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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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NASA NTRS1979

Quality assurance and control in the production and static tests of the solid rocket boosters for the Space Shuttle

The paper surveys the various aspects of design and overhaul of the solid rocket boosters. It is noted that quality control is an integral part of the design specifications. Attention is given to the production process which is optimized towards highest quality. Also discussed is the role of the DCA (Defense Contract Administration) in inspecting the products of subcontractors, noting that the USAF performs this role for prime contractors. Fabrication and construction of the booster is detailed with attention given to the lining of the booster cylinder and the mixing of the propellant and the subsequent X-ray inspection.

Cerny, O. F.↗

NASA NTRS1984

Alternatives for jet engine control

The technical progress of researches on alternatives for jet engine control is reported. Extensive numerical testing is included. It is indicated that optimal inputs contribute significantly to the process of calculating tensor approximations for nonlinear systems, and that the resulting approximations may be order-reduced in a systematic way.

Sain, M. K.↗

NASA NTRS1988

The PC/AT compatible computer as a mission control center display processor at Ames-Dryden Flight Research Facility

The NASA Ames-Dryden Flight Research Facility's Western Aeronautical Test Range will assign the flight test data display processing function to Mission Control Centers in order to allow research engineers to flexibly configure their own display-processing system to optimize performance during a flight research mission. This will leave the Telemetry Radar Acquisition and Processing System more time to acquire data. One of the processors chosen to handle the display-processing function is an IBM PC/AT-compatible, rack-mounted PC giving engineers a personalized set of analytic and display tools, developed on the basis of off-the-shelf PC/AT-compatible engineering hardware and software items.

Hammons, Kevin R.↗

NASA NTRS1990

Structure/control synthesis with nonnegligible actuator mass

The simultaneous design of a structure/active control system is addressed in which the mass of the actuators required to implement the active control is considered. An algorithm for estimating the required actuator mass given the control law and the desired maneuver is presented. A nonlinear optimization algorithm is used to direct the design process. Results are given for the design of a L shaped structure where it is desired to minimize the line of sight pointing error after a worst case slew maneuver.

Zimmerman, David C.↗

NASA NTRS2013

Neutron Characterization for Additive Manufacturing

Oak Ridge National Laboratory (ORNL) is leveraging decades of experience in neutron characterization of advanced materials together with resources such as the Spallation Neutron Source (SNS) and the High Flux Isotope Reactor (HFIR) shown in Fig. 1 to solve challenging problems in additive manufacturing (AM). Additive manufacturing, or three-dimensional (3-D) printing, is a rapidly maturing technology wherein components are built by selectively adding feedstock material at locations specified by a computer model. The majority of these technologies use thermally driven phase change mechanisms to convert the feedstock into functioning material. As the molten material cools and solidifies, the component is subjected to significant thermal gradients, generating significant internal stresses throughout the part (Fig. 2). As layers are added, inherent residual stresses cause warping and distortions that lead to geometrical differences between the final part and the original computer generated design. This effect also limits geometries that can be fabricated using AM, such as thin-walled, high-aspect- ratio, and overhanging structures. Distortion may be minimized by intelligent toolpath planning or strategic placement of support structures, but these approaches are not well understood and often "Edisonian" in nature. Residual stresses can also impact component performance during operation. For example, in a thermally cycled environment such as a high-pressure turbine engine, residual stresses can cause components to distort unpredictably. Different thermal treatments on as-fabricated AM components have been used to minimize residual stress, but components still retain a nonhomogeneous stress state and/or demonstrate a relaxation-derived geometric distortion. Industry, federal laboratory, and university collaboration is needed to address these challenges and enable the U.S. to compete in the global market. Work is currently being conducted on AM technologies at the ORNL Manufacturing Demonstration Facility (MDF) sponsored by the DOE's Advanced Manufacturing Office. The MDF is focusing on R&D of both metal and polymer AM pertaining to in-situ process monitoring and closed-loop controls; implementation of advanced materials in AM technologies; and demonstration, characterization, and optimization of next-generation technologies. ORNL is working directly with industry partners to leverage world-leading facilities in fields such as high performance computing, advanced materials characterization, and neutron sciences to solve fundamental challenges in advanced manufacturing. Specifically, MDF is leveraging two of the world's most advanced neutron facilities, the HFIR and SNS, to characterize additive manufactured components.

