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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 NTRS2001

Cryogenic Treatment of Al-Li Alloys for Improved Weldability, Repairability, and Reduction of Residual Stresses

Service performance has shown that cryogenic treatment of some metals provides improved strength, fatigue life, and wear resistance to the processed material. Effects such as these were initially discovered by NASA engineers while evaluating spacecraft that had returned from the cold vacuum of space. Factors such as high cost, poor repairability, and poor machinability are currently prohibitive for wide range use of some aerospace aluminum alloys. Application of a cryogenic treatment process to these alloys is expected provide improvements in weldability and weld properties coupled with a reduction in repairs resulting in a significant reduction in the cost to manufacture and life cycle cost of aerospace hardware. The primary purpose of this effort was to evaluate the effects of deep cryogenic treatment of some aluminum alloy plate products, welds, and weld repairs, and optimize a process for the treatment of these materials. The optimized process is being evaluated for improvements in properties of plate and welds, improvements in weldability and repairability of treated materials, and as an alternative technique for the reduction of residual stresses in repaired welds. This paper will present the results of testing and evaluation conducted in this effort. These results will include assessments of changes in strength, toughness, stress corrosion susceptability, weldability, repairability, and reduction in residual stresses of repaired welds.

Malone, Tina W.↗

NASA NTRS2003

Probabilistic Unsteady Aerodynamic Analysis

Probabilistic CFD design is needed because we are asked to do more with less. To cost effectively accomplish the design task, we need to formally quantify the effect of uncertainties (variables) in the design. Probabilistic design is one effective method to formally quantify the effect of uncertainties. Our objective is to establish a revolutionary new early design process, by developing non-deterministic physics-based probabilistic design tools, which will include all the life cycle processes. This work was concerned with the usefulness of parametric optimization method coupled with a Navier-Stokes analysis code for the aero-thermodynamic design of turbomachinery combustor liner. The interconnection between the CFD code and NESSUS codes will facilitate the coupling between the thermal profiles and structural design. We have developed new concepts for reducing the computational cost of unsteady, three-dimensional, compressible aerodynamic analyses for multistage turbomachinery flows. The flow was modeled by the three-dimensional Favre-Reynolds-averaged Navier-Stokes equations using the k-E turbulence closure, which was integrated using an implicit third-order upwind solver. The methodology developed in this work is expected to lead to the design optimization of turbomachinery blades.

Gorla, Rama S. R.↗

NASA NTRS1989

Development of a funding, cost, and spending model for satellite projects

The need for a predictive budget/funging model is obvious. The current models used by the Resource Analysis Office (RAO) are used to predict the total costs of satellite projects. An effort to extend the modeling capabilities from total budget analysis to total budget and budget outlays over time analysis was conducted. A statistical based and data driven methodology was used to derive and develop the model. Th budget data for the last 18 GSFC-sponsored satellite projects were analyzed and used to build a funding model which would describe the historical spending patterns. This raw data consisted of dollars spent in that specific year and their 1989 dollar equivalent. This data was converted to the standard format used by the RAO group and placed in a database. A simple statistical analysis was performed to calculate the gross statistics associated with project length and project cost ant the conditional statistics on project length and project cost. The modeling approach used is derived form the theory of embedded statistics which states that properly analyzed data will produce the underlying generating function. The process of funding large scale projects over extended periods of time is described by Life Cycle Cost Models (LCCM). The data was analyzed to find a model in the generic form of a LCCM. The model developed is based on a Weibull function whose parameters are found by both nonlinear optimization and nonlinear regression. In order to use this model it is necessary to transform the problem from a dollar/time space to a percentage of total budget/time space. This transformation is equivalent to moving to a probability space. By using the basic rules of probability, the validity of both the optimization and the regression steps are insured. This statistically significant model is then integrated and inverted. The resulting output represents a project schedule which relates the amount of money spent to the percentage of project completion.

