could be used to reduce either the fine-tuning required to set a multigroup energy structure for a specific reactor type or the number of energy groups required to obtain a desired level of accuracy for a given problem. This trade-off could increase the costs of generating multigroup cross sections, and has the potential to require more memory for storing the multigroup library during the transport calculations, but it can significantly reduce the computational time required since the runtime of a discrete ordinates or method of characteristics neutron transport solver scales roughly linearly with the number of groups.

42 ENGINEERING↗
DOE OSTI2025

Distinguishing Orbiting and Infalling Dark Matter Particles with Machine Learning

Dark matter halos are typically defined as spheres that enclose some overdensity, but these sharp, somewhat arbitrary boundaries introduce nonphysical artifacts such as backsplash halos, pseudo-volution, and an incomplete accounting of halo mass. A more physically motivated alternative is to define halos as the collection of particles that are physically orbiting within their potential well. However, existing methods to classify particles as orbiting or infalling suffer from trade-offs between accuracy, computational cost, and generalizability across cosmologies. We present an efficient, yet accurate, supervised machine learning approach using decision trees. The classification is based on only the particle radii and velocities at two epochs. Compared to detailed analysis of particle trajectories, we find that our model matches the classification of 97% of particles. Consequently, we are able to quickly and accurately reproduce the density profiles of the orbiting and infalling components out to many virial radii. We demonstrate that our model generalizes to a significantly different cosmology that lies outside the training data set. We make publicly available both our final model and the code to train similar models.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS1974

Earth Observatory Satellite system definition study. Report 6: Space shuttle interfaces/utilization

An analysis was conducted to determine the compatibility of the Earth Observatory Satellite (EOS) with the space shuttle. The mechanical interfaces and provisions required for a launch or retrieval of the EOS by the space shuttle are summarized. The space shuttle flight support equipment required for the operation is defined. Diagrams of the space shuttle in various configurations are provised to show the mission capability with the EOS. The subjects considered are as follows: (1) structural and mechanical interfaces, (2) spacecraft retention and deployment, (3) spacecraft retrieval, (4) electrical interfaces, (5) payload shuttle operations, (6) shuttle mode cost analysis, (7) shuttle orbit trades, and (8) safety considerations.

Source record↗
NASA NTRS1976

Addendum report to atmospheric science facility pallet-only mode space transportation system payload feasibility study, volume 3, revision A

The feasibility of accomplishing selected atmospheric science mission using a pallet-only mode was studied. Certain unresolved issues were identified. The first issue was that of assuring that the on-board computer facility was adequate to process scientific data, control subsystems such as instrument pointing, provide mission operational program capability, and accomplish display and control. The second issue evolved from an investigation of the availability of existing substitute instruments that could be used instead of the prime instrumentation where the development tests and schedules are incompatible with the realistic budgets and shuttle vehicle schedules. Some effort was expended on identifying candidate substitute instruments, and the performance, cost, and development schedule trade-offs found during that effort were significant enough to warrant a follow-on investigation. This addendum documents the results of that follow-on effort, as it applies to the Atmospheric Sciences Facility.

Source record↗
NASA NTRS1980

Geostationary platform systems concepts definition study. Volume 2: Technical, book 1

The initial selection and definition of operational geostationary platform concepts is discussed. Candidate geostationary platform missions and payloads were identified from COMSAT, Aerospace, and NASA studies. These missions and payloads were cataloged; classified with to communications, military, or scientific uses; screened for application and compatibility with geostationary platforms; and analyzed to identify platform requirements. Two platform locations were then selected (Western Hemisphere - 110 deg W, and Atlantic - 15 deg W), and payloads allocated based on nominal and high traffic models. Trade studies were performed leading to recommendation of selected concepts. Of 30 Orbit Transfer Vehicle (0TV) configuration and operating mode options identified, 18 viable candidates compatible with the operational geostationary platform missions were selected for analysis. Each was considered using four platform operational modes - 8 or 16 year life, and serviced or nonserviced, providing a total of 72 OTV/platform-mode options. For final trade study concept selection, a cost program was developed considering payload and platform costs and weight; transportation unit and total costs for the shuttle and OTV; and operational costs such as assembly or construction time, mating time, and loiter time. Servicing costs were added for final analysis and recommended selection.

Source record↗