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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 NTRS2015

Low Cost Upper Stage-Class Propulsion (LCUSP)

NASA is making space exploration more affordable and viable by developing and utilizing innovative manufacturing technologies. Technology development efforts at NASA in propulsion are committed to continuous innovation of design and manufacturing technologies for rocket engines in order to reduce the cost of NASA's journey to Mars. The Low Cost Upper Stage-Class Propulsion (LCUSP) effort will develop and utilize emerging Additive Manufacturing (AM) to significantly reduce the development time and cost for complex rocket propulsion hardware. Benefit of Additive Manufacturing (3-D Printing) Current rocket propulsion manufacturing techniques are costly and have lengthy development times. In order to fabricate rocket engines, numerous complex parts made of different materials are assembled in a way that allow the propellant to collect heat at the right places to drive the turbopump and simultaneously keep the thrust chamber from melting. The heat conditioned fuel and oxidizer come together and burn inside the combustion chamber to provide thrust. The efforts to make multiple parts precisely fit together and not leak after experiencing cryogenic temperatures on one-side and combustion temperatures on the other is quite challenging. Additive manufacturing has the potential to significantly reduce the time and cost of making rocket parts like the copper liner and Nickel-alloy jackets found in rocket combustion chambers where super-cold cryogenic propellants are heated and mixed to the extreme temperatures needed to propel rockets in space. The Selective Laser Melting (SLM) machine fuses 8,255 layers of copper powder to make a section of the chamber in 10 days. Machining an equivalent part and assembling it with welding and brazing techniques could take months to accomplish with potential failures or leaks that could require fixes. The design process is also enhanced since it does not require the 3D model to be converted to 2-D drawings. The design and fabrication process can be sped up and improved with fewer errors to be accomplished in weeks instead of months.

Vickers, John↗
NASA NTRS2015

Iodine Propulsion Advantages for Low Cost Mission Applications and the Iodine Satellite (ISAT) Technology Demonstration

The NASA Marshall Space Flight Center Science and Technology Office is continuously exploring technology options to increase performance or reduce cost and risk to future NASA missions including science and exploration. Electric propulsion is a prevalent technology known to reduce mission costs by reduction in launch costs and spacecraft mass through increased post launch propulsion performance. The exploration of alternative propellants for electric propulsion continues to be of interest to the community. Iodine testing has demonstrated comparable performance to xenon. However, iodine has a higher storage density resulting in higher ΔV capability for volume constrained systems. Iodine's unique properties also allow for unpressurized storage yet sublimation with minimal power requirements to produce required gas flow rates. These characteristics make iodine an ideal propellant for secondary spacecraft. A range of mission have been evaluated with a focus on low-cost applications. Results highlight the potential for significant cost reduction over state of the art. Based on the potential, NASA has been developing the iodine Satellite for a near-term iodine Hall propulsion technology demonstration. Mission applications and progress of the iodine Satellite project are presented.

Dankanich, John W.↗
NASA NTRS2016

Cost-Benefit Analysis for the Advanced Near Net Shape Technology (ANNST) Method for Fabricating Stiffened Cylinders

This cost-benefit analysis assesses the benefits of the Advanced Near Net Shape Technology (ANNST) manufacturing process for fabricating integrally stiffened cylinders. These preliminary, rough order-of-magnitude results report a 46 to 58 percent reduction in production costs and a 7-percent reduction in weight over the conventional metallic manufacturing technique used in this study for comparison. Production cost savings of 35 to 58 percent were reported over the composite manufacturing technique used in this study for comparison; however, the ANNST concept was heavier. In this study, the predicted return on investment of equipment required for the ANNST method was ten cryogenic tank barrels when compared with conventional metallic manufacturing. The ANNST method was compared with the conventional multi-piece metallic construction and composite processes for fabricating integrally stiffened cylinders. A case study compared these three alternatives for manufacturing a cylinder of specified geometry, with particular focus placed on production costs and process complexity, with cost analyses performed by the analogy and parametric methods. Furthermore, a scalability study was conducted for three tank diameters to assess the highest potential payoff of the ANNST process for manufacture of large-diameter cryogenic tanks. The analytical hierarchy process (AHP) was subsequently used with a group of selected subject matter experts to assess the value of the various benefits achieved by the ANNST method for potential stakeholders. The AHP study results revealed that decreased final cylinder mass and quality assurance were the most valued benefits of cylinder manufacturing methods, therefore emphasizing the relevance of the benefits achieved with the ANNST process for future projects.