Johnson, Jesse P.↗

NASA NTRS2008

Communication Needs Assessment for Distributed Turbine Engine Control

Control system architecture is a major contributor to future propulsion engine performance enhancement and life cycle cost reduction. The control system architecture can be a means to effect net weight reduction in future engine systems, provide a streamlined approach to system design and implementation, and enable new opportunities for performance optimization and increased awareness about system health. The transition from a centralized, point-to-point analog control topology to a modular, networked, distributed system is paramount to extracting these system improvements. However, distributed engine control systems are only possible through the successful design and implementation of a suitable communication system. In a networked system, understanding the data flow between control elements is a fundamental requirement for specifying the communication architecture which, itself, is dependent on the functional capability of electronics in the engine environment. This paper presents an assessment of the communication needs for distributed control using strawman designs and relates how system design decisions relate to overall goals as we progress from the baseline centralized architecture, through partially distributed and fully distributed control systems.

Culley, Dennis E.↗

NASA NTRS2005

Knowledge Capture and Management for Space Flight Systems

The incorporation of knowledge capture and knowledge management strategies early in the development phase of an exploration program is necessary for safe and successful missions of human and robotic exploration vehicles over the life of a program. Following the transition from the development to the flight phase, loss of underlying theory and rationale governing design and requirements occur through a number of mechanisms. This degrades the quality of engineering work resulting in increased life cycle costs and risk to mission success and safety of flight. Due to budget constraints, concerned personnel in legacy programs often have to improvise methods for knowledge capture and management using existing, but often sub-optimal, information technology and archival resources. Application of advanced information technology to perform knowledge capture and management would be most effective if program wide requirements are defined at the beginning of a program.

Goodman, John L.↗

NASA NTRS1990

Minimizing life cycle cost for subsonic commercial aircraft

A methodology is presented which facilitates the identification of that aircraft design concept which will incur the lowest life-cycle costs (LCCs) while meeting mission requirements. The methodology consists of an LCC module whose constituent elements calculate the costs associated with R&D, testing, evaluation, and production, as well as direct and indirect operating costs, in conjunction with the 'Flight Optimization System' conceptual design/analysis code. Provision is made in the methodology for sensitivities to advanced technologies for the subsonic commercial aircraft in question, which are optimized with respect to minimum gross weight, fuel consumption, acquisition cost, and direct operating cost.

Johnson, Vicki S.↗

NASA NTRS2002

Probabilistic Study of Fluid Structure Interaction

Probabilistic CFD design is needed because we are asked to do more with less. To cost effectively accomplish the design task, we need to formally quantify the effect of uncertainties (variables) in the design. Probabilistic design is one effective method to formally quantify the effect of uncertainties. Our objective is to establish a revolutionary new early design process, by developing non-deterministic physics-based probabilistic design tools, which will include all the life cycle processes. Breakthroughs will be sought in speed, accuracy, intelligence, and usability of the system. This paper is concerned with the usefulness of parametric optimization method coupled with a Navier-Stokes analysis code for the aero-thermodynamic design of turbomachinery combustor liner. The interconnection between the CFD code and NESSUS codes facilitated the coupling between the thermal profiles and structural design. We have developed new concepts for reducing the computational cost of unsteady, three-dimensional, compressible aerodynamic analyses for multistage turbomachinery flows. The flow was modeled by the three-dimensional Favre-Reynolds-averaged Navier-Stokes equations using the k-epsilon turbulence closure, which was integrated using an implicit third-order upwind solver. The methodology developed in this paper is expected to lead to the design optimization of turbomachinery blades.

Gorla, Rama S. R.↗

NASA NTRS1979

Phase 1 of the near team hybrid passenger vehicle development program. Appendix C: Preliminary design data package, volume 1

The methodology used for vehicle layout and component definition is described as well as techniques for system optimization and energy evaluation. The preliminary design is examined with particular attention given to body and structure; propulsion system; crash analysis and handling; internal combustion engine; DC motor separately excited; Ni-Zn battery; transmission; control system; vehicle auxiliarries; weight breakdown, and life cycle costs. Formulas are given for the quantification of energy consumption and results are compared with the reference vehicle.

Piccolo, R.↗

NASA NTRS1993

More sense for less cents: Cost effective servicing of remote sensing satellites

This paper addresses the design considerations for Earth observation spacecraft bus and payload subsystems such that cost-effective spacecraft maintainability is enhanced through optimized reliability and the application of robotic on-orbit support. In the past, for most satellites, maintainability has been associated with the clever application of telemetry reconfiguration and the use of redundant systems as necessary over the life cycle of the spacecraft. This presentation addresses the opportunities and challenges of leveraging the extensive work already accomplished in the development of on-orbit servicing technologies.