Watkins, Thomas↗

NASA NTRS2003

The Role of Design-of-Experiments in Managing Flow in Compact Air Vehicle Inlets

It is the purpose of this study to demonstrate the viability and economy of Design-of-Experiments methodologies to arrive at microscale secondary flow control array designs that maintain optimal inlet performance over a wide range of the mission variables and to explore how these statistical methods provide a better understanding of the management of flow in compact air vehicle inlets. These statistical design concepts were used to investigate the robustness properties of low unit strength micro-effector arrays. Low unit strength micro-effectors are micro-vanes set at very low angles-of-incidence with very long chord lengths. They were designed to influence the near wall inlet flow over an extended streamwise distance, and their advantage lies in low total pressure loss and high effectiveness in managing engine face distortion. The term robustness is used in this paper in the same sense as it is used in the industrial problem solving community. It refers to minimizing the effects of the hard-to-control factors that influence the development of a product or process. In Robustness Engineering, the effects of the hard-to-control factors are often called noise , and the hard-to-control factors themselves are referred to as the environmental variables or sometimes as the Taguchi noise variables. Hence Robust Optimization refers to minimizing the effects of the environmental or noise variables on the development (design) of a product or process. In the management of flow in compact inlets, the environmental or noise variables can be identified with the mission variables. Therefore this paper formulates a statistical design methodology that minimizes the impact of variations in the mission variables on inlet performance and demonstrates that these statistical design concepts can lead to simpler inlet flow management systems.

Anderson, Bernhard H.↗

NASA NTRS1992

A stochastic optimal feedforward and feedback control methodology for superagility

A new control design methodology is developed: Stochastic Optimal Feedforward and Feedback Technology (SOFFT). Traditional design techniques optimize a single cost function (which expresses the design objectives) to obtain both the feedforward and feedback control laws. This approach places conflicting demands on the control law such as fast tracking versus noise atttenuation/disturbance rejection. In the SOFFT approach, two cost functions are defined. The feedforward control law is designed to optimize one cost function, the feedback optimizes the other. By separating the design objectives and decoupling the feedforward and feedback design processes, both objectives can be achieved fully. A new measure of command tracking performance, Z-plots, is also developed. By analyzing these plots at off-nominal conditions, the sensitivity or robustness of the system in tracking commands can be predicted. Z-plots provide an important tool for designing robust control systems. The Variable-Gain SOFFT methodology was used to design a flight control system for the F/A-18 aircraft. It is shown that SOFFT can be used to expand the operating regime and provide greater performance (flying/handling qualities) throughout the extended flight regime. This work was performed under the NASA SBIR program. ICS plans to market the software developed as a new module in its commercial CACSD software package: ACET.

Halyo, Nesim↗

NASA NTRS1995

Rapid Airplane Parametric Input Design (RAPID)

RAPID is a methodology and software system to define a class of airplane configurations and directly evaluate surface grids, volume grids, and grid sensitivity on and about the configurations. A distinguishing characteristic which separates RAPID from other airplane surface modellers is that the output grids and grid sensitivity are directly applicable in CFD analysis. A small set of design parameters and grid control parameters govern the process which is incorporated into interactive software for 'real time' visual analysis and into batch software for the application of optimization technology. The computed surface grids and volume grids are suitable for a wide range of Computational Fluid Dynamics (CFD) simulation. The general airplane configuration has wing, fuselage, horizontal tail, and vertical tail components. The double-delta wing and tail components are manifested by solving a fourth order partial differential equation (PDE) subject to Dirichlet and Neumann boundary conditions. The design parameters are incorporated into the boundary conditions and therefore govern the shapes of the surfaces. The PDE solution yields a smooth transition between boundaries. Surface grids suitable for CFD calculation are created by establishing an H-type topology about the configuration and incorporating grid spacing functions in the PDE equation for the lifting components and the fuselage definition equations. User specified grid parameters govern the location and degree of grid concentration. A two-block volume grid about a configuration is calculated using the Control Point Form (CPF) technique. The interactive software, which runs on Silicon Graphics IRIS workstations, allows design parameters to be continuously varied and the resulting surface grid to be observed in real time. The batch software computes both the surface and volume grids and also computes the sensitivity of the output grid with respect to the input design parameters by applying the precompiler tool ADIFOR to the grid generation program. The output of ADIFOR is a new source code containing the old code plus expressions for derivatives of specified dependent variables (grid coordinates) with respect to specified independent variables (design parameters). The RAPID methodology and software provide a means of rapidly defining numerical prototypes, grids, and grid sensitivity of a class of airplane configurations. This technology and software is highly useful for CFD research for preliminary design and optimization processes.

