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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 NTRS2006

Advances in Hot-Structure Development

The National Aeronautics and Space Administration has actively participated in the development of hot structures technology for application to hypersonic flight systems. Hot structures have been developed for vehicles including the X-43A, X-37, and the Space Shuttle. These trans-atmospheric and atmospheric entry flight systems that incorporate hot-structures technology are lighter weight and require less maintenance than those that incorporate parasitic, thermal-protection materials that attach to warm or cool substructure. The development of hot structures requires a thorough understanding of material performance in an extreme environment, boundary conditions and load interactions, structural joint performance, and thermal and mechanical performance of integrated structural systems that operate at temperatures ranging from 1500 C to 3000 C, depending on the application. This paper will present recent advances in the development of hot structures, including development of environmentally durable, high temperature leading edges and control surfaces, integrated thermal protection systems, and repair technologies. The X-43A Mach-10 vehicle utilized carbon/carbon (C/C) leading edges on the nose, horizontal control surface, and vertical tail. The nose and vertical and horizontal tail leading edges were fabricated out of a 3:1 biased, high thermal conductivity C/C. The leading edges were coated with a three-layer coating comprised of a SiC conversion of the C/C, followed by a CVD layer of SiC, followed by a thin CVD layer of HfC. Work has also been performed on the development of an integrated structure and was focused on both hot and warm (insulated) structures and integrated fuselage/tank/TPS systems. The objective was to develop integrated multifunctional airframe structures that eliminate fragile external thermal-protection systems and incorporate the insulating function within the structure. The approach taken to achieve this goal was to develop candidate hypersonic airframe concepts, including structural arrangement, load paths, thermal-structural wall design, thermal accommodation features, and integration of major components, optimize thermalstructural configurations, and validate concepts through a building block test program and generate data to improve and validate analytical and design tools.

Rivers, H. Kevin↗
NASA NTRS2006

Difficult Decisions Made Easier

NASA missions are extremely complex and prone to sudden, catastrophic failure if equipment falters or if an unforeseen event occurs. For these reasons, NASA trains to expect the unexpected. It tests its equipment and systems in extreme conditions, and it develops risk-analysis tests to foresee any possible problems. The Space Agency recently worked with an industry partner to develop reliability analysis software capable of modeling complex, highly dynamic systems, taking into account variations in input parameters and the evolution of the system over the course of a mission. The goal of this research was multifold. It included performance and risk analyses of complex, multiphase missions, like the insertion of the Mars Reconnaissance Orbiter; reliability analyses of systems with redundant and/or repairable components; optimization analyses of system configurations with respect to cost and reliability; and sensitivity analyses to identify optimal areas for uncertainty reduction or performance enhancement.

Source record↗
NASA NTRS2010

Florida Tech CubeSat Experiment Feasibility Study

CubeSats are a relatively new type of satellite. Smaller than long-term (5+ year life expectancy) satellites, these pico-satellites are comparatively cheap, small (10x10x10 cm), and are very versatile. Universities world-wide are using CubeSats to conduct a variety of experiments in space without the need for a large experimental platform. Today CubeSats are considered to be one of the most effective ways to send a small payload into space and has attracted the attention of many educational and non-profit organizations. As this pico-satellite model continues to gain penetration into the satellite build and launch industry, it is expected that more governmental, educational, and commercial interests will emerge. As an example, more of the space-related items of high interest to the National Science Foundation may be tackled with a CubeSat platform resulting in lower life cycle costs than traditional satellite options. NASA LSP, in cooperation with the Florida Institute of Technology, has initiated a feasibility study to investigate the technical aspects of measuring and transferring vibration, acceleration, temperature, and video data from a CubeSat to NASA Hanger AE on Cape Canaveral Air Force Station (CCAFS) a.k.a. Kennedy Space Center (KSC). This report provides a technical feasibility analysis to determine whether-or-not a specific set of NASA/LSP requirements can be accomplished. Our approach has been to provide a "notional" component layout to determine the feasibility of the NASA/LSP stakeholder requirements. The notional layout is used to consider component level technical issues such as size, weight, & power (SWaP), bandwidth, and other critical technical parameters. Even though the notional components may satisfy the stated requirements and thereby demonstrate feasibility, the notional layout is NOT considered a design since no component optimization and design trade-off analysis has taken place. This activity should be accomplished in an appropriate design phase that is outside of the scope of this effort.