Lee, Jeannie↗

NASA NTRS1995

System-Availability And Resource-Allocation Program

ACARA analyzes availability, life-cycle cost, and scheduling of resources. Uses statistical Monte Carlo method to simulate capacity states of system as well as failure and repair of components. Failures of components modeled mathematically by use of combination of exponential and Weibull probability distributions. Schedules replacement of components to optimize performance of system. Made to comply with any constraints on production of components, capacities of resupply vehicles, spares kept on site, crews, and/or equipment. Written in APL2.

Viterna, L. A.↗

NASA NTRS1991

Scorpion: Close Air Support (CAS) aircraft

The objective is to outline the results of the preliminary design of the Scorpion, a proposed close air support aircraft. The results obtained include complete preliminary analysis of the aircraft in the areas of aerodynamics, structures, avionics and electronics, stability and control, weight and balance, propulsion systems, and costs. A conventional wing, twin jet, twin-tail aircraft was chosen to maximize the desirable characteristics. The Scorpion will feature low speed maneuverability, high survivability, low cost, and low maintenance. The life cycle cost per aircraft will be 17.5 million dollars. The maximum takeoff weight will be 52,760 pounds. Wing loading will be 90 psf. The thrust to weight will be 0.6 lbs/lb. This aircraft meets the specified mission requirements. Some modifications have been suggested to further optimize the design.

Allen, Chris↗

NASA NTRS2022

Assurance Equations: A Cost and Criticality Model for Optimizing Quality Assurance Surveillance

The cost of quality vs cost of failure correction has been a long-running topic of discussion within the Aerospace community. It leads directly to concepts of “risk tolerance”, and risk-based decision-making. It would be valuable if there was a way to compute the optimal investment in customer-executed quality assurance activities using defect significance with respect to performance objectives, the activities’ defect detection effectiveness, and the cost-penalty for late discovery of impactful defects. This optimization is particularly of interest to projects whose budget constraints significantly limit their risk management options.The cost to fix defects (i.e., failure correction) escalates as the project matures. There have been studies attempting to determine the relative cost of fixing defects discovered during various phases of a project life cycle with important implications, all of which suggest growth factors are large. The commonly referred to 1:10:100 rule represents a cost multiplier for repair/rework across the Design to Fab to Test hardware development phases. Cost premiums for QA activities also accumulate when they are treated as mandatory (due to schedule drag) or are performed later than their assigned phase.This paper describes the modeling of development phase -dependencies in the conduct of typical customer-executed quality assurance activities. Our initial modeling encompasses:• Distinct phases of the production lifecycle• Multiple kinds of Defects, each with some a-priori likelihood of being present• Each defect’s impact on performance Objectives for a type of hardware• The cost and efficacy of assurance techniques at detecting such Defects• The costs of fixing those Defects detected in a given phase of the production lifecycleThe model captures assurance activities’ abilities to Detect defects. Upon detection it is assumed that the Defect is immediately fixed. Defects that “escape” detection by some activity may thereafter be detected by a later activity, but by then the cost of fixing the Defect may have escalated. Defects are related to the performance Objectives they would detract from, were those Defects to remain present in the operating system.We have constructed and are exploring, a model that relates the importance of hardware system elements to mission objectives, the impact of types of Defects on those hardware types, the cost of customer-executed assurance activities (i.e., supplier controls) and their effectiveness towards reducing an impactful quality escape, and the cost of Defect correction across production phase. We describe the approach taken to select the key model aspects, why they are relevant to our NASA mission, and our efforts to populate it with relevant and contemporary data. We use a notional example to illustrate model design and function.