Smith, Robert E.↗

DOE OSTI2026

Texture development in magnetostrictive Fe-Ga alloys processed by laser powder bed fusion

Iron-gallium (Fe-Ga, Galfenol) alloys are promising magnetostrictive materials for actuators, sensors, and energy harvesting, but their performance is highly sensitive to microstructure and texture. Additive manufacturing by laser powder bed fusion (LPBF) offers a pathway to engineer texture and integrate functional materials into complex geometries. Here, we fabricate Fe-Ga alloys (Fe 82.2 Ga 17.8 ) by LPBF of gas-atomized powders and systematically optimize laser power and scan speed to maximize density and control texture. Nearly full-density parts (up to 99.6 %) are achieved within a narrow processing window. Electron backscatter diffraction (EBSD) reveals a strong <100> fiber texture aligned with the build direction and columnar grains up to 1 mm long. Magnetostriction measurements show saturation magnetostriction of 190 ppm in the build direction. Correlating texture data with macroscopic magnetostriction, we estimate intrinsic magnetostriction constants (λ 100 = 228 ppm, λ 111 = 12 ppm), closely matching single crystal-derived values. These results demonstrate the critical interplay between processing, texture, and functional performance in additively manufactured Fe-Ga alloys and establish LPBF as a viable route for high-performance magnetostrictive materials.

Additive manufacturing↗

NASA NTRS1991

Description of real-time Ada software implementation of a power system monitor for the Space Station Freedom PMAD DC testbed

The Ada language software development to perform the electrical system monitoring functions for the NASA Lewis Research Center's Power Management and Distribution (PMAD) DC testbed is described. The results of the effort to implement this monitor are presented. The PMAD DC testbed is a reduced-scale prototype of the electrical power system to be used in the Space Station Freedom. The power is controlled by smart switches known as power control components (or switchgear). The power control components are currently coordinated by five Compaq 382/20e computers connected through an 802.4 local area network. One of these computers is designated as the control node with the other four acting as subsidiary controllers. The subsidiary controllers are connected to the power control components with a Mil-Std-1553 network. An operator interface is supplied by adding a sixth computer. The power system monitor algorithm is comprised of several functions including: periodic data acquisition, data smoothing, system performance analysis, and status reporting. Data is collected from the switchgear sensors every 100 milliseconds, then passed through a 2 Hz digital filter. System performance analysis includes power interruption and overcurrent detection. The reporting mechanism notifies an operator of any abnormalities in the system. Once per second, the system monitor provides data to the control node for further processing, such as state estimation. The system monitor required a hardware time interrupt to activate the data acquisition function. The execution time of the code was optimized using an assembly language routine. The routine allows direct vectoring of the processor to Ada language procedures that perform periodic control activities. A summary of the advantages and side effects of this technique are discussed.

Ludwig, Kimberly↗

NASA NTRS2016

The Business Change Initiative: A Novel Approach to Improved Cost and Schedule Management

Goddard Space Flight Center's Flight Projects Directorate employed a Business Change Initiative (BCI) to infuse a series of activities coordinated to drive improved cost and schedule performance across Goddard's missions. This sustaining change framework provides a platform to manage and implement cost and schedule control techniques throughout the project portfolio. The BCI concluded in December 2014, deploying over 100 cost and schedule management changes including best practices, tools, methods, training, and knowledge sharing. The new business approach has driven the portfolio to improved programmatic performance. The last eight launched GSFC missions have optimized cost, schedule, and technical performance on a sustained basis to deliver on time and within budget, returning funds in many cases. While not every future mission will boast such strong performance, improved cost and schedule tools, management practices, and ongoing comprehensive evaluations of program planning and control methods to refine and implement best practices will continue to provide a framework for sustained performance. This paper will describe the tools, techniques, and processes developed during the BCI and the utilization of collaborative content management tools to disseminate project planning and control techniques to ensure continuous collaboration and optimization of cost and schedule management in the future.

