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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 37 records · Page 2

Process-level cost analysis of hybrid manufacturing pathways for aerospace structural components

Hybrid manufacturing is a promising route for producing complex aerospace components, yet systematic cost benchmarking across multiple additive-subtractive pathways remains limited. This study presents a comprehensive process-based cost analysis of seven hybrid manufacturing routes, including laser powder bed fusion (L-PBF), powder- and wire-directed energy deposition (DED), wire arc additive manufacturing (WAAM), additive friction stir deposition (AFSD), metal binder jetting (MBJ), and agility forging, followed by scanning and finish machining. Parametric cost models incorporating direct material, labor, and energy costs were developed. L-PBF results are discussed in detail for a pickle fork component and directly compared with commercial pricing. Across all hybrid routes, labor emerged as the dominant cost driver, contributing more than 70% of total manufacturing cost in some cases. AFSD exhibited the lowest cost for aluminum components, with MBJ being its 316 L stainless steel counterpart, after accounting for geometric scaling. Benchmarking against industrial quotes suggests that hybrid manufacturing can achieve cost levels comparable to those of commercial services, although labor-intensive processes exhibit greater deviation. The analysis highlights automation of material handling, setup, and supervision as key opportunities for improving economic competitiveness. Overall, the proposed framework provides a quantitative basis for evaluating and optimizing hybrid manufacturing pathways for aerospace applications.

Baruah, Sweta [ORNL] (ORCID:0009000174256207)↗

Correlational selection and genetic architecture shape the evolution of the leaf economics spectrum in a perennial grass

The generality of the worldwide leaf economics spectrum (LES) has made it a pillar of trait-based ecological research. Yet, few studies have examined the processes shaping the evolution of the LES within species, in part, because most species occupy only a small portion of the LES. Here, to address this gap, we took advantage of the distinct leaf economics strategies present in different ecotypes of the phenotypically diverse perennial grass Panicum virgatum (switchgrass) to generate a genetic mapping population, which we planted in common gardens at three sites spanning 12 degrees of latitude in the central United States. With this genetic mapping population, we evaluated two potentially interacting causes of LES evolution: 1) genetic architecture, where multiple traits are influenced by either the same gene (pleiotropy) or by genes in close physical proximity (genetic linkage), and 2) correlational selection, where selection acts on traits in combination rather than in isolation. We found that shared genetic architecture influenced covariation between photosynthetic rate (A MASS ) and leaf nitrogen (N MASS ) and between A MASS and leaf mass per area (LMA). We also found that correlational selection favored the trait combinations predicted by the LES (e.g., high LMA with low N MASS or low LMA with high N MASS ) and disfavored other, mismatched trait combinations at two of the three sites. Together, these results demonstrate how the evolution of an integrated LES within species can arise from multiple evolutionary causes.

59 BASIC BIOLOGICAL SCIENCES↗

De-Risking High-Recovery Brackish Water Desalination via Flow Reversal and Feed Flushing Using Techno-Economic Assessment

Novel desalination technologies have demonstrated enhanced performance and improved financial metrics over existing processes adopted by industry. Establishing quantitative performance targets is essential for achieving financial benefits over the current state of the art. Herein, we demonstrate how WaterTAP, a techno-economic assessment (TEA) tool, can be used to identify minimum performance metrics necessary to achieve financial benefit over using existing processes. This study evaluates the feasibility of increasing water recovery at the Chino Desalter I above 90 % through the addition of a third variable configuration reverse osmosis (VCRO) stage. Sensitivity analyses revealed flow reversal frequency, feed flushing volume (used as a cleaning step), and membrane lifespan are key factors influencing the financial viability of the VCRO process. The TEA analysis demonstrated that the system must achieve a recovery of 84 % and a 1-year membrane lifespan to have a breakeven LCOW, while achieving 90 % recovery can ultimately reduce the LCOW by 16 %. Notably, a trade-off between decreasing frictional losses and increased osmotic pressure across the recovery range, resulted in a stable specific energy consumption across the recovery range, enabling meaningful LCOW reductions without an energy penalty, a key finding that contrasts with conventional RO. This work demonstrates how TEA can guide system design by identifying key performance targets and exploring trade-offs, enabling data-driven decisions to de-risk innovative processes. These findings underscore the importance of leveraging TEA to evaluate scaling mitigation strategies and optimize inland desalination systems for sustainable and cost-effective operation.

