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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 NTRS2007

ESAS-Derived Earth Departure Stage Design for Human Mars Exploration

The Vision for Space Exploration has set the nation on a course to have humans on Mars as early as 2030. To reduce the cost and risk associated with human Mars exploration, NASA is planning for the Mars architecture to leverage the lunar architecture as fully as possible. This study takes the defined launch vehicles and system capabilities from ESAS and extends their application to DRM 3.0 to design an Earth Departure Stage suitable for the cargo and crew missions to Mars. The impact of a propellant depot in LEO was assessed and sLzed for use with the EDS. To quantitatively assess and compare the effectiveness of alternative designs, an initial baseline architecture was defined using the ESAS launch vehicles and DRM 3.0. The baseline architecture uses three NTR engines, LH2 propellant, no propellant depot in LEO, and launches on the Ares I and Ares V. The Mars transfer and surface elements from DRM 3.0 were considered to be fixed payloads in the design of the EDS. Feasible architecture alternatives were identified from previous architecture studies and anticipated capabilities and compiled in a morphological matrix. ESAS FOMs were used to determine the most critical design attributes for the effectiveness of the EDS. The ESAS-derived FOMs used in this study to assess alternative designs are effectiveness and performance, affordability, reliability, and risk. The individual FOMs were prioritized using the AHP, a method for pairwise comparison. All trades performed were evaluated with respect to the weighted FOMs, creating a Pareto frontier of equivalently ideal solutions. Additionally, each design on the frontier was evaluated based on its fulfillment of the weighted FOMs using TOPSIS, a quantitative method for ordinal ranking of the alternatives. The designs were assessed in an integrated environment using physics-based models for subsystem analysis where possible. However, for certain attributes such as engine type, historical, performance-based mass estimating relations were more easily employed. The elements from the design process were integrated into a single loop, allowing for rapid iteration of subsystem analyses and compilation of resulting designs.

Flaherty, Kevin↗
NASA NTRS2003

Electron Beam Freeform Fabrication: A Rapid Metal Deposition Process

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley REsearch Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. The EBF process introduces metal wire feedstock into a molten pool that is created and sustained using a focused electron beam in a vacuum environment. Thus far, this technique has been demonstrated on aluminum and titanium alloys of interest for aerospace structural applications nickel and ferrous based alloys are also planned. Deposits resulting from 2219 aluminum demonstrations have exhibited a range of grain morphologies depending upon the deposition parameters. These materials ave exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF process is capable of bulk metal deposition at deposition rated in excess of 2500 cubic centimeters per hour (150 cubic inches per our) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

Taminger, Karen M. B.↗
DOE OSTI2026

Toward a Climate OSSE Framework for Satellite Mission Design

The rich history of observing system simulation experiments (OSSEs) does not yet include a well-established framework for using climate models. The need for a climate OSSE is triggered by the need to quantify the value of a particular measurement for reducing the uncertainty in climate predictions, which differ from numerical weather predictions in that they depend on future atmospheric composition rather than the current state of the weather. However, both weather and climate modeling communities share a need for motivating major observing system investments. Here, we outline a new framework for climate OSSEs that leverages the use of machine learning to calibrate climate model physics against existing satellite data. We demonstrate its application using NASA’s GISS-E3 model to objectively quantify the value of potential future improvements in spaceborne measurements of Earth’s planetary boundary layer. A mature climate OSSE framework should be able to quantitatively compare the ability of proposed observing system architectures to answer a climate-related question, thus offering added value throughout the mission design process, which is subject to increasingly rapid advances in instrument and satellite technology. Technical considerations include selection of observational benchmarks and climate projection metrics, approaches to pinpoint the sources of model physics uncertainty that dominate uncertainty in projections, and the use of instrument simulators. Community and policy-making considerations include the potential to interface with an established culture of model intercomparison projects and a growing need to economically assess the value-driven efficiency of social spending on Earth observations.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2015

Materials Genome Initiative

The Materials Genome Initiative (MGI) project element is a cross-Center effort that is focused on the integration of computational tools to simulate manufacturing processes and materials behavior. These computational simulations will be utilized to gain understanding of processes and materials behavior to accelerate process development and certification to more efficiently integrate new materials in existing NASA projects and to lead to the design of new materials for improved performance. This NASA effort looks to collaborate with efforts at other government agencies and universities working under the national MGI. MGI plans to develop integrated computational/experimental/ processing methodologies for accelerating discovery and insertion of materials to satisfy NASA's unique mission demands. The challenges include validated design tools that incorporate materials properties, processes, and design requirements; and materials process control to rapidly mature emerging manufacturing methods and develop certified manufacturing processes