Plante, Jeannette↗

NASA NTRS2002

Bioregenerative food system cost based on optimized menus for advanced life support

Optimized menus for a bioregenerative life support system have been developed based on measures of crop productivity, food item acceptability, menu diversity, and nutritional requirements of crew. Crop-specific biomass requirements were calculated from menu recipe demands while accounting for food processing and preparation losses. Under the assumption of staggered planting, the optimized menu demanded a total crop production area of 453 m2 for six crew. Cost of the bioregenerative food system is estimated at 439 kg per menu cycle or 7.3 kg ESM crew-1 day-1, including agricultural waste processing costs. On average, about 60% (263.6 kg ESM) of the food system cost is tied up in equipment, 26% (114.2 kg ESM) in labor, and 14% (61.5 kg ESM) in power and cooling. This number is high compared to the STS and ISS (nonregenerative) systems but reductions in ESM may be achieved through intensive crop productivity improvements, reductions in equipment masses associated with crop production, and planning of production, processing, and preparation to minimize the requirement for crew labor.

Non-NASA Center↗

NASA NTRS1986

Multiple-Purpose Subsonic Naval Aircraft (MPSNA): Multiple Application Propfan Study (MAPS)

Study requirements, assumptions and guidelines were identified regarding carrier suitability, aircraft missions, technology availability, and propulsion considerations. Conceptual designs were executed for two missions, a full multimission aircraft and a minimum mission aircraft using three different propulsion systems, the UnDucted Fan (UDF), the Propfan and an advanced Turbofan. Detailed aircraft optimization was completed on those configurations yielding gross weight performance and carrier spot factors. Propfan STOVL conceptual designs were exercised also to show the effects of STOVL on gross weight, spot factor and cost. An advanced technology research plan was generated to identify additional investigation opportunities from an airframe contractors standpoint. Life cycle cost analysis was accomplished yielding a comparison of the UDF and propfan configurations against each other as well as against a turbofan with equivalent state of the art turbo-machinery.

Engelbeck, R. M.↗

NASA NTRS2017

Improvement of Automated POST Case Success Rate Using Support Vector Machines

Zwack, Mathew R.↗

NASA NTRS2017

Improvement of Automated POST Case Success Rate Using Support Vector Machines

During early conceptual design of complex systems, concept down selection can have a large impact upon program life-cycle cost. Therefore, any concepts selected during early design will inherently commit program costs and affect the overall probability of program success. For this reason it is important to consider as large a design space as possible in order to better inform the down selection process. For conceptual design of launch vehicles, trajectory analysis and optimization often presents the largest obstacle to evaluating large trade spaces. This is due to the sensitivity of the trajectory discipline to changes in all other aspects of the vehicle design. Small deltas in the performance of other subsystems can result in relatively large fluctuations in the ascent trajectory because the solution space is non-linear and multi-modal [1]. In order to help capture large design spaces for new launch vehicles, the authors have performed previous work seeking to automate the execution of the industry standard tool, Program to Optimize Simulated Trajectories (POST). This work initially focused on implementation of analyst heuristics to enable closure of cases in an automated fashion, with the goal of applying the concepts of design of experiments (DOE) and surrogate modeling to enable near instantaneous throughput of vehicle cases [2]. Additional work was then completed to improve the DOE process by utilizing a graph theory based approach to connect similar design points [3]. The conclusion of the previous work illustrated the utility of the graph theory approach for completing a DOE through POST. However, this approach was still dependent upon the use of random repetitions to generate seed points for the graph. As noted in [3], only 8% of these random repetitions resulted in converged trajectories. This ultimately affects the ability of the random reps method to confidently approach the global optima for a given vehicle case in a reasonable amount of time. With only an 8% pass rate, tens or hundreds of thousands of reps may be needed to be confident that the best repetition is at least close to the global optima. However, typical design study time constraints require that fewer repetitions be attempted, sometimes resulting in seed points that have only a handful of successful completions. If a small number of successful repetitions are used to generate a seed point, the graph method may inherit some inaccuracies as it chains DOE cases from the non-global-optimal seed points. This creates inherent noise in the graph data, which can limit the accuracy of the resulting surrogate models. For this reason, the goal of this work is to improve the seed point generation method and ultimately the accuracy of the resulting POST surrogate model. The work focuses on increasing the case pass rate for seed point generation.

