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NASA NTRS1978

Research requirements to reduce maintenance costs of civil helicopters

The maintenance problems faced by the operators of civil helicopters that result in high costs are documented. Existing technology that can be applied to reduce maintenance costs and research that should be carried out were identified. Good design practice and application of existing technology were described as having a significant impact on reducing maintenance costs immediately. The research and development that have potential for long range reduction of maintenance costs are presented.

Million, D. J.↗

NASA NTRS1990

Taguchi Approach to Design Optimization for Quality and Cost: An Overview

Calibrations to existing cost of doing business in space indicate that to establish human presence on the Moon and Mars with the Space Exploration Initiative (SEI) will require resources, felt by many, to be more than the national budget can afford. In order for SEI to succeed, we must actually design and build space systems at lower cost this time, even with tremendous increases in quality and performance requirements, such as extremely high reliability. This implies that both government and industry must change the way they do business. Therefore, new philosophy and technology must be employed to design and produce reliable, high quality space systems at low cost. In recognizing the need to reduce cost and improve quality and productivity, Department of Defense (DoD) and National Aeronautics and Space Administration (NASA) have initiated Total Quality Management (TQM). TQM is a revolutionary management strategy in quality assurance and cost reduction. TQM requires complete management commitment, employee involvement, and use of statistical tools. The quality engineering methods of Dr. Taguchi, employing design of experiments (DOE), is one of the most important statistical tools of TQM for designing high quality systems at reduced cost. Taguchi methods provide an efficient and systematic way to optimize designs for performance, quality, and cost. Taguchi methods have been used successfully in Japan and the United States in designing reliable, high quality products at low cost in such areas as automobiles and consumer electronics. However, these methods are just beginning to see application in the aerospace industry. The purpose of this paper is to present an overview of the Taguchi methods for improving quality and reducing cost, describe the current state of applications and its role in identifying cost sensitive design parameters.

Unal, Resit↗

DOE OSTI2026

Enabling Dynamic Probabilistic Risk Assessment of Physical Security Using EMRALD and MAAP (Presentation)

The optimization of physical security in nuclear power plants requires sophisticated methodologies that integrate operator actions and plant behavior through advanced simulation tools. Idaho National Laboratory has developed the Modeling and Analysis for Safety and Security using the Dynamic EMRALD Framework (MASS-DEF) methodology, an approach that integrates force-on-force simulations, dynamic probabilistic risk assessment, and thermal hydraulics modeling to enhance security planning while reducing costs. A reduced order model for thermal hydraulic simulations performed by the Modular Accident Analysis Program (MAAP) was developed to evaluate reactor core behavior during attack scenarios. MAAP simulations are computationally intensive and must be run in a secure environment, complicating analysis and validation. By pre-computed scenario outcomes for a small number of modified parameters, the reduced order model significantly decreases the computational cost and enables offsite review of the results.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Reducing the Cost of CCSD Basis Set Extrapolation in Ab Initio Computational Thermochemistry

Here, a series of approximations to CCSD contributions in computational model chemistries is presented in the context of kcal mol –1 , kJ mol –1 , and 20 cm –1 theoretical predictions of total atomization energies, benchmarked within the HEAT+CH 4 test suite. A specific set of circumstances where MP2, without empirical scaling, may be used as an effective intermediate in the first two of these accuracy ranges was determined. However, SDQ-MP4, a method long used in pursuit of kcal mol –1 accuracy but relatively unstudied in the subchemical accuracy community, offers significant improvement over the quality of MP2 as a basis-set intermediate at significantly reduced cost compared to CCSD. Given this, we argue for SDQ-MP4 as the de facto CCSD basis-set intermediate in sub-chemical accuracy calculations when CCSD in a desired basis set becomes unaffordable. We additionally report on a “CBS-like” scheme, where MP2 and SDQ-MP4 are used in conjunction to create a “cheap” three-part approximation of large CCSD basis set limits. The data for the CCSD approximation schemes are organized in such a way that model chemistry developers can locate an analog of their current approach for the CCSD basis set limit and explore alternative intermediates that either decrease computational cost or increase computational accuracy. We also show, for a handful of molecules, that SDQ-MP4 shows promise as an effective basis-set intermediate for harmonic and fundamental frequency computations, allowing for zero-point corrections of nearly CCSD(T)/ANO1 quality using simple composite methods that only require CCSD(T)/ANO0.