Stoner, Mary Cecilia↗
NASA NTRS2015

NASA Software Cost Estimation Model: An Analogy Based Estimation Model

The cost estimation of software development activities is increasingly critical for large scale integrated projects such as those at DOD and NASA especially as the software systems become larger and more complex. As an example MSL (Mars Scientific Laboratory) developed at the Jet Propulsion Laboratory launched with over 2 million lines of code making it the largest robotic spacecraft ever flown (Based on the size of the software). Software development activities are also notorious for their cost growth, with NASA flight software averaging over 50% cost growth. All across the agency, estimators and analysts are increasingly being tasked to develop reliable cost estimates in support of program planning and execution. While there has been extensive work on improving parametric methods there is very little focus on the use of models based on analogy and clustering algorithms. In this paper we summarize our findings on effort/cost model estimation and model development based on ten years of software effort estimation research using data mining and machine learning methods to develop estimation models based on analogy and clustering. The NASA Software Cost Model performance is evaluated by comparing it to COCOMO II, linear regression, and K-­ nearest neighbor prediction model performance on the same data set.

Hihn, Jairus↗
NASA NTRS2018

Cost of Quality for Government

The American society for Quality (ASQ) has recently published ASQ TR2:2018: Cost of Quality: Guidelines for Development, Implementation and Monitoring to Improve Quality and Performance.1 Efforts were made during the Technical Report drafting process to ensure that examples were provided which could apply to government services, rather than just private sector production. The concept of "Cost of Quality" was first described by Joseph Juran in 1951 and Armand Feigenbaum expanded on the topic in 1956.2 Since that time, systems have been developed by the private sector to monitor and measure these costs. The concept is often described as "cost of poor quality". ASQ sets forth guidance for development of a Cost of Quality Program in TR2:2018.

Shepherd, Christena C.↗
NASA NTRS2015

Resource Prospector (RP): A Cost-Effective Lunar Resource Pathfinder

Resource Prospector (RP) is an in-situ resource utilization (ISRU) technology demonstration mission under study by the NASA Human Exploration and Operations Mission Directorates (HEOMD). This clever mission is currently planned to launch in 2020 and will demonstrate extraction of oxygen, water and other volatiles, as well measure mineralogical content such as silicon and light metals, like aluminum and titanium, from lunar regolith. Expanding human presence beyond low-Earth orbit to asteroids and Mars will require the maximum possible use of local materials, so-called in-situ resources, and the moon presents a unique destination to conduct robotic investigations that advance ISRU capabilities, as well as providing significant exploration and science value. This mission is equally important; however, for how it executes as a risk-tolerant, cost-effective mission. RP follows on the path-finding approaches of the Lunar Crater Observation and Sensing Satellite (LCROSS) mission. The LCROSS mission confirmed the presence of water-ice on the moon, but also established a new lightweight-approach to project and mission execution which was considerably cheaper and faster than traditional NASA missions. RP has been designated as a Class D mission, just as LCROSS. This mission classification is the most risk-tolerant class of mission within the NASA risk framework and as such, is given more latitude to accept higher-levels of residual risk. The intention is that by saving monies normally spent attempting to assure a single missions success, more missions can be funded. A well-designed portfolio can accept occasional mission failure, as it still gets more done for the same investment of resources. This classification enables tailoring the NASA Policy Requirements (NPRs) to lighter-weight approaches to mission management and execution. RP is also studying both international and commercial partnerships as a means to maximize return on the investment. International partnerships provide both capabilities synergies and cost-sharing opportunities, while the evolving new space commercial options are revealing new approaches to acquiring cost-effective services, including the benefits of bundling services. Even the world of launch vehicles is changing, offering much less expensive access to space, especially if NASA is able to be flexible in how it approaches mission assurance. Finally, leveraging investments being made elsewhere within a program portfolio, can enable cost-savings by enabling two applications with one investment. RP will be the next pathfinder mission to both enable exploration capabilities for future missions, and continue to evolve cost-effective approaches for NASA.

