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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1991

Designing for Cost

Designing for cost is a state of mind. Of course, a lot of technical knowledge is required and the use of appropriate tools will improve the process. Unfortunately, the extensive use of weight based cost estimating relationships has generated a perception in the aerospace community that the primary way to reduce cost is to reduce weight. Wrong! Based upon an approximation of an industry accepted formula, the PRICE H (tm) production-production equation, Dean demonstrated theoretically that the optimal trajectory for cost reduction is predominantly in the direction of system complexity reduction, not system weight reduction. Thus the phrase "keep it simple" is a primary state of mind required for reducing cost throughout the design process.

Dean, Edwin B.↗
NASA NTRS2000

Oxygen Compatibility Testing of Composite Materials

The development of polymer composite liquid oxygen LO2 tanks is a critical step in creating the next generation of launch vehicles. Future launch vehicles need to minimize the gross liftoff weight (GLOW), which is possible due to the 25%-40% reduction in weight that composite materials could provide over current aluminum technology. Although a composite LO2 tank makes these weight savings feasible, composite materials have not historically been viewed as "LO2 compatible." To be considered LO2 compatible, materials must be selected that will resist any type of detrimental, combustible reaction when exposed to usage environments. This is traditionally evaluated using a standard set of tests. However, materials that do not pass the standard tests can be shown to be safe for a particular application. This paper documents the approach and results of a joint NASA/Lockheed Martin program to select and verify LO2 compatible composite materials for liquid oxygen fuel tanks. The test approach developed included tests such as mechanical impact, particle impact, puncture, electrostatic discharge, friction, and pyrotechnic shock. These tests showed that composite liquid oxygen tanks are indeed feasible for future launch vehicles.

Graf, Neil A.↗
NASA NTRS2003

Composite Development and Applications for RLV Tankage

The development of polymer composite cryogenic tanks is a critical step in creating the next generation of launch vehicles. Future launch vehicles need to minimize the gross liftoff weight (GLOW), which is possible due to the 28%-41% reduction in weight that composite materials can provide over current aluminum technology. The development of composite cryogenic tanks, feedlines, and unpressurized structures are key enabling technologies for performance and cost enhancements for Reusable Launch Vehicles (RLVs). The technology development of composite tanks has provided direct and applicable data for feedlines, unpressurized structures, material compatibility, and cryogenic fluid containment for highly loaded complex structures and interfaces. All three types of structure have similar material systems, processing parameters, scaling issues, analysis methodologies, NDE development, damage tolerance, and repair scenarios. Composite cryogenic tankage is the most complex of the 3 areas and provides the largest breakthrough in technology. A building block approach has been employed to bring this family of difficult technologies to maturity. This approach has built up composite materials, processes, design, analysis and test methods technology through a series of composite test programs beginning with the NASP program to meet aggressive performance goals for reusable launch vehicles. In this paper, the development and application of advanced composites for RLV use is described.

Wright, Richard J.↗
NASA NTRS2001

Increased Body Weight Reduces Voluntary Movement to Maintain Energy Expenditure of Rats Exposed to Increases in Gravity

With the increase in obesity related diseases there is heightened interest in mechanisms regulating body weight. To assess the influence of increases in body weight on energy expenditure and intake in rats we employed variable levels of gravity. Our approach afforded the means to measure interactions of energy expenditure and intake in response to increases in body weight (body mass x gravity level). We found a dose relationship between rapid elevation of body weight and reduction of voluntary movement, such that the energy requirements for activity are unchanged, and total energy expenditure and intake maintained. Reduction of movement appears to be a response to increased body weight, rather than a contributing factor, suggesting a new regulatory pathway.