Thorpe, James H. [Argonne National Laboratory (ANL↗

NASA NTRS1984

Spacelab Mission Implementation Cost Assessment (SMICA)

A total savings of approximately 20 percent is attainable if: (1) mission management and ground processing schedules are compressed; (2) the equipping, staffing, and operating of the Payload Operations Control Center is revised, and (3) methods of working with experiment developers are changed. The development of a new mission implementation technique, which includes mission definition, experiment development, and mission integration/operations, is examined. The Payload Operations Control Center is to relocate and utilize new computer equipment to produce cost savings. Methods of reducing costs by minimizing the Spacelab and payload processing time during pre- and post-mission operation at KSC are analyzed. The changes required to reduce costs in the analytical integration process are studied. The influence of time, requirements accountability, and risk on costs is discussed. Recommendation for cost reductions developed by the Spacelab Mission Implementation Cost Assessment study are listed.

Guynes, B. V.↗

NASA NTRS1989

A methodology for commonality analysis, with applications to selected space station systems

The application of commonality in a system represents an attempt to reduce costs by reducing the number of unique components. A formal method for conducting commonality analysis has not been established. In this dissertation, commonality analysis is characterized as a partitioning problem. The cost impacts of commonality are quantified in an objective function, and the solution is that partition which minimizes this objective function. Clustering techniques are used to approximate a solution, and sufficient conditions are developed which can be used to verify the optimality of the solution. This method for commonality analysis is general in scope. It may be applied to the various types of commonality analysis required in the conceptual, preliminary, and detail design phases of the system development cycle.

Thomas, Lawrence Dale↗

DOE OSTI2024

Transmission Interconnection Roadmap: Transforming Bulk Transmission Interconnection by 2035

The U.S. electricity system is amid a rapidly occurring and widespread energy transition. Regional, Tribal, state, and customer demand for new energy resources, combined with favorable policies, is driving a rapid rise of interconnection requests. Interconnection processes will need to evolve to handle this larger number of requests today and into the future, as policy and economic drivers continue to motivate significant resource development. This roadmap identifies and organizes nearer- and longer-term solutions to enable transmission interconnection processes to meet this expected demand, and it is intended for a diverse audience of stakeholders participating within transmission interconnection processes. The roadmap is a result of the Interconnection Innovation e-Xchange (i2X) program launched by the U.S. Department of Energy (DOE) in June 2022 to convene stakeholders and address interconnection challenges. The roadmap is organized into four primary goal areas, each important to the overall i2X mission to enable a simpler, faster, and fairer interconnection of clean energy resources while enhancing the reliability, resiliency, and security of our electric grid. The first goal aims to improve interconnection data transparency, to aid interconnection customers’ ability to screen and site potential projects, better enable third-party modeling, facilitate more process automation, enhance competition while ensuring equitable outcomes, and enable benchmarking, tracking, and auditing of interconnection processes and reforms. The second goal covers solutions to improve queue management practices, affected system studies, fair processes, and workforce development. The third goal incorporates solutions that aim to improve cost allocation, reduce costs to electricity consumers, enhance the coordination between transmission planning and the interconnection process, and optimize the rightsizing of transmission investment through improvements in interconnection studies. The fourth and final goal aims to reduce the performance issues not identified during interconnection studies by updating technical requirements within interconnection studies, models, and tools while also improving industry interconnection standards.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1982

The all electric airplane-benefits and challenges

The all electric aircraft considered in the present investigation is an aircraft which has digital flight crucial controls, electromechanical actuators, and electrical secondary power. There are no hydraulic or pneumatic systems. The characteristics of an all electric aircraft are related to reduced acquisition cost, reduced weight, reduced fuel consumption, increased reliability, reduced support equipment, simpler maintenance, an expanded flight envelope, and improved survivability. An additional benefit is the dramatically increased design flexibility and mission adaptability. However, the implementation of the all electric aircraft concept requires the resolution of a number of major technology issues. Issues in the digital flight controls area are related to achieving the required levels of safety and reliability in a cost effective manner. Other challenges which have to be met are concerned with electromechanical actuators, environmental control and ice protection systems, and engine technology.