Schedule↗

DOE OSTI2025

Screw-Dislocation-Driven Growth of 2D Perovskite Spiral Microplates

Two-dimensional (2D) organic–inorganic halide perovskites are solution-processable semiconductors that are promising for optoelectronic applications. Understanding crystallization mechanisms to achieve control over nanostructures is important for optimizing desired properties. Here we introduce a versatile strategy to synthesize spiral microplates of diverse 2D perovskites at the air–water interface through screw-dislocation-driven growth. Spirals of 11 2D perovskite compositions (LA) 2 (A) n−1 Pb n X 3n+1 with different spacer (LA) cations, A-cations, halide (X) anions, and n-number can be grown. They typically consist of single- or few-layer perovskite step heights but exhibit stacking complexity when multiple dislocations interact. The spiral microplates exhibit the characteristic optical properties (photoluminescence and second-harmonic generation) of the underlying 2D perovskites. Fluorescence-detected circular dichroism imaging shows that the chirality of the spiral center does not translate to the observed chiroptical properties of the microplate, consistent with the length scale of the chiral distortion. Furthermore, this solution growth of perovskite spirals diversifies the perovskite microstructures for optoelectronics and other applications.

2D halide perovskites↗

NASA NTRS1983

Development of a Multilevel Optimization Approach to the Design of Modern Engineering Systems

A general algorithm is proposed which carries out the design process iteratively, starting at the top of the hierarchy and proceeding downward. Each subproblem is optimized separately for fixed controls from higher level subproblems. An optimum sensitivity analysis is then performed which determines the sensitivity of the subproblem design to changes in higher level subproblem controls. The resulting sensitivity derivatives are used to construct constraints which force the controlling subproblems into chosing their own designs so as to improve the lower levels subproblem designs while satisfying their own constraints. The applicability of the proposed algorithm is demonstrated by devising a four-level hierarchy to perform the simultaneous aerodynamic and structural design of a high-performance sailplane wing for maximum cross-country speed. Finally, the concepts discussed are applied to the two-level minimum weight structural design of the sailplane wing. The numerical experiments show that discontinuities in the sensitivity derivatives may delay convergence, but that the algorithm is robust enough to overcome these discontinuities and produce low-weight feasible designs, regardless of whether the optimization is started from the feasible space or the infeasible one.

Barthelemy, J. F. M.↗

NASA NTRS2001

Predictor-Corrector Entry Guidance for Reusable Launch Vehicles

An online entry guidance algorithm has been developed using a predictor-corrector approach. The algorithm is designed for the Reusable Launch Vehicle (RLV) and is demonstrated by using, the X-33 model. The objective of the design is to handle widely dispersed entry conditions and deliver the vehicle at the Terminal Area Energy Management (TAEM) interface box within an acceptable tolerance and without violating any of the vehicle physical constraints. Combination of several control variables is used in testing the performance and computational requirement of the algorithm. The control variables are the bank angle, angle-of-attack and the time for roll reversal. The bank angle and angle-of-attack profiles are the nominal profiles plus the perturbations in each direction. The initial guess of the bank profile is a 45 degrees bank angle with reversal at 360 seconds from liftoff. A six-element state vector is propagated to the TAEM interface box through the integration of the equations of motion (EOM). Altitude, heading and range errors are computed between the desired and the achieved state at the TAEM interface. These errors are used to correct the initial guess of the control variables. This process is repeated until the errors meet an acceptable level at the TAEM interface. Several numerical optimization methods are used to evaluate the convergent property of the predictor-predictor methodology. Successful results are demonstrated using the X-33 model.