Lunar↗
NASA NTRS2019

Moon Base Life Support Design Depends on Launch Cost, Crew Size, and Mission Duration

Brief human space missions such as Apollo and the Space Shuttle used material storage for life support but a long mission such as a space station uses a recycling life support system. The upcoming Moon visits will probably be brief with few crew at first but in the future there may be a long-term or even permanent Moon base with a large crew. The initial life support system will probably use storage and resupply of materials from Earth, but it could be replaced later by recycling, especially if launch cost per kilogram is high. Moon base life support design is investigated considering requirements, performance, reliability, cost, and risk. The launch cost, crew size, and mission duration are variable parameters that affect the life support design choice. Greater launch cost, crew size, or mission duration all tend to make recycling more cost-effective than resupply.

Jones, Harry W.↗
NASA NTRS2019

Evolving Management Strategies to Improve NASA Flagship's Cost and Schedule Performance: LUVOIR as a Case Study

The large ultraviolet optical infrared surveyor (LUVOIR) study process has brought to fruition an extremely exciting scientific mission concept. The 3.5 year LUVOIR study duration enabled an unprecedented level of scientific, engineering, and technology thoroughness prior to the Astro2020 Decadal. This detail also shed light on many technical and programmatic challenges for efficiently developing a mission of this scale within the context of NASA’s flagships cost and schedule performances to date. While NASA’s flagships perform exquisitely once on orbit, there is understandable growing frustration in their development cost and schedule overruns. We felt it incumbent upon ourselves to ask how we could improve on delivering LUVOIR (or any of NASA’s future flagships) on schedule and on budget, not just for the next mission, but for all NASA large strategic missions to come. We researched past and current NASA flagship’s lessons learned publications and other large government projects that pointed to some systemic challenges that will only grow with larger and more complex strategic missions. Our findings pointed us to some ways that could potentially evolve NASA’s current flagship management practices to help improve on their development cost and schedule performance despite their growing complexity. This paper briefly comments on the motivations for NASA’s flagships and on the science motivations for a LUVOIR-like mission. We argue the incentives for improving NASA’s flagships development cost and schedule performance. We review the specific additional challenges of NASA’s flagships to acknowledge their specific issues. We then examine the most repeated systemic challenges we found from previous NASA flagships and other large government projects lessons learned/observed. Lastly, we offer recommendations to tackle these repeated systemic challenges facing NASA’s flagships. The recommendations culminate into a proactive integrated development and funding framework to enable improving the execution of NASA’s future flagship’s cost and schedule performance.

Crooke, Julie A.↗
NASA NTRS2019

Developments on Low Cost Manufacturing Methods for Cylindrical Launch Vehicle Structures

Due to the increasing international competition and growing pressure to lower the cost of launch vehicles, enhanced technologies and competences for efficient, low cost manufacturing have to be developed. In this paper, an innovative manufacturing technology for launch vehicle applications is presented that was developed over the last few years at MT Aerospace AG (MTA) in collaboration with NASA Langley Research Center, the European Space Agency (ESA), Lockheed Martin Corporation (LMCO), Leifeld Metal Spinning and Scot Forge. The Integrally Stiffened Cylinder (ISC) manufacturing method was first investigated in 2010. Early results indicated a high mass saving potential for cylindrical structures for launch vehicle systems, such as cryogenic tank barrels and intertanks, produced using the ISC method. Cost-benefit studies conducted at NASA and MTA estimated up to 50% reduction in manufacturing costs is possible compared to conventional multi-piece, welded fabrication methods. Associated reductions in manufacturing lead times have shown that a 40% faster production rate is possible by the ISC process. Following proof of concept and process development efforts, a cylindrical structure manufactured using the ISC method had its maiden flight in 2015 on a Black Brant sounding rocket at NASA Wallops Flight Facility. Further collaboration between ESA, NASA, MTA, LMCO, and Scot Forge led to manufacturing test campaigns at MT Aerospace in 2017 and 2018 that successfully demonstrated ISC fabrication at a scale representative of commercial launch vehicles. This paper summarizes the status and relevant results of the development sequence of the ISC cylinder manufacturing method. Results of cost / benefit and structural performance analyses are also summarized. Moreover, an outlook will be given on further planned activities and development steps.