14 SOLAR ENERGY↗

Enhancing Short-Term Flexibility through Characterization of HVDC Transmission Systems

Efficient power grid operation hinges on maintaining safety and reliability through adaptable system flexibility standards. However, in a future power grid characterized by extensive renewable energy integration, conventional system flexibility and predetermined requirements may falter under extreme conditions. This paper addresses the formidable challenge of sustaining secure and dependable power grid operations under these circumstances, emphasizing the role of controllable high voltage direct current (HVdc) transmission systems in amplifying overall system flexibility and tackling operational complexities. To quantitatively assess short-term flexibility and its associated economic benefits from HVdc within specific regions, we propose a Power Flow Distribution Factors (PTDFs) based approach. This methodology takes into account both dispatchable generators and HVdc systems, pinpointing their contributions. Through an analysis of the Western Electricity Coordinating Council (WECC) system, we demonstrate the practical application of this approach to scrutinize the impacts of existing and future HVdc lines.

Operational Flexibility, Multi-terminal HVdc, tran↗

Towards Disentangling Lockdown-Driven Air Quality Changes in the Northeastern U.S.

In the absence of preventive therapies or effective treatment for most cases of coronavirus disease 2019 (COVID-19), governments worldwide have sought to minimize person-to-person severe acute respiratory syndrome coronavirus 2 (SARS-CoV-2) transmission through a variety of lock-down measures and social distancing policies. Extreme events like the COVID-19 pandemic present a tremendous opportunity to make quantitative connections between changes in anthropogenic forcing, social and economic activity, and the related Earth system response. In this comment, we examine air quality impacts associated with pandemic response measures in the Northeastern United States.

Air Quality↗

Runway configuration improvement programming model.

The basic objectives of the study were to subject a set of runway configurations to cost analysis and to develop a dynamic programming model which would enable an airport to economically match the ground capacity to its air traffic demand. Quantitative differences in the capacity of runway configurations result from the various aircraft/aircraft and aircraft/air-system interactions. A problem formulation and solution procedure is presented which is intended to be a meaningful technique for the long-range planning of runway expansion programs.

Yu, J. C.↗

Analysis of the effectiveness of industrial R and D

The criteria used by private industry in evaluating and selecting proposed research and development projects for implementation, and also in determining which R and D facilities are to be acquired were investigated. Conceptual and practical issues inherent in any quantitative analysis of the contribution of R and D to economic growth were identified in order to assist NASA in developing approaches for analzying the economic implication of its own R and D efforts.

Fisher, W. H.↗

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.↗

ORACLES: Optimized Rational Algorithm for Conjecture of Long-term Exploration of Space

ORACLES is a joint venture between the United States Space Force (USSF) and the National Aeronautics and Space Administration (NASA) to develop a model for future space exploration, commercialization, and expansion. Following the success of qualitative future scenario exploration during the Space Futures Workshops (SFW), ORACLES aims to produce a quantitative means of evaluating these same factors. This model considers the social, economic, and political environment and determines possible inflection points; that is, the most crucial investments in technologies, infrastructure, and policy for the support and protection of U.S. and allied space assets. The development of ORACLES is in its infancy, with front end interfaces constructed for discussion and debate before the overall algorithm is finalized. Comments are highly encouraged as the team wishes to gain the broadest level of perspectives before continuing with development.

Robert B Adams↗

Review of Technical Photovoltaic Key Performance Indicators and the Importance of Data Quality Routines

Technical key performance indicators (KPIs) are important metrics used to assess and quantitatively summarize various aspects of photovoltaic (PV) systems, including long-term performance, economic viability, and carbon footprint. Herein, a group of experts of the International Energy Agency's Photovoltaic Power Systems Programme Task 13 collect and describ the most important technical KPIs used in the industry. Thereby, a set of best practices for reliably handling PV system data is presented and the impact of data quality and climatic variability on KPI calculation is investigated. Further, the effective use of technical KPIs allows triggering data-driven and informed decisions to optimize PV systems and providing a comprehensive overview of how PV systems operate across different conditions and climates. With the worldwide growth of the PV industry, more companies operate/own PV systems in different regions, where the climatic and seasonal profiles differ. This requires context-aware evaluation of KPIs, or the judicious application of multiple KPIs, to ensure that each asset is evaluated correctly. Beyond that, there is untapped potential in the utilization of KPIs through geospatial mapping and extrapolation of fleet KPIs. This study demonstrates that the uncertainty in KPI estimation is not well understood and depends on data quality, climatic variability, and system configuration.