Arrasmith, William W.↗
NASA NTRS2012

Miniaturized Gas Correlation Radiometer for the Detection of Trace Gases in the Martian Atmosphere

We present a miniaturized and simplified version of a gas correlation radiometer (GCR) capable of simultaneously mapping multiple trace gases and identifying active regions on the Mars surface. Gas correlation radiometry (GCR) has been shown to be a sensitive and versatile method for detecting trace gases in Earth's atmosphere. Reduction of the size and mass of the GCR was achieved by implementing compact, light-weight 1 mm inner diameter hollow-core optical fibers (hollow waveguides) as the gas correlation cells. In a comparison with an Earth orbiting CO2 GCR instrument, exchanging the 10 m multipass cells with hollow waveguide gas correlation cells of equivalent path length reduces the mass from approximately 150 kg to approximately 0.5 kg, and reduces the volume from 1.9 m x 1.3 m x 0.86 m to a small bundle of fiber coils approximately 1 meter in diameter by 0.05 m in height (mass and volume reductions of greater than 99%). A unique feature of this instrument is its stackable module design, with a single module for each trace gas. Each of the modules is self-contained, and fundamentally identical; differing by the bandpass filter wavelength range and gas mixtures inside the hollow-waveguide absorption cells. The current configuration contains four stacked modules for simultaneous measurements of methane (CH4), formaldehyde (H2CO), water vapor (H2O), and deuterated water vapor (HDO) but could easily be expanded to include measurements of additional species of interest including nitrous oxide (N2O), hydrogen sulfide (H2S), methanol (CH3OH), and sulfur dioxide (SO2), as well as carbon dioxide (CO2) for a simultaneous measure of mass balance. Preliminary results indicate that a 1 ppb detection limit is possible for both formaldehyde and methane with one second of averaging. Using non-optimized components, we have demonstrated an instrument sensitivity equivalent to approximately 30 ppb for formaldehyde, and approximately 500 ppb for methane. We expect custom bandpass filters and 6 m long waveguides to significantly improve these promising results. Ongoing testing is being conducted on water vapor and deuterated water vapor.

Melroy, Hilary R.↗
DOE OSTI2020

EVALUATING FACILITY ENERGY EFFICIENCY AND RESILIENCE OPPORTUNITIES WITH FEDS AND MCOR

Energy resilience has become increasingly important for critical building infrastructure, in response to concerns over potential disruptions to the electrical grid from threats both natural and man-made. Energy efficiency can provide a valuable resource for reducing critical loads and therefore lowering the cost of supplying alternative power. This paper highlights two tools that are well-suited for analyzing building energy efficiency and resilience opportunities and presents a case study for their combined application. The Facility Energy Decision System (FEDS) and Microgrid Component Optimization for Resilience (MCOR) tools can be used together to simulate building systems, identify energy efficiency measures, and evaluate resilience options for powering a site during an outage.

FEDS, MCOR, Energy Efficiency, Resilience, Simulat↗
DOE OSTI2021

Evaluating the resilience benefits of marine energy in microgrids

Marine energy resources could promote clean energy and resilience of coastal and island microgrids, and thus, these applications are a key future market for marine energy development. To demonstrate these benefits, this paper illustrates how inclusion of wave resources into energy resilience solutions can improve overall grid efficiency and sustainability, as well as maintain electricity supply during grid outages. The paper describes a case study evaluation of the potential to add wave energy to the Moloka’i grid as Hawaii strives to meet a 100% clean energy target. The Microgrid Component Optimization for Resilience tool is used to simulate operation in off- grid conditions and size different combinations of wave, solar photovoltaic (PV), wind, storage, and fuel resources required to meet resilience objectives. This research in- vestigates how including wave resources in a microgrid contributes to reducing biofuel generation, producing a zero-greenhouse gas emission profile, and avoiding the over-sizing of PV and battery systems to accommodate periods of unavailability or high demand. Insight from this paper supports the value proposition of wave resources for future markets and informs the relationship between marine generators and microgrids or isolated grids.