Zwack, Matthew R.↗

NASA NTRS2011

Hybrid Power Management-Based Vehicle Architecture

Hybrid Power Management (HPM) is the integration of diverse, state-of-the-art power devices in an optimal configuration for space and terrestrial applications (s ee figure). The appropriate application and control of the various power devices significantly improves overall system performance and efficiency. The basic vehicle architecture consists of a primary power source, and possibly other power sources, that provides all power to a common energy storage system that is used to power the drive motors and vehicle accessory systems. This architecture also provides power as an emergency power system. Each component is independent, permitting it to be optimized for its intended purpose. The key element of HPM is the energy storage system. All generated power is sent to the energy storage system, and all loads derive their power from that system. This can significantly reduce the power requirement of the primary power source, while increasing the vehicle reliability. Ultracapacitors are ideal for an HPM-based energy storage system due to their exceptionally long cycle life, high reliability, high efficiency, high power density, and excellent low-temperature performance. Multiple power sources and multiple loads are easily incorporated into an HPM-based vehicle. A gas turbine is a good primary power source because of its high efficiency, high power density, long life, high reliability, and ability to operate on a wide range of fuels. An HPM controller maintains optimal control over each vehicle component. This flexible operating system can be applied to all vehicles to considerably improve vehicle efficiency, reliability, safety, security, and performance. The HPM-based vehicle architecture has many advantages over conventional vehicle architectures. Ultracapacitors have a much longer cycle life than batteries, which greatly improves system reliability, reduces life-of-system costs, and reduces environmental impact as ultracapacitors will probably never need to be replaced and disposed of. The environmentally safe ultracapacitor components reduce disposal concerns, and their recyclable nature reduces the environmental impact. High ultracapacitor power density provides high power during surges, and the ability to absorb high power during recharging. Ultracapacitors are extremely efficient in capturing recharging energy, are rugged, reliable, maintenance-free, have excellent lowtemperature characteristic, provide consistent performance over time, and promote safety as they can be left indefinitely in a safe, discharged state whereas batteries cannot.

Eichenberg, Dennis J.↗

NASA NTRS2022

Application Table: A Bridge Connecting the Designing “With-The-Material” and “The-Material” Paradigms

Over the last few decades, advances in high-performance computing, new material characterization methods, and, more recently, an emphasis on integrated computational materials engineering (ICME) have been a catalyst for multiscale modeling and simulation-based design of materials and structures in the aerospace industry. In 2016 NASA sponsored a 2040 Vision study (which appeared in 2018) to define the potential 25-year future state required for integrated multiscale modeling of materials and systems (e.g., load-bearing structures) to accelerate the pace and reduce the expense of innovation in future aerospace and aeronautical systems. The study envisions a cyber-physical-social ecosystem comprised of experimentally verified and validated (V & V) computational models, tools, and techniques, along with the associated digital tapestry, that impacts the entire supply chain to enable cost-effective, rapid, and revolutionary design of “fit-for-purpose” materials, components, and systems. Consequently, the development of a robust information management system that incorporates (across the full life cycle) both experimental (real data) and virtual data resulting from the application of various simulation tools (at single or multiple length scales), therefore enabling the virtual design and optimization of materials throughout their processing – internal structure – property – performance envelope, has become critical. This need is also fueled by the demands for higher efficiency in material testing; consistency, quality, and traceability of data; product design; engineering analysis; as well as control of access to proprietary or sensitive information. This is particularly true when attempting to merge ICME practices with recent additive manufacturing technology which will enable production of the resulting 2040 Vision material and structural designs. At NASA Glenn Research Center we are exploring the future of material science through the use of novel characterization methodologies, high performance computing, and recently an emphasis on integrated computational materials engineering (ICME). Herein, recent efforts to incorporate an Application Table within NASA Glenn Research Center’s ICME Granta MI database is presented. The goal is to provide a place where material and structural application information/requirements can be linked so as to marry the “design the-material” and the “design-with-material” paradigms and thereby enable application-driven design and optimization of materials and structures by providing a central location that links material processing at various length scales to the application’s performance requirements. This paper discusses the specifics of this Application Table as well as best practices and key principles for the development of a robust materials information management system to enable the 2040 Vision integrated materials and structures ecosystem. Furthermore, it presents the intended role of the Application Table in the future of ICME design of “fit-for-purpose” materials, showing the need for a well-established framework that can successfully bridge the gap between the design “the material” and design “with-the-material” paradigms.

Materials↗