Vickers, John↗
NASA NTRS2010

Aircraft Conceptual Design Using Vehicle Sketch Pad

Vehicle Sketch Pad (VSP) is a parametric geometry modeling tool that is intended for use in the conceptual design of aircraft. The intent of this software is to rapidly model aircraft configurations without expending the expertise and time that is typically required for modeling with traditional Computer Aided Design (CAD) packages. VSP accomplishes this by using parametrically defined components, such as a wing that is defined by span, area, sweep, taper ratio, thickness to cord, and so on. During this phase of frequent design builds, changes to the model can be rapidly visualized along with the internal volumetric layout. Using this geometry-based approach, parameters such as wetted areas and cord lengths can be easily extracted for rapid external performance analyses, such as a parasite drag buildup. At the completion of the conceptual design phase, VSP can export its geometry to higher fidelity tools. This geometry tool was developed by NASA and is freely available to U.S. companies and universities. It has become integral to conceptual design in the Aeronautics Systems Analysis Branch (ASAB) here at NASA Langley Research Center and is currently being used at over 100 universities, aerospace companies, and other government agencies. This paper focuses on the use of VSP in recent NASA conceptual design studies to facilitate geometry-centered design methodology. Such a process is shown to promote greater levels of creativity, more rapid assessment of critical design issues, and improved ability to quickly interact with higher order analyses. A number of VSP vehicle model examples are compared to CAD-based conceptual design, from a designer perspective; comparisons are also made of the time and expertise required to build the geometry representations as well.

Fredericks, William J.↗
NASA NTRS1999

Advanced Geosynchronous Imager

For improved understanding of chaotic processes and the diurnal cycle, an advanced GOES imager must also have the multi-spectral spectral bands used by low earth orbit (LEO) imagers, with on-orbit calibration for all bands. A synergy between GEO and LEO radiometry would enable earth system scientists to fuse the remote sensing data from all the spaceborne platforms. These additional radiometric capabilities are designed to observe important physical processes that vary rapidly and unpredicably: smoke, fires, precipitation, ozone, volcanic ash, cloud phase and height, and surface temperature. We believe the technology now exists to develop an imaging system that can meet future weather reporting and earth system science needs. To meet this need, we propose a design for a comprehensive geosynchronous atmospheric imager. This imager is envisioned to fly on a GOES-N class spacecraft, within the volume, weight and power constraints of a platform similar to GOES-N while delivering 100 times more data and radiometric quality than the GOES-N imager. The higher data rate probably requires its own ground station, which could serve as a systems prototype for NOAA's next generation of operational satellites. For operational compatibility, our proposed advanced GOES imaging system contains the GOES-R requirements as a subset, and the GOES-N imager capabilities (and the sounder's imaging channels) as a further subset.

Chesters, Dennis↗
NASA NTRS1994

Concept of using a benchmark part to evaluate rapid prototype processes

A conceptual benchmark part for guiding manufacturers and users of rapid prototyping technologies is proposed. This is based on a need to have some tool to evaluate the development of this technology and to assist the user in judiciously selecting a process. The benchmark part is designed to have unique product details and features. The extent to which a rapid prototyping process can reproduce these features becomes a measure of the capability of the process. Since rapid prototyping is a dynamic technology, this benchmark part should be used to continuously monitor process capability of existing and developing technologies. Development of this benchmark part is, therefore, based on an understanding of the properties required from prototypes and characteristics of various rapid prototyping processes and measuring equipment that is used for evaluation.

Cariapa, Vikram↗
NASA NTRS1994

Rapid prototype fabrication processes for high-performance thrust cells

The Thrust Cell Technologies Program (Air Force Phillips Laboratory Contract No. F04611-92-C-0050) is currently being performed by Rocketdyne to demonstrate advanced materials and fabrication technologies which can be utilized to produce low-cost, high-performance thrust cells for launch and space transportation rocket engines. Under Phase 2 of the Thrust Cell Technologies Program (TCTP), rapid prototyping and investment casting techniques are being employed to fabricate a 12,000-lbf thrust class combustion chamber for delivery and hot-fire testing at Phillips Lab. The integrated process of investment casting directly from rapid prototype patterns dramatically reduces design-to-delivery cycle time, and greatly enhances design flexibility over conventionally processed cast or machined parts.