Newman, Sarah F.↗
DOE OSTI2024

Synthesizing, Compounding, and Characterizing a Heat Labile Polyurethane Foam

ABSTRACT A need exists for a packaging foam material that can be converted from solid to gaseous degradation products at reasonably low energy levels or temperatures, such as 100O C. This paper will primarily discuss the approaches currently being used to synthesize and characterize such a material. These approaches include the incorporation of novel polyols such as azo containing diols, polycarbonate diols, and polypropylene carbonate polyols into polyurethane foams. Characterization methods include NMR, FTIR, TGA, finite element analysis, impact strength, and others. This project will be funded for a duration of three years. Year 1 focused on developing the proposed test methods and producing an initial rigid polyurethane foam. Year 2 focuses on refining the materials and test methods. If appropriate, design of experiment (doe) techniques will be used to optimize components, component levels, density and other variables to attain required final material properties (TGA weight loss, impact strength, etc.). Year 3 focuses on scaling up to larger engineering quantities. The application for this material is in load securement for transportation of low level radioactive waste materials within the US Department of Energy (DOE) complex. Foam in place process equipment and operators will be shielded using this novel method over current practice. Current practice can involve time consuming methods of load securement in low level radiation environments. This new technique would eliminate exposure time securing the load and greatly improve the As Low As Reasonably Attainable (ALARA) conditions. The objective is to progress to higher Technical Readiness Levels (TRL) and larger pilot scale quantities. This paper discusses methodologies and presents current results to date.

Kranjc, Mark D.↗
DOE OSTI2021

A moving morphable component‐based topology optimization approach considering transient structural dynamic responses

Abstract A novel approach is developed under the moving morphable component (MMC) framework to solve topology optimization problems considering transient structural dynamic responses, where the structure for optimization is constructed with a collection of structural components, and the structural layout can be described explicitly via only a small number of design variables characterizing the positions and geometries of the components. The transient dynamic response of the structure and corresponding sensitivities are computed via step‐by‐step numerical integration and mode reduction technique is also employed to enhance the computational efficiency. Compared with existing works, the numerical instabilities induced by localized vibration modes can be substantially alleviated and the computational effort for direct sensitivity analysis is significantly reduced in the proposed approach. Two and three‐dimensional numerical examples considering the cases of nonproportional damping mechanism and time‐varying mass are also provided to manifest the validity of the proposed approach.

Li, Jialin↗
NASA NTRS2009

Sequential Principal Component Analysis -An Optimal and Hardware-Implementable Transform for Image Compression

This paper presents the JPL-developed Sequential Principal Component Analysis (SPCA) algorithm for feature extraction / image compression, based on "dominant-term selection" unsupervised learning technique that requires an order-of-magnitude lesser computation and has simpler architecture compared to the state of the art gradient-descent techniques. This algorithm is inherently amenable to a compact, low power and high speed VLSI hardware embodiment. The paper compares the lossless image compression performance of the JPL's SPCA algorithm with the state of the art JPEG2000, widely used due to its simplified hardware implementability. JPEG2000 is not an optimal data compression technique because of its fixed transform characteristics, regardless of its data structure. On the other hand, conventional Principal Component Analysis based transform (PCA-transform) is a data-dependent-structure transform. However, it is not easy to implement the PCA in compact VLSI hardware, due to its highly computational and architectural complexity. In contrast, the JPL's "dominant-term selection" SPCA algorithm allows, for the first time, a compact, low-power hardware implementation of the powerful PCA algorithm. This paper presents a direct comparison of the JPL's SPCA versus JPEG2000, incorporating the Huffman and arithmetic coding for completeness of the data compression operation. The simulation results show that JPL's SPCA algorithm is superior as an optimal data-dependent-transform over the state of the art JPEG2000. When implemented in hardware, this technique is projected to be ideally suited to future NASA missions for autonomous on-board image data processing to improve the bandwidth of communication.