Wade, C. E.↗
NASA NTRS2001

Vapor Growth of Binary and Ternary Chalcogenides in Preparation for Microgravity Experiments

In the bulk crystal growth of some technologically important semiconducting chalcopyrites, such as ZnTe, CdS, ZnSe and ZnS, vapor growth techniques have significant advantages over melt growth techniques due to the high melting points of these materials. The realization of routine production of high-quality single crystals of these semiconductors requires a fundamental, systematic and in-depth study on the PVT growth process and crystal growth by vapor transport in low gravity offers a set of unique conditions for this study. Previously, two reasons have been put forward to account for this. The first is weight-related reductions in crystal strain and defects. These are thought to be caused by the weight of the crystals during processing at elevated temperatures and retained on cooling, particularly for materials with a low yield strength. The second, and more general, reason is related to the reduction in density-gradient driven convection. The PVT crystal growth process consists of essentially three processes: sublimation of the source material, transport of the vapor species and condensation of the vapor species to form the crystal. The latter two processes can be affected by the convection caused by gravitational accelerations on Earth. Reductions in such convection in low gravity is expected to yield a nearly diffusion-limited growth condition which results in more uniform growth rates (on the microscopic scale) and hence greater crystalline perfection and compositional homogeneity. The reduction of convective contamination by performing flight experiments in a reduced gravity environment will help to understand the relation between fluid phase processes (growth parameters) and defect and impurity incorporation in grown crystals.

Su, C.↗
NASA NTRS2001

Vapor Growth of Binary and Ternary Chalcogenides in Preparation for Microgravity Experiments

In the bulk crystal growth of some technologically important semiconducting chalcopyrites, such as ZnTe, CdS, ZnSe and ZnS, vapor growth techniques have significant advantages over melt growth techniques due to the high melting points of these materials. The realization of routine production of high-quality single crystals of these semiconductors requires a fundamental, systematic and in-depth study on the PVT growth process and crystal growth by vapor transport in low gravity offers a set of unique conditions for this study. Previously, two reasons have been put forward to account for this. The first is weight-related reductions in crystal strain and defects. These are thought to be caused by the weight of the crystals during processing at elevated temperatures and retained on cooling, particularly for materials with a low yield strength. The second, and more general, reason is related to the reduction in density-gradient driven convection. The PVT crystal growth process consists of essentially three processes: sublimation of the source material, transport of the vapor species and condensation of the vapor species to form the crystal. The latter two processes can be affected by the convection caused by gravitational accelerations on Earth. Reductions in such convection in low gravity is expected to yield a nearly diffusion-limited growth condition which results in more uniform growth rates (on the microscopic scale) and hence greater crystalline perfection and compositional homogeneity. The reduction of convective contamination by performing flight experiments in a reduced gravity environment will help to understand the relation between fluid phase processes (growth parameters) and defect and impurity incorporation in grown crystals.

Su, Ching-Hua↗
NASA NTRS2026

A Modular Conjugate Heat Transfer Optimization Framework for Thermal Management of Electric Aircraft

Conjugate heat transfer (CHT) analysis and optimization is a powerful method for improving thermal management, as it simultaneously resolves the temperature distribution in both fluid and solid domains. This paper presents a modular, discrete adjoint-based CHT optimization capability integrated within the OpenMDAO/MPhys framework. A unique feature of the proposed framework is its flexibility to extend to multidisciplinary optimization, including aero-structural-thermal applications. The fluid domain is modeled using a finite-volume Computational Fluid Dynamics (CFD) solver, and the solid domain with a conduction heat transfer solver. A mixed Neumann-Dirichlet boundary condition is developed to enable full submersion of the solid geometry within the fluid domain, while ensuring consistent temperature and heat flux coupling at the CHT interface. Gradient-based optimization is performed; the gradients are efficiently computed using the discrete adjoint solvers implemented in DAFoam. To demonstrate the method, this paper considers two cases related to electric aircraft thermal management: a U-bend heat exchanger and an actively cooled battery pack. The U-bend case aims to minimize pressure loss while maximizing heat flux by changing the pipe geometry. The optimized design reduces pressure loss by 52.7% and increases total heat flux by 2.3%. In the battery pack case, a 3-by-3 cell configuration is cooled by ambient airflow, with constant heat generation prescribed in the cells. The battery casing shape serves as the design variable, and the objective function is a weighted sum of pressure loss and pack weight, subject to a maximum temperature constraint. The optimized design achieves a 44.6% reduction in pressure loss and a 1.5% reduction in weight, while satisfying the thermal constraint. To ensure the reliability of the optimized designs, this study validates coarse-mesh, steady-state predictions against fine-mesh unsteady simulations, demonstrating consistency within acceptable errors. This work demonstrates the potential of the developed framework to enable rapid, high-fidelity design of thermal management systems for electric aircraft.