Martin Stachulla↗
NASA NTRS2021

Online NASA Software Estimating Tools (ONSET): A Suite of Web-Based Cost Analysis Tools

This paper provides an overview of ONSET theOnline NASA Software Estimating Tools suite of web-basedcosts analysis tools. ONSET is comprised of the AnalogySoftware Cost Tool (ASCoT) [1], and the CubeSat Or MicrosatProbabilistic and Analogies Cost Tool (COMPACT) [2]. TheOnline NASA Space Estimation Tool (ONSET) has beendeveloped to provide a standardized platform for hosting webbasedNASA cost estimation tools on NASA ONCE (OneNASA Cost Engineering). It evolved from the BETA version ofASCoT (The NASA Analogy Software Cost Tool) which wasreleased in 2017 and was presented at the 2017 IEEEAerospace Conference. This first release of ONSET contains anew version of ASCoT as well as the first official release ofCOMPACT (CubeSat Or Microsat Probabilistic + AnalogiesCost Tool). In this paper we will provide an overview ofONSET, all its features and a high-level summary of bothASCoT and COMPACT. The heart of both tools arealgorithms for analogy-based estimation based on system levelinputs.

Johnson, James↗
NASA NTRSDate not supplied

Feasibility of using Low-Cost COTS Sensors for Particulate Monitoring in Space Missions

Real-time measurement of particles suspended in the spacecraft cabin is of great importance to verify that maximum allowable dust concentrations are not exceeded. This is primarily to protect astronaut health, but also has implications for dust-sensitive equipment. Recently, there is growing interest in low-cost commercial off-the-shelf (COTS) particle sensors by air quality researchers for their ability to map concentrations of airborne particulate matter in various terrestrial settings. In addition to low cost (< $2,000), the compact size and minimal weight of these sensors make them a potential choice for space missions. The detection mechanism for these aerosol sensors is typically measurement of light scattered by particles as they flow through a sensing volume. The amount of scattered light for detection depends on the particle size, shape, density, and refractive index of the particle material. Ideally, particle instruments should be calibrated with reference instruments for each different type of aerosol measurement. In this study we review multiple parameters that may impact the performance of state-of-the-art low-cost aerosol sensors. Environmental factors such as temperature, relative humidity, low ambient pressure, radiation and charge environment, partial-gravity and microgravity can affect the accuracy of particle measurements. Characteristics of the dust aerosols including particle size distribution, aerosol composition, refractive index, morphology and concentration levels also affect the measurement accuracy. Finally, we look at these parameters and issues with respect to an example COTS low-cost aerosol sensor. Instrument performance specifications are evaluated, and experiments are performed to measure real-time concentrations of Arizona Road Dust (a terrestrial reference test dust) and lunar dust simulant in a laboratory chamber. Overall, this study provides insight for evaluating spacecraft particulate monitoring technologies and raises questions to be answered before incorporating low-cost COTS sensors in future space missions to dusty destinations.