Duong, Tuan A.↗
NASA NTRS2009

Reliability-Based Design Optimization of a Composite Airframe Component

A stochastic design optimization methodology (SDO) has been developed to design components of an airframe structure that can be made of metallic and composite materials. The design is obtained as a function of the risk level, or reliability, p. The design method treats uncertainties in load, strength, and material properties as distribution functions, which are defined with mean values and standard deviations. A design constraint or a failure mode is specified as a function of reliability p. Solution to stochastic optimization yields the weight of a structure as a function of reliability p. Optimum weight versus reliability p traced out an inverted-S-shaped graph. The center of the inverted-S graph corresponded to 50 percent (p = 0.5) probability of success. A heavy design with weight approaching infinity could be produced for a near-zero rate of failure that corresponds to unity for reliability p (or p = 1). Weight can be reduced to a small value for the most failure-prone design with a reliability that approaches zero (p = 0). Reliability can be changed for different components of an airframe structure. For example, the landing gear can be designed for a very high reliability, whereas it can be reduced to a small extent for a raked wingtip. The SDO capability is obtained by combining three codes: (1) The MSC/Nastran code was the deterministic analysis tool, (2) The fast probabilistic integrator, or the FPI module of the NESSUS software, was the probabilistic calculator, and (3) NASA Glenn Research Center s optimization testbed CometBoards became the optimizer. The SDO capability requires a finite element structural model, a material model, a load model, and a design model. The stochastic optimization concept is illustrated considering an academic example and a real-life raked wingtip structure of the Boeing 767-400 extended range airliner made of metallic and composite materials.

Patnaik, Surya N.↗
DOE OSTI2021

Deep Symbolic Optimization for Electric Component Sizing in Fixed Topology Power Converters

Power converters (PC) are a major component in any current electronic hardware device. The development and design is usually guided by expert knowledge and heavily relies on human intuition and experience. The process is a very time consuming and costly activity and it is generally hard to improve upon current designs. As a first step towards autonomous PC design, we are here proposing a new framework for the sizing of components for fixed topology PCs based on given design requirements. To this end, we developed surrogate models for rapid evaluation of new topologies and adapt the deep symbolic optimization (DSO) framework to generate new topologies guided by a reinforcement learning training signal. In an empirical evaluation, we show that our DSO based approach is able to find the optimal configuration for all investigated topologies, while reducing the learning time by at least a factor of 100 compared to popular RL algorithms.

Xue, Lincoln↗
NASA NTRS2007

Translator for Optimizing Fluid-Handling Components

A software interface has been devised to facilitate optimization of the shapes of valves, elbows, fittings, and other components used to handle fluids under extreme conditions. This software interface translates data files generated by PLOT3D (a NASA grid-based plotting-and- data-display program) and by computational fluid dynamics (CFD) software into a format in which the files can be read by Sculptor, which is a shape-deformation- and-optimization program. Sculptor enables the user to interactively, smoothly, and arbitrarily deform the surfaces and volumes in two- and three-dimensional CFD models. Sculptor also includes design-optimization algorithms that can be used in conjunction with the arbitrary-shape-deformation components to perform automatic shape optimization. In the optimization process, the output of the CFD software is used as feedback while the optimizer strives to satisfy design criteria that could include, for example, improved values of pressure loss, velocity, flow quality, mass flow, etc.