heat transfer↗
NASA NTRS2007

Structural Design and Analysis of Un-pressurized Cargo Delivery Vehicle

As part of the Exploration Systems Architecture Study, NASA has defined a family of vehicles to support lunar exploration and International Space Station (ISS) re-supply missions after the Shuttle s retirement. The Un-pressurized Cargo Delivery Vehicle (UCDV) has been envisioned to be an expendable logistics delivery vehicle that would be used to deliver external cargo to the ISS. It would be launched on the Crew Launch Vehicle and would replace the Crew Exploration Vehicle. The estimated cargo would be the weight of external logistics to the ISS. Determining the minimum weight design of the UCDV during conceptual design is the major issue addressed in this paper. This task was accomplished using a procedure for rapid weight estimation that was based on Finite Element Analysis and sizing of the vehicle by the use of commercially available codes. Three design concepts were analyzed and their respective weights were compared. The analytical structural weight was increased by a factor to account for structural elements that were not modeled. Significant reduction in weight of a composite design over metallic was achieved for similar panel concepts.

Martinovic, Zoran N.↗
DOE OSTI2025

Understanding and Estimating Error Propagation in Neural Networks for Scientific Data Analysis

Neural networks are increasingly integrated into scientific discovery, where input data reduction and model quantization play a key role in accelerating inference. However, understanding and mitigating the impact of these techniques on output error is critical for ensuring reliable results, particularly in tasks demanding high numerical precision. This paper introduces a comprehensive framework for optimizing neural network inference in scientific computing by combining data reduction and weight quantization while maintaining error-controlled outcomes. We develop theoretical analyses to bound error propagation under these reductions and propose a framework that balances computational performance with error constraints. Evaluation on real-world learning-based combustion simulations and satellite image classification demonstrates that our derived error bounds accurately predict observed errors while enabling significant computational speedup under our framework. This work highlights the potential for further leveraging advancements in modern lossy compression algorithms and hardware accelerators that support lower-precision formats.

He, Weiming [New Jersey Institute of Technology]↗
NASA NTRS1976

Research requirements to reduce empty weight of helicopters by use of advanced materials

Utilization of the new, lightweight, high-strength, aerospace structural-composite (filament/matrix) materials, when specifically designed into a new aircraft, promises reductions in structural empty weight of 12 percent at recurring costs competive with metals. A program of basic and applied research and demonstration is identified with the objective of advancing the state of the art to the point where civil helicopters are confidently designed, produced, certified, and marketed by 1985. A structural empty-weight reduction of 12 percent was shown to significantly reduce energy consumption in modern high-performance helicopters.

Hoffstedt, D. J.↗
NASA NTRS1952

Effect of Various Blade Modifications in Performance of a 16-Stage Axial-flow Compressor. IV - Effect on Over-all Performance Characteristics of Decreasing Twelfth through Fifteenth Stage Stator-blade Angles 3 deg and Increasing Stator Angles in the Inlet Stages

The performance of a 16-stage axial-flow compressor, in which two modifications of unloaded inlet stages were combined with loaded exit stages, has been determined. In the first modification the exit stages were loaded by decreasing the twelfth through fifteenth stage stator angles 3 deg. as compared with the blade angles in the original compressor, and the inlet stages were unloaded by increasing the blade angles the following amounts: guide vanes and first-stage stator, 6 deg; second- and third-stage stators, 4 deg.; and fourth-stage stators, 3 deg. The over-all performance of this configuration was compared with that of the compressor with the original blade angles. The peak efficiency was increased at all speeds below design and the weight flow was higher at speeds below 80 percent of design, the same at 80 percent of design, and lower at speeds abovce 80 percent of design. The maximum reduction in weight flow occurred at design speed. The surge limit line was higher at speeds between 75 and 90 percent of design when presented on a pressure ratio against weight flow basis. The second configuration was the same as the first with the exception that the second-, third-, and fourth-stage stator blade angles were the same as in the compressor with the original blade angles. A comparison of the performance of this configuration with that of the compressor with the original blade angles showed the same general trends of changes in performance as the first configuration. Comparisons were made of compressor configurations to show the effects upon the performance of decreased loading in the inlet stages. Below 75 percent of design speed, decreased loading results in increased weight flow and peak efficiency; above 80 percent of design speed, decreased loading in the inlet stages results in decreased weight flow and small changes in peak efficiencies. Between 75 and 90 percent of design the changes in surge weight flow and pressure ratio were such that the surge limit line was raised with decreased loading in the inlet stages when presented as pressure ratio against weight flow.