Hunt, K.↗
DOE OSTI2025

Rapid Bayesian High Entropy Alloy Designs Fabricated via Wire Arc Additive Manufacturing

Purpose: This project seeks to demonstrate a new high-throughput (rapid) alloy design technique applied to creating new high entropy alloys (HEAs) for extreme environments. High entropy alloys shift the design paradigm from being focused on a single principal element (e.g. nickel-based alloys) to target alloys that include high atomic fractions (X >10%) of multiple elements. These HEA materials can exhibit sluggish diffusion and enhanced corrosion resistance, ideal for potential applications in advanced ultra supercritical (A-USC) steam cycles for power generation. Scope: The addition of multiple elements in high atomic fractions creates an enormous design space that cannot easily be investigated by traditional material design strategies such as designed of experiments (DOE). This project utilizes a Bayesian machine learning algorithm that has been modified to work with calculation of phase diagrams (CALPHAD) software. This Bayesian algorithm reduces manual inputs and increase the likelihood of achieving an optimal solution. Compositional inputs to this algorithm will be assessed using existing material property models for high temperature strength and corrosion resistance. The target for alloy performance will be a 15% (~100 ⁰C) increase in allowable service temperature beyond heat-resistant stainless steels while maintaining or improving alloy cost and corrosion resistance. Haynes 230 was selected as a baseline, which is 57 wt% Ni with 22 wt% Cr 14 wt% W, and 2 wt% Mo as solid solution strengtheners. In addition to rapid design via Bayesian machine learning, the alloys were rapidly fabricated using a multi-wire arc additive manufacturing (mWAAM) technique which allows for precise control of alloy composition and assessing of alloy design “windows” to study composition effects. Build speeds for wire-arc additive processes are among the highest for additive technologies enabling rapid and reliable sample fabrication when compared to conventional methods such as arc button melting. The mWAAM samples will be rapidly characterized via instrumented indentation for room temperature modulus and strength and for elevated temperature strength via hot hardness tests. After being screened with hardness testing, potential alloys will be further evaluated with conventional microscopy techniques including scanning electron microscopy (SEM) and transmission electron microscopy (TEM) to assess agreement with modeling results. The most promising compositions will also be evaluated by printing full sized tensile specimens for mechanical behavior tests at elevated temperatures. Results: Bayesian machine learning of a single performance function was initially used to optimize five performance metrics: 1) single phase stability, 2) yield strength, 3) creep resistance (low diffusion coefficient), 4) freezing range (weldability), and 5) material cost. The single performance function was suboptimal as assumptions had to be made about the results while formulating the optimization. A goal-oriented Bayesian optimization strategy (Hanaoka, 2021) was implemented with CALPHAD for use with the five metrics above. This multi-objective Bayesian optimization (MOBO) enabled the design of NiCrCoFe alloys with V and W additions. A base composition of NiCoCr was selected as Ni provides a stable FCC matrix, Cr aids corrosion/oxidation resistance, and Co is a solid-solutions strengthener that also improves creep by increasing the activation energy. Fe helps reduce diffusion coefficients and cost. Finally, V and W were selected for their reasonable solubility and high atomic misfit to aid in solid solution strengthening. Cracking of the mWAAM specimens was an early issue, and the Easton solidification cracking model (Easton et al., 2014a) was selected for addition to the MOBO function. High performing alloys fabricated by mWAAM included Ni 28 Cr 25 Co 26 Fe 15 V 8 and Ni 62 Cr 18 Co 1 Fe 3 W 15 . It was observed that even after adapting the mWAAM process for W, the W did not fully dissolve. To fully evaluate the Ni 62 Cr 18 Co 1 Fe 3 W 15 composition, a cored wire (80-20 NiCr sheath/powder core) was manufactured and printed via WAAM, and HIP’ing was utilized to homogenize and densify the printed alloy. The V and W alloys produced met metrics 1 (solid solution), 4 (solidification cracking), and 5 (cost). However, an unmodeled mechanism of thermal stress cracking was identified in the WAAM produced materials, perhaps exacerbated by the lack of grain boundary strengthening elements (B, C). Conclusions & Recommendations: A high-throughput (rapid) alloy design technique was applied to designing and manufacturing new high entropy alloys (HEAs) for extreme environments utilizing MOBO and mWAAM. The developed process was rapid and effective in addressing the mechanisms included in the model. The lack of grain boundary strengthening element additions (e.g., B, C) was a simplification that likely produced thermal stress cracking that turned into a large part of the investigation. Additions on the order of 0.005 wt% B and 0.05 wt% C likely would have minimized thermal stress grain boundary cracking. Overall, the high throughput design strategy is promising for rapid design of metrics-driven alloys for advanced ultra supercritical (A-USC) steam cycles for power generation. The MOBO and mWAAM process could be commercialized to accelerate metrics-driven alloy design. In addition, the cored-wire process utilized for scale-up is a promising high-volume process for WAAM alloy development and scale-up.