Youssef, Hussein↗

NASA NTRSDate not supplied

Toward the fabrication of a 5 μm resolution Wolter microscope for the National Ignition Facility

Advancements in computer-controlled polishing, metrology, and replication have led to a x-ray mirror fabrication process that is capable of producing high-resolution Wolter microscopes. The mirror is a nickel-cobalt replicated full-shell mirror that was electroformed from a finely figured and polished mandrel. This mandrel was designed and fabricated for a 8 m source-to-detector distance microscope, with 10× magnification. A computer controlled polishing process corrected the low-frequency mandrel figure to < 2.0 nm RMS error. The mandrel design was optimized to reduce shell distortions that occur mainly < 20 mm from the shell ends. This design, in combination with improved replication tooling design and refined bath parameters informed by a detailed COMSOL model, have led to reductions in replication errors in the mirror shell. X-ray tests performed on a pair of mirror shells replicated from the mandrel have demonstrated < 10 μm FWHM source plane imaging resolution. Here we discuss the development process, highlight results from metrology and x-ray testing, and define a path for achieving 5 μm FWHM resolution.

Grazing Incidence, Wolter Microscope, X-ray Optics↗

DOE OSTI2025

Safe Reinforcement Learning-Based Transient Stability Control for Islanded Microgrids With Topology Reconfiguration

This paper proposes a safe reinforcement learning (RL)-based transient stability emergency control (TSEC) method for islanded microgrids. RL requires extensive interaction with the environment to learn control strategies, hence, a data-driven approach is used as a substitute for time-consuming time-domain simulation calculations. Deep sigma point processes (DSPP), which is a Gaussian process model, is utilized to predict the normal distribution of transient stability of microgrids and to construct a transient stability chance constraint. Reward-constrained policy optimization (RCPO) can simultaneously achieve objective prediction, policy learning, and constraint cost coefficient update across multiple timescales. RCPO interacts with the DSPP-based microgrid environment through a multi-process parallel manner, greatly increasing the training speed. Case studies on a real islanded microgrid demonstrate that the proposed method can efficiently and quickly obtain the optimal emergency control strategy while adhering to all hard constraints.

14 SOLAR ENERGY↗

NASA NTRS2004

Pre-Hardware Optimization and Implementation Of Fast Optics Closed Control Loop Algorithms

One of the main heritage tools used in scientific and engineering data spectrum analysis is the Fourier Integral Transform and its high performance digital equivalent - the Fast Fourier Transform (FFT). The FFT is particularly useful in two-dimensional (2-D) image processing (FFT2) within optical systems control. However, timing constraints of a fast optics closed control loop would require a supercomputer to run the software implementation of the FFT2 and its inverse, as well as other image processing representative algorithm, such as numerical image folding and fringe feature extraction. A laboratory supercomputer is not always available even for ground operations and is not feasible for a night project. However, the computationally intensive algorithms still warrant alternative implementation using reconfigurable computing technologies (RC) such as Digital Signal Processors (DSP) and Field Programmable Gate Arrays (FPGA), which provide low cost compact super-computing capabilities. We present a new RC hardware implementation and utilization architecture that significantly reduces the computational complexity of a few basic image-processing algorithm, such as FFT2, image folding and phase diversity for the NASA Solar Viewing Interferometer Prototype (SVIP) using a cluster of DSPs and FPGAs. The DSP cluster utilization architecture also assures avoidance of a single point of failure, while using commercially available hardware. This, combined with the control algorithms pre-hardware optimization, or the first time allows construction of image-based 800 Hertz (Hz) optics closed control loops on-board a spacecraft, based on the SVIP ground instrument. That spacecraft is the proposed Earth Atmosphere Solar Occultation Imager (EASI) to study greenhouse gases CO2, C2H, H2O, O3, O2, N2O from Lagrange-2 point in space. This paper provides an advanced insight into a new type of science capabilities for future space exploration missions based on on-board image processing for control and for robotics missions using vision sensors. It presents a top-level description of technologies required for the design and construction of SVIP and EASI and to advance the spatial-spectral imaging and large-scale space interferometry science and engineering.

Kizhner, Semion↗

NASA NTRS1998

A Numerical Optimization Approach for Tuning Fuzzy Logic Controllers

This paper develops a method to tune fuzzy controllers using numerical optimization. The main attribute of this approach is that it allows fuzzy logic controllers to be tuned to achieve global performance requirements. Furthermore, this approach allows design constraints to be implemented during the tuning process. The method tunes the controller by parameterizing the membership functions for error, change-in-error and control output. The resulting parameters form a design vector which is iteratively changed to minimize an objective function. The minimal objective function results in an optimal performance of the system. A spacecraft mounted science instrument line-of-sight pointing control is used to demonstrate results.

Woodard, Stanley E.↗