Hatch, James E.↗
NASA NTRS2001

Exoskeletal Engine Concept: Feasibility Studies for Medium and Small Thrust Engines

The exoskeletal engine concept is one in which the shafts and disks are eliminated and are replaced by rotating casings that support the blades in spanwise compression. Omission of the shafts and disks leads to an open channel at the engine centerline. This has immense potential for reduced jet noise and for the accommodation of an alternative form of thruster for use in a combined cycle. The use of ceramic composite materials has the potential for significantly reduced weight as well as higher working temperatures without cooling air. The exoskeletal configuration is also a natural stepping-stone to complete counter-rotating turbomachinery. Ultimately this will lead to reductions in weight, length, parts count and improved efficiency. The feasibility studies are in three parts. Part 1: Systems and Component Requirements addressed the mechanical aspects of components from a functionality perspective. This effort laid the groundwork for preliminary design studies. Although important, it is not felt to be particularly original, and has therefore not been included in the current overview. Part 2: Preliminary Design Studies turned to some of the cycle and performance issues inherent in an exoskeletal configuration and some initial attempts at preliminary design of turbomachinery were described. Twin-spoon and single-spool 25,800-lbf-thrust turbofans were used as reference vehicles in a mid-size commercial subsonic category in addition to a single-spool 5,000-lbf-thrust turbofan that represented a general aviation application. The exoskeletal engine, with its open centerline, has tremendous potential for noise suppression and some preliminary analysis was done which began to quantify the benefits. Part 3: Additional Preliminary Design Studies revisited the design of single-spool 25,800-lbf-thrust turbofan configurations, but in addition to the original FPR = 1.6 and BPR = 5.1 reference engine. two additional configurations used FPR = 2.4 and BPR = 3.0 and FPR = 3.2 and BPR = 2.0 were investigated. The single-spool 5.000-lbf-thrust turbofan was refined and the small engine study was extended to include a 2,000-lbf-thrust turbojet. More attention was paid to optimizing the turbomachinery. Turbine cooling flows were eliminated, in keeping with the use of uncooled CMC materials in exoskeletal engines. The turbine performance parameters moved much closer to the nominal target values, demonstrating the great benefits to the cycle of uncooled turbines.

Halliwell, Ian↗
NASA NTRS2001

Exoskeletal Engine Concept: Feasibility Studies for Medium and Small Thrust Engines

The exoskeletal engine concept is one in which the shafts and disks are eliminated and are replaced by rotating casings that support the blades in spanwise compression. Omission of the shafts and disks leads to an open channel at the engine centerline. This has immense potential for reduced jet noise and for the accomodation of an alternative form of thruster for use in a combined cycle. The use of ceramic composite materials has the potential for significantly reduced weight as well as higher working temperatures without cooling air. The exoskeletal configuration is also a natural stepping-stone to complete counter-rotating turbomachinery. Ultimately this will lead to reductions in weight, length, parts count and improved efficiency. The feasibility studies are in three parts. Part I-Systems and Component Requirements addressed the mechanical aspects of components from a functionality perspective. This effort laid the groundwork for preliminary design studies. Although important, it is not felt to be particularly original, and has therefore not been included in the current overview. Part 2-Preliminary Design Studies turned to some of the cycle and performance issues inherent in an exoskeletal configuration and some initial attempts at preliminary design of turbomachinery were described. Twin-spoon and single-spool 25.800-lbf-thrust turbofans were used as reference vehicles in a mid-size commercial subsonic category in addition to a single-spool 5,000-lbf-thrust turbofan that represented a general aviation application. The exoskeletal engine, with its open centerline, has tremendous potential for noise suppression and some preliminary analysis was done which began to quantify the benefits. Part 3-Additional Preliminary Design Studies revisited the design of single-spool 25,800-lbf-thrust turbofan configurations, but in addition to the original FPR = 1.6 and BPR = 5.1 reference engine, two additional configurations used FPR = 2.4 and BPR = 3.0 and FPR = 3.2 and BPR = 2.0 were investigated. The single-spool 5,000-lbf-thrust turbofan was refined and the small engine study was extended to include a 2,000-lbf-thrust turbojet. More attention was paid to optimizing the turbomachinery. Turbine cooling flows were eliminated, in keeping with the use of uncooled CMC material in exoskeletal engines. The turbine performance parameters moved much closer to the nominal target values, demonstrating the great benefits to the cycle of uncooled turbines.