36 MATERIALS SCIENCE↗
NASA NTRS1997

Rapid Modeling, Assembly and Simulation in Design Optimization

A new capability for design is reviewed. This capability provides for rapid assembly of detail finite element models early in the design process where costs are most effectively impacted. This creates an engineering environment which enables comprehensive analysis and design optimization early in the design process. Graphical interactive computing makes it possible for the engineer to interact with the design while performing comprehensive design studies. This rapid assembly capability is enabled by the use of Interface Technology, to couple independently created models which can be archived and made accessible to the designer. Results are presented to demonstrate the capability.

Housner, Jerry↗
NASA NTRS1993

Appendix C: Rapid development approaches for system engineering and design

Conventional system architectures, development processes, and tool environments often produce systems which exceed cost expectations and are obsolete before they are fielded. This paper explores some of the reasons for this and provides recommendations for how we can do better. These recommendations are based on DoD and NASA system developments and on our exploration and development of system/software engineering tools.

Source record↗
NASA NTRS1994

From neural-based object recognition toward microelectronic eyes

Engineering neural network systems are best known for their abilities to adapt to the changing characteristics of the surrounding environment by adjusting system parameter values during the learning process. Rapid advances in analog current-mode design techniques have made possible the implementation of major neural network functions in custom VLSI chips. An electrically programmable analog synapse cell with large dynamic range can be realized in a compact silicon area. New designs of the synapse cells, neurons, and analog processor are presented. A synapse cell based on Gilbert multiplier structure can perform the linear multiplication for back-propagation networks. A double differential-pair synapse cell can perform the Gaussian function for radial-basis network. The synapse cells can be biased in the strong inversion region for high-speed operation or biased in the subthreshold region for low-power operation. The voltage gain of the sigmoid-function neurons is externally adjustable which greatly facilitates the search of optimal solutions in certain networks. Various building blocks can be intelligently connected to form useful industrial applications. Efficient data communication is a key system-level design issue for large-scale networks. We also present analog neural processors based on perceptron architecture and Hopfield network for communication applications. Biologically inspired neural networks have played an important role towards the creation of powerful intelligent machines. Accuracy, limitations, and prospects of analog current-mode design of the biologically inspired vision processing chips and cellular neural network chips are key design issues.

Sheu, Bing J.↗
DOE OSTI2024

Automated AI-driven Molecular Design for Therapeutic Discovery

In recent years, artificial intelligence and machine learning (AI/ML) approaches have revolutionized the process of designing new therapeutics, enabling scientists to rapidly respond to emerging threats from various pathogens. A prime example is the SARS-CoV-2 main protease, a key target for the development of antiviral inhibitors. In this study, we employed a novel, integrated approach that combines AI-driven iterative design of inhibitor candidates, screening based on physio-chemical properties and toxicity, physics-based computational modeling of protein-inhibitor interactions, and AI-assisted analysis of Native MS biophysical assay and characterization of designed candidates. Our deep learning 3D-scaffold model, which uses an input scaffold as a starting point, generated tens of thousands of compounds while preserving the key scaffold. To optimize these candidates, we calculated a comprehensive set of 136 descriptors, including both 2D and 3D molecular features, for compounds targeting the SARS-CoV-2 Main protease (Mpro) and a neurodegenerative disease-associated protein, cyclophilin (Cyp). The generated compounds were initially filtered based on their properties and then ranked according to their predicted binding affinity using our automated modeling and ML methods. Experimental validation of the Mpro candidates showing inhibitory activity demonstrates that our workflow can expedite the therapeutic discovery.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