Spitzer, C. R.↗

DOE OSTI2023

Book Chapter: Small Modular Reactors

Small Modular Reactors (SMRs) have been a very promising development in nuclear power over the last two decades. SMRs are defined as nuclear reactors with a power output of less than 300 MWe. This is in comparison to gigawatt-size reactors, which can have electrical output of 1000–1500 MWe or more. This chapter will consist of two major sections. The first will be a detailed summary of the small modular reactor designs being proposed around the world. This section will focus on those that are the furthest along in their development, but will also include some information about the wide variety of proposed designs that require significant research and development. The second part will be a discussion of the remaining challenges to the adoption of SMRs as a major energy source. SMRs are not a new concept, but they do represent a new vision for an older concept. These reactors have the potential to become a major source of energy in the near future. The development of small, modular designs can help promote the adoption of nuclear energy by reducing upfront costs, reducing the financial risk associated with nuclear power, and the barriers to entry. However, the adoption of SMRs is not without challenges. Regulatory and licensing changes to address the unique benefits and concerns associated with SMRs will continue to be a challenge as regulators adapt to the unique features emerging from the design process. The development of new instrumentation and control systems is an ongoing issue. And economics is possibly the most significant challenge, with high construction costs, cheap natural gas, and government subsidies, combining to result in significant financial risk associated with adopting nuclear generation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS2015

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing

The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute, represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies to fabricate polymer matrix composite and ceramic matrix composite turbine engine components. The benefits include: 50 weight reduction compared to metallic parts, reduced manufacturing costs, reduced part count and rapid design iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature polymer filaments. The CMC effort uses a binder jet process to fabricate silicon carbide test coupons and demonstration articles. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The research project includes a multidisciplinary, multiorganization NASA - industry team that includes experts in ceramic materials and CMCs, polymers and PMCs, structural engineering, additive manufacturing, engine design and analysis, and system analysis.

Ceramics↗

DOE OSTI2022

Corrosion of Stainless and Carbon Steel in Aqueous Piperazine for CO2 Capture

Current obstacles that prevent commercial implementation of amine-scrubbing CO2 capture are the high costs. Reducing capital costs by appropriate selection of construction materials, which requires knowledge of material corrosion performance for the process, will improve the economic feasibility of this technology. Corrosion was evaluated in three pilot plant campaigns using aqueous piperazine with the Advanced Stripper (PZAS). 316L stainless steel (SS) experienced higher corrosion than 304 SS and 2205 duplex SS, and the corrosion rate showed strong dependence on the temperature. 304 and 2205 performed well at all locations and should be good construction materials for PZAS. Degraded PZ exacerbated 316L corrosion, and removal of PZ degradation products using a carbon adsorption bed significantly reduced corrosion. Carbon steel (CS) corrosion showed a weak temperature effect because the corrosion was more dependent on the protective siderite film. The protectiveness of the films was related to fluid velocity. Ni-based alloys corroded in PZ, and the rate increased with temperature. Corrosion of C1010 CS and SS (304, 316L, 430) was measured at absorber and water wash conditions on the bench-scale. Corrosion rate decreases with increasing PZ. 8 With more than 0.003 m PZ in solution, CS has acceptable corrosion performance. Corrosion of CS increases with increasing partial pressure of CO2, suggesting loading is another dominant parameter for carbon steel corrosion. Temperature has a less significant effect than PZ concentration and loading. CS corrosion increases with increasing flow velocity at both absorber and