Halliwell, Ian↗
NASA NTRS1975

DC-9 flight demonstration program with refanned JT8D engines. Volume 4: Flyover noise

Flyover noise tests were conducted to determine the noise reductions achievable by modifying the engines and nacelles of DC-9-30 airplanes. The two stage fan of the JT8D-9 engine was replaced with a larger diameter, single stage fan and sound absorbing materials were incorporated in the engines and nacelles. The noise levels were determined to be 95.3 EPNdB at the sideline, 96.2 EPNdB for a full thrust takeoff, 87.5 EPNdB for takeoff with thrust cutback, and 97.4 EPNdB for landing approach. The noise reductions relative to the hardwall JT8D-9 were 8.2 EPNdB for takeoff with cutback and 8.7 EPNdB for landing. The 90 EPNdB noise contour areas were reduced by 40% for missions requiring maximum design takeoff and landing weights. For typical mission weights, the reductions were 19% for full thrust takeoff and 34% for takeoff with cutback. The 95 EPNdB contour areas were reduced by 50% for takeoff and 30% for takeoff with cutback for both missions.

Source record↗
NASA NTRS2011

Reliability Based Design for a Raked Wing Tip of an Airframe

A reliability-based optimization methodology has been developed to design the raked wing tip of the Boeing 767-400 extended range airliner made of composite and metallic materials. Design is formulated for an accepted level of risk or reliability. The design variables, weight and the constraints became functions of reliability. Uncertainties in the load, strength and the material properties, as well as the design variables, were modeled as random parameters with specified distributions, like normal, Weibull or Gumbel functions. The objective function and constraint, or a failure mode, became derived functions of the risk-level. Solution to the problem produced the optimum design with weight, variables and constraints as a function of the risk-level. Optimum weight versus reliability traced out an inverted-S shaped graph. The center of the graph corresponded to a 50 percent probability of success, or one failure in two samples. Under some assumptions, this design would be quite close to the deterministic optimum solution. The weight increased when reliability exceeded 50 percent, and decreased when the reliability was compromised. A design could be selected depending on the level of risk acceptable to a situation. The optimization process achieved up to a 20-percent reduction in weight over traditional design.