WarpX: Delivering Unprecedented Particle-in-Cell Simulation Capability

Since 1939, more than 30 percent of all Nobel prizes in physics and four of the past 14 prizes in chemistry have been awarded for work with particle accelerators. These tools are now used to treat cancer and produce medical supplies, support research in applied fields such as pharmaceuticals, create microcircuits, and sterilize food—and the applications list continues to grow. However, the size of the facilities needed to house these machines—which are often dozens of kilometers long—has limited their future potential. Thus, researchers are motivated to create novel particle accelerator designs that provide new imaging capability but have a much smaller footprint. The Exascale Computing Project’s WarpX application captures the full complexity of the acceleration processes within plasma-based design, supporting the rapid and cost-efficient development of tens of thousands of new particle accelerators for various applications from improving human health to nuclear fusion reactors.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1980

Spacecraft loads methodology - Transient vs. shock spectra method

The methodology for the establishment of spacecraft loads is strongly influenced by project constraints which include the cost, schedule and allowable weight. The most rigorous approach is the transient loads analysis which requires a composite mathematical model of the spacecraft and launch vehicle. The structural member loads for the entire composite structure are computed by applying the forcing functions, which represent various dynamic environments during the mission, to the composite model. Although this method ideally leads to a lightweight design, it is costly and time consuming due to complex interfaces involving many organizations. To reduce complexity and cost a shock spectra method has been used to design spacecraft structures. This method utilizes envelopes of shock spectra of launch vehicle accelerations obtained from analysis and/or flight measurements. Since only limited information on the launch vehicle model is involved in this process the design loads iteration cycle can be rapidly performed within the payload organization. In the present paper, these two methods will be evaluated by comparing the loads for several spacecraft. Flight measured loads will also be used in the evaluation.

Chen, J. C.↗
NASA NTRS1995

Micromechanical Machining Processes and their Application to Aerospace Structures, Devices and Systems

Micromechanical machining processes are those micro fabrication techniques which directly remove work piece material by either a physical cutting tool or an energy process. These processes are direct and therefore they can help reduce the cost and time for prototype development of micro mechanical components and systems. This is especially true for aerospace applications where size and weight are critical, and reliability and the operating environment are an integral part of the design and development process. The micromechanical machining processes are rapidly being recognized as a complementary set of tools to traditional lithographic processes (such as LIGA) for the fabrication of micromechanical components. Worldwide efforts in the U.S., Germany, and Japan are leading to results which sometimes rival lithography at a fraction of the time and cost. Efforts to develop processes and systems specific to aerospace applications are well underway.

Friedrich, Craig R.↗
DOE OSTI2025

Rapid data acquisition and machine learning-assisted composition design of functionally graded alloys via wire arc additive manufacturing

Abstract The lack of high-quality datasets in materials science hinders artificial intelligence (AI)-driven alloy design. To address this challenge, wire arc additive manufacturing (WAAM) was employed to fabricate graded alloys, generating extensive data for machine learning (ML)-assisted property prediction. ML models were developed using high-throughput experiments, computational models, and genetic algorithm to optimize feature selection, successfully predicting hardness and porosity. The ML model demonstrated its efficacy by designing a gradient alloy with enhanced properties. However, scaling up revealed uncertainties in tensile property and porosity due to differences in size and thermal conditions between the designed alloy build and the gradient print used to construct the ML model. This underscores the need for uncertainty quantification and process optimization in WAAM-driven alloy design. Our work advances AI-integrated additive manufacturing, offering a rapid approach to exploring process–structure–property relationships and accelerating materials development.

Wang, Xin↗
NASA NTRS2013

Dawn Orbit Determination Team: Trajectory Modeling and Reconstruction Processes at Vesta

The Dawn spacecraft spent over a year in orbit around Vesta from July 2011 through August 2012. In order to maintain the designated science reference orbits and enable the transfers between those orbits, precise and timely orbit determination was required. Challenges included low-thrust ion propulsion modeling, estimation of relatively unknown Vesta gravity and rotation models, track-ing data limitations, incorporation of real-time telemetry into dynamics model updates, and rapid maneuver design cycles during transfers. This paper discusses the dynamics models, filter configuration, and data processing implemented to deliver a rapid orbit determination capability to the Dawn project.

low thrust↗