lunar dust↗
NASA NTRSDate not supplied

Power Hibernation for Low-Cost Solar Powered Lunar Missions

Because the surface of the Moon drops to cryogenic temperatures, no solar-powered lunar spacecraft have reliably operated beyond a single lunar day. Passive thermal control cannot keep a spacecraft sufficiently warm for the 354-hour lunar night, and active thermal control requires a dramatic increase in battery mass at the expense of payload mass. Extreme conditions seen on the lunar surface suggest a radioisotope solution is ideal, but mass, cost, and schedule are inconsistent with low-cost frequent flight intent of the commercial lunar payload services (CLPS) program. To solve the issue of lunar night survivability without radioisotope sources of power and heat, a lunar power hibernation approach is being developed at the Glenn Research Center, which exploits the ability of common 18650 Lithium-ion cells to passively survive cryogenic freeze-thaw cycles and recover without apparent performance degradation. A key aspect of this hibernation approach is the use of cryogenically operable electronics that safely manage the restoration of the battery thermal environment at lunar dawn. A spacecraft utilizing this strategy will operate into the lunar night on batteries until the state of charge or spacecraft temperature reaches a predetermined threshold. At this point, systems are shut down and the battery is isolated from the main bus to prevent charge or discharge during the freezing and thawing transitions. The system remains passive until lunar dawn, where temperatures can reach as low as 50 K. All electronics must be tolerant to these conditions. When the solar arrays are finally illuminated at lunar dawn, the main bus power electronics will initiate a “cold start” and begin regulating array power. The main bus electronics must be designed to operate at cryogenic temperatures. Array power is used to warm the battery and passive electronics back to operational temperatures. Once batteries are returned to normal temperatures, diagnostics and precharging is performed, as needed, and the battery is reconnected. The overall spacecraft system reboots and returns to nominal operations until lunar night returns. To assure that we can develop batteries suited for many hibernation freeze/thaw cycles, STMD Space Technology Research Grant Program (STRG) has selected two principal investigators that will thoroughly characterize of the Li-ion cell through the freeze-thaw process, investigate degradation mechanisms, and identify potential diagnostic techniques. STMD STRG is also funding an investigation of Gallium-Nitride semiconductors for cryogenic power applications. This work includes physics-informed modeling that considers cryogenic conductivity, carrier mobility, and quantum effects that govern semiconductor performance at cryogenic temperatures. These models can enable engineers to develop accurate cryogenic simulation models that assist in the design of power controls stable over the entire lunar surface temperature range. Meanwhile, Glenn is performing cryogenic testing of batteries and electronics, establishing design guidelines for power applications in extreme cold lunar environment, and potentially developing a hibernation technology demonstrator. The hibernation approach will enable low-cost lunar robotic missions to extend their operating lifetime to many months while minimizing development costs and impact on payload capacity. The need for cryogenically operable electronics is restricted to only main bus power and battery controls, as the majority of systems simply need to passively tolerate cryogenic temperatures. This allows developers to continue to exploit the cost savings of legacy and COTS hardware with minimum modification. For these reasons, lunar power hibernation is a viable near-term solution for lunar night survivability for solar powered commercial landers.

Space power↗
NASA NTRS2006

The JPL Cost Risk Analysis Approach that Incorporates Engineering Realism

This paper discusses the JPL Cost Engineering Group (CEG) cost risk analysis approach that accounts for all three types of cost risk. It will also describe the evaluation of historical cost data upon which this method is based. This investigation is essential in developing a method that is rooted in engineering realism and produces credible, dependable results to aid decision makers.

cost risk↗
NASA NTRS2007

Antenna and Electronics Cost Tradeoffs For Large Arrays

This viewgraph presentation describes the cost tradeoffs for large antenna arrays. The contents include: 1) Cost modeling for large arrays; 2) Antenna mechanical cost over a wide range of sizes; and 3) Cost of per-antenna electronics.

antenna mechanical costs↗
NASA NTRS2015

X-1 to X-Wings: Developing a Parametric Cost Model

In todays cost-constrained environment, NASA needs an X-Plane database and parametric cost model that can quickly provide rough order of magnitude predictions of cost from initial concept to first fight of potential X-Plane aircraft. This paper takes a look at the steps taken in developing such a model and reports the results. The challenges encountered in the collection of historical data and recommendations for future database management are discussed. A step-by-step discussion of the development of Cost Estimating Relationships (CERs) is then covered.

parametric cost model↗
NASA NTRSDate not supplied

Preliminary Parametric Cost Model for X-Ray Grazing Incidence Optics for Space Flight

Parametric cost models offer a lot of utility in planning and comparing different missions and concepts. Furthermore, they have a significant advantage over other estimating methodologies as they can be quickly and easily replicated. The cost model presented in this paper focuses on estimating the most likely cost for the X-ray Mirror Assembly (XMA) of space-based X-ray telescopes with grazing incidence optics. The authors recognize the complexities of generating a single cost model that covers multiple fabrication techniques, so they have limited this preliminary study to techniques used on previous and current missions, such as direct polished glass full shell, replicated, and foil optics

Space Telescope Cost Model↗