14 SOLAR ENERGY↗

Ecologically inspired metrics for transitioning to a sustainable and resilient circular economy with application to multilayer plastic films

Current Circular Economy (CE) frameworks applied to product chains exhibit notable shortcomings. These include neglecting the resilience and robustness of design, requiring detailed economic and environmental data for impact assessment, and relying on qualitative rather than quantitative metrics capturing certain CE design aspects. In the current contribution, we addressed these shortcomings by developing an Ecologically inspired (Eco-inspired) Framework using the mathematical foundations of Ecological Network Analysis (ENA). While ENA metrics have previously found application in designing circular economies, particularly in Industrial Symbiosis (IS) networks, our adaptation tailors these metrics for use in product-level CE, recognizing the inherent distinctions between product-level CE and IS. Our Eco-inspired Framework comprises three key categories to provide holistic and granular-level metrics for designing product-level CE. The first set of metrics assesses circularity and resource efficiency. The second set gauges network intensity and robustness as complementary indicators ensuring a CE is both sustainable and resilient. The third group of metrics evaluates enhancement potential of CE strategies through introducing quantitative metrics for measuring the degree of closed-loop strategies and average circularity level of a CE design. The three comprehensive set of indicators within the Eco-inspired Framework uniquely captures various facets of circular design, whether originating from technological innovations and recovery improvement at the end of life (EoL), shifts in human consumption patterns, alterations in product design, or changes in business models. The framework’s application is tested in designing a CE for multilayer Polyethylene-Polyamide (PE-PA) films. Using the Eco-inspired Framework, we identified the best strategy for designing a resilient and sustainable CE for PE-PA films. A diverse set of EoL strategies along with a reduction in product consumption can improve circularity and resilience by 650% and 255%, respectively, and mitigate greenhouse gas emissions by 90%. The framework minimizes trade-offs between sustainability and circularity goals and offers insights on how to enhance each strategy for achieving a resilient and sustainable CE for products.

54 ENVIRONMENTAL SCIENCES↗

Cost and Benefit Analysis of Mitigating, Tracking, and Remediating Orbital Debris

Orbital debris may collide with crewed and robotic spacecraft, placing them at risk. The wide range of debris, from 9,000-kilogram rocket bodies to millions of millimeter-size debris, has led to a similarly wide range of proposed actions for addressing the risks posed by debris. However, the costs and benefits of these actions have historically been unknown. This is a challenge for decision makers who are choosing which actions to support through technology development or policy changes. NASA’s Office of Technology, Policy, and Strategy is addressing these technical and economic uncertainties by building a capability to (1) complete rigorous calculations of the net present value of each action, (2) identify an optimal portfolio of actions to reduce risk, and (3) quantitatively analyze policies related to space sustainability. This report describes our progress toward that capability and to solicit feedback from the space and economic communities. Our previous work, referred to here as Phase 1, assessed the costs and benefits of performing debris remediation on operationally relevant timescales. The current analysis contains major updates to the risk model used in Phase 1 and expands the breadth of actions considered to include mitigating the creation of debris, improving the ability to track debris, and more methods for cleaning up existing debris. We demonstrate that our approach of measuring risks in dollars allows for the effectiveness of seemingly incommensurate actions to be compared and generates insights that other approaches to measuring risk have missed.

Jericho Locke↗

Cost and Benefit Analysis of Mitigating, Tracking, and Remediating Orbital Debris

Presentation accompanying the technical report with the same name. The abstract for the report and the full study is repeated below. Orbital debris may collide with crewed and robotic spacecraft, placing them at risk. The wide range of debris, from 9,000-kilogram rocket bodies to millions of millimeter-size debris, has led to a similarly wide range of proposed actions for addressing the risks posed by debris. However, the costs and benefits of these actions have historically been unknown. This is a challenge for decision makers who are choosing which actions to support through technology development or policy changes. NASA’s Office of Technology, Policy, and Strategy is addressing these technical and economic uncertainties by building a capability to (1) complete rigorous calculations of the net present value of each action, (2) identify an optimal portfolio of actions to reduce risk, and (3) quantitatively analyze policies related to space sustainability. This report describes our progress toward that capability and to solicit feedback from the space and economic communities. Our previous work, referred to here as Phase 1, assessed the costs and benefits of performing debris remediation on operationally relevant timescales. The current analysis contains major updates to the risk model used in Phase 1 and expands the breadth of actions considered to include mitigating the creation of debris, improving the ability to track debris, and more methods for cleaning up existing debris. We demonstrate that our approach of measuring risks in dollars allows for the effectiveness of seemingly incommensurate actions to be compared and generates insights that other approaches to measuring risk have missed.