Landon, Mark↗
DOE OSTI2026

Enabling On-Demand Aerospace Component Manufacturing: Topology Optimization of GE Engine Bracket and Fabrication Using Metal FFF

Additive Manufacturing (AM) offers advantages over conventional manufacturing processes, particularly by reducing the number of parts produced through multistage combined technologies, but these often result in low manufacturing yields or require post-processing. AM facilitates the production of complex geometries with fine features, overhangs, and lattice structures. For instance, Laser Powder Bed Fusion (LPBF) technology enables the fabrication of intricate parts that can be easily post-processed by removing residual powder. Laser powder bed AM technologies are widely discussed in the literature due to their design freedom in creating complex geometries, with and without the need for support generation. However, rapid solidification due to a thermal gradient in the build direction, which leads to the formation of columnar grains and warpage, is one of the challenges. To address this challenge, we propose layer-by-layer metal FFF technology, followed by the debinding and sintering process, as an alternative to powder- and laser-based approaches. Furthermore, design for additive manufacturing (DfAM) principles are discussed to minimize the need for support generation and enable easy post-processing, thereby improving surface finish to meet high tolerances in fabricating components for aerospace and healthcare applications.

Singh, Abhishek [University of Michigan, Ann Arbor↗
NASA NTRS1987

Shape optimization of three-dimensional stamped and solid automotive components

The shape optimization of realistic, 3-D automotive components is discussed. The integration of the major parts of the total process: modeling, mesh generation, finite element and sensitivity analysis, and optimization are stressed. Stamped components and solid components are treated separately. For stamped parts a highly automated capability was developed. The problem description is based upon a parameterized boundary design element concept for the definition of the geometry. Automatic triangulation and adaptive mesh refinement are used to provide an automated analysis capability which requires only boundary data and takes into account sensitivity of the solution accuracy to boundary shape. For solid components a general extension of the 2-D boundary design element concept has not been achieved. In this case, the parameterized surface shape is provided using a generic modeling concept based upon isoparametric mapping patches which also serves as the mesh generator. Emphasis is placed upon the coupling of optimization with a commercially available finite element program. To do this it is necessary to modularize the program architecture and obtain shape design sensitivities using the material derivative approach so that only boundary solution data is needed.

Botkin, M. E.↗
DOE OSTI2024

Optimization of prefabricated component installation using a real-time evaluator (RTE) connection locating system

Prefabrication promises to industrialize the construction industry. By constructing elements within a manufacturing environment, producers can better control quality and maximize production efficiency. Since the major adoption of prefabrication, a wide variety of prefabricated components have been produced for varying applications such as new construction and exterior wall retrofits. While the production processes of these prefabricated components have seen much innovation, the installation process has remained relatively unchanged for decades. To innovate the installation process with modern technologies, a real-time evaluator (RTE) has been developed to reduce the installation cost of prefabricated components by reducing installation time, decreasing rework, and improving accuracy. The RTE uses developed software solutions with off-the-shelf hardware to assist erectors in completing an installation by measuring the real-time positions of connections and prefabricated components, providing installation guidance through a graphical user interface, and monitoring the accumulated installation errors. An overview of the RTE and proposed workflow is presented. A connection locating system that guides users in expediting the installation of connections is introduced. Laboratory experiments were conducted to determine the accuracy improvement and time savings of the RTE in installing connections for prefabricated components. RTE enabled a time saving of up to 37% compared to traditional connection installation methods using handheld measurement tools.

Hayes, Nolan↗
NASA NTRS1993

Preliminary analysis of a membrane-based atmosphere-control subsystem

Controlled ecological life supprot systems will require subsystems for maintaining the consentrations of atmospheric gases within acceptable ranges in human habitat chambers and plant growth chambers. The goal of this work was to develop a membrane-based atmosphere comntrol (MBAC) subsystem that allows the controlled exchange of atmospheric componets (e.g., oxygen, carbon dioxide, and water vapor) between these chambers. The MBAC subsystem promises to offer a simple, nonenergy intensive method to separate, store and exchange atmospheric components, producing optimal concentrations of components in each chamber. In this paper, the results of a preliminary analysis of the MBAC subsystem for control of oxygen and nitrogen are presented. Additionally, the MBAC subsystem and its operation are described.

Mccray, Scott B.↗