Patnaik, Surya N.↗
NASA NTRS2005

Series-Connected Buck Boost Regulators

A series-connected buck boost regulator (SCBBR) is an electronic circuit that bucks a power-supply voltage to a lower regulated value or boosts it to a higher regulated value. The concept of the SCBBR is a generalization of the concept of the SCBR, which was reported in "Series-Connected Boost Regulators" (LEW-15918), NASA Tech Briefs, Vol. 23, No. 7 (July 1997), page 42. Relative to prior DC-voltage-regulator concepts, the SCBBR concept can yield significant reductions in weight and increases in power-conversion efficiency in many applications in which input/output voltage ratios are relatively small and isolation is not required, as solar-array regulation or battery charging with DC-bus regulation. Usually, a DC voltage regulator is designed to include a DC-to-DC converter to reduce its power loss, size, and weight. Advances in components, increases in operating frequencies, and improved circuit topologies have led to continual increases in efficiency and/or decreases in the sizes and weights of DC voltage regulators. The primary source of inefficiency in the DC-to-DC converter portion of a voltage regulator is the conduction loss and, especially at high frequencies, the switching loss. Although improved components and topology can reduce the switching loss, the reduction is limited by the fact that the converter generally switches all the power being regulated. Like the SCBR concept, the SCBBR concept involves a circuit configuration in which only a fraction of the power is switched, so that the switching loss is reduced by an amount that is largely independent of the specific components and circuit topology used. In an SCBBR, the amount of power switched by the DC-to-DC converter is only the amount needed to make up the difference between the input and output bus voltage. The remaining majority of the power passes through the converter without being switched. The weight and power loss of a DC-to-DC converter are determined primarily by the amount of power processed. In the SCBBR, the unswitched majority of the power is passed through with very little power loss, and little if any increase in the sizes of the converter components is needed to enable the components to handle the unswitched power. As a result, the power-conversion efficiency of the regulator can be very high, as shown in the example of Figure 1. A basic SCBBR includes a DC-to-DC converter (see Figure 2). The switches and primary winding of a transformer in the converter is connected across the input bus, while the secondary winding and switches are connected in series with the output bus, so that the output voltage is the sum of the input voltage and the secondary voltage of the converter. In the breadboard SCBBR, the input voltage applied to the primary winding is switched by use of metal oxide/semiconductor field-effect transistors (MOSFETs) in a full bridge circuit; the secondary winding is center-tapped, with two MOSFET switches and diode rectifiers connected in opposed series in each leg. The sets of opposed switches and rectifiers are what enable operation in either a boost or a buck mode. In the boost mode, input voltage and current, and the output voltage and current are all positive; that is, the secondary voltage is added to the input voltage and the net output voltage can be regulated at a value equal or greater than the input voltage. In the buck mode, input voltage is still positive and the current still flows in the same direction in the secondary, but the switches are controlled such that some power flows from the secondary to the primary. The voltage across the secondary and the current into the primary are reversed. The result is that the output voltage is lower than the input voltage, and some power is recirculated from the converter secondary back to the input. Quantitatively, the advantage of an SCBBR is a direct function of the regulation range required. If, for example, a regulation range of 20 percent is required for a 500-W supply, th it suffices to design the DC-to-DC converter in the SCBBR for a power rating of only 100 W. The switching loss and size are much smaller than those of a conventional regulator that must be rated for switching of all 500 W. The reduction in size and the increase in efficiency are not directly proportional to switched-power ratio of 5:1 because the additional switches contribute some conduction loss and the input and output filters must be larger than those typically required for a 100-W converter. Nevertheless, the power loss and the size can be much smaller than those of a 500-W converter.

Birchenough, Arthur G.↗
NASA NTRS2006

Lower-Conductivity Ceramic Materials for Thermal-Barrier Coatings

Doped pyrochlore oxides of a type described below are under consideration as alternative materials for high-temperature thermal-barrier coatings (TBCs). In comparison with partially-yttria-stabilized zirconia (YSZ), which is the state-of-the-art TBC material now in commercial use, these doped pyrochlore oxides exhibit lower thermal conductivities, which could be exploited to obtain the following advantages: For a given difference in temperature between an outer coating surface and the coating/substrate interface, the coating could be thinner. Reductions in coating thicknesses could translate to reductions in weight of hot-section components of turbine engines (e.g., combustor liners, blades, and vanes) to which TBCs are typically applied. For a given coating thickness, the difference in temperature between the outer coating surface and the coating/substrate interface could be greater. For turbine engines, this could translate to higher operating temperatures, with consequent increases in efficiency and reductions in polluting emissions. TBCs are needed because the temperatures in some turbine-engine hot sections exceed the maximum temperatures that the substrate materials (superalloys, Si-based ceramics, and others) can withstand. YSZ TBCs are applied to engine components as thin layers by plasma spraying or electron-beam physical vapor deposition. During operation at higher temperatures, YSZ layers undergo sintering, which increases their thermal conductivities and thereby renders them less effective as TBCs. Moreover, the sintered YSZ TBCs are less tolerant of stress and strain and, hence, are less durable.

Bansal, Narottam P.↗
NASA NTRS1967

Flight computers and sequencers

At present, the most common method of increasing reliability of a system against permanent random component failures is to triplicate the entire system and use voters. This method, though it enhances the reliability, does exact a heavy toll in weight and power consumption which increase by about 225%. In the future, computers will be required to perform complex tasks under adverse conditions on surfaces of planets for long periods of time (6 months or more), without any human intervention. At the same time there will be severe limitations on the weight and power consumption of these computers. For such systems it is obvious that simple triple-redundancy will not do. A more efficient and sophisticated design in redundancy has to evolve. This study has been directed toward that goal. It is understood that the initial design of such a system will be too complex and expensive to be used in a commercial computer; but for a space computer, reduction in weight (without reducing reliability) of every ounce means a great deal.

REDUNDANCY↗