Jericho Locke↗

A Cost and Benefit Analysis of Orbital Debris Remediation, Mitigation,Tracking, and Characterization

Orbital debris may collide with crewed and robotic spacecraft, placing them at risk. The wide range of debris, from 9,000-kilogram rocket bodies to millions of millimeter-size debris, has led to a similarly wide range of proposed actions for addressing the risks posed by debris. However, the costs and benefits of these actions have historically been unknown. This is a challenge for decision makers who are choosing which actions to support through technology development or policy changes. NASA’s Office of Technology, Policy, and Strategy is addressing these technical and economic uncertainties by building a capability to (1) complete rigorous calculations of the net present value of each action, (2) identify an optimal portfolio of actions to reduce risk, and (3) quantitatively analyze policies related to space sustainability. This report describes our progress toward that capability and to solicit feedback from the space and economic communities. Our previous work(Colvin, Karcz, and Wusk. 2023), referred to here as Phase 1, assessed the costs and benefits of performing debris remediation on operationally relevant timescales. The current paper summarizes the work of Locke and Colvin (2024), which contains major updates to the risk model used in Phase 1 and expands the breadth of actions considered to include mitigating the creation of debris, improving the ability to track debris, and more methods for cleaning up existing debris. We demonstrate that our approach of measuring risks in dollars allows for the effectiveness of seemingly incommensurate actions to be compared and generates insights that other approaches to measuring risk have missed.

Orbital Debris↗

CO2 Storage Economic Analysis: CarbonSAFE Use Case

Poster on “CO2 Storage Economic Analysis: CarbonSAFE Use Case” for the CCUS 2025 conference held in Houston, Texas March 3-5, 2025. The cost of designing, permitting, constructing, operating, and closing a CO2 storage project is of vital importance to project developers. The National Energy Technology Laboratory has developed the NRAP/SMART Technoeconomic and Liability Evaluation for Storage (TALES) Model to provide quantitative cost-based insights to support developers planning CO2 injection and storage projects. This study presents a collaborative economic analysis applying TALES with data from the San Juan Basin CarbonSAFE Phase III project led by the New Mexico Institute of Mining and Technology to estimate potential costs incurred during the implementation of a real-world commercial-scale carbon storage project. Scenario analysis was implemented in which different operational and cost attributes were varied and the associated cost implications observed. Key results data and project cost summary metrics, first-year breakeven price of CO2 ($/tonne) and net present value (NPV), are presented for base and alternative cases. Output provides a unique perspective for project stakeholders towards evaluating the influence of different operational strategies and financing approaches on overall project cost and financial viability.

carbon storage↗

Computational study of nonlinear plasma waves

A low-noise plasma simulation model is developed and applied to a series of linear and nonlinear problems associated with electrostatic wave propagation in a one-dimensional, collisionless, Maxwellian plasma, in the absence of magnetic field. It is demonstrated that use of the hybrid simulation model allows economical studies to be carried out in both the linear and nonlinear regimes with better quantitative results, for comparable computing time, than can be obtained by conventional particle simulation models, or direct solution of the Vlasov equation. The characteristics of the hybrid simulation model itself are first investigated, and it is shown to be capable of verifying the theoretical linear dispersion relation at wave energy levels as low as .000001 of the plasma thermal energy. Having established the validity of the hybrid simulation model, it is then used to study the nonlinear dynamics of monochromatic wave, sideband instability due to trapped particles, and satellite growth.

Matsuda, Y.↗

Human Spaceflight Architecture Model (HSFAM) Data Dictionary

HSFAM is a data model based on the DoDAF 2.02 data model with some for purpose extensions. These extensions are designed to permit quantitative analyses regarding stakeholder concerns about technical feasibility, configuration and interface issues, and budgetary and/or economic viability.

architecture definition↗

An Integrated Economics Model for ISRU in Support of a Mars Colony - Initial Status Report

The aim of this effort is to develop an integrated set of risk-based financial and technical models to evaluate multiple Off-Earth Mining (OEM) scenarios. This quantitative, scenario- and simulation-based tool will help identify combinations of market variables, technical parameters, and policy levers that will enable the expansion of the global economy into the solar system and return economic benefits. Human ventures in space are entering a new phase in which missions formerly driven by government agencies are now being replaced by those led by commercial enterprises - in launch, satellite deployment, resupply of the International Space Station, and space tourism. In the not-too-distant future, commercial opportunities will also include the mining of asteroids, the Moon, and Mars. This investigation will examine the role of OEM in a growing space economy. (In this investigation, the term 'mining' is taken to embrace minerals, ice/water, and other in situ resources.) OEM can be the engine that drives the space economy, so it would be useful to understand what OEM market conditions and technology requirements are needed for that economy to prosper. These specific elements will be studied in the wider context of creating an economy that could ultimately support a sustainable Mars Colony. Such a colony will need in situ resources not only for its own survival, but to prosper and grow, it must create viable business ventures, essentially by fulfilling the demand for in situ resources from and on Mars. This investigation will focus on understanding the role and economic prospect for OEM associated with the Human Colonization of Mars (HCM).

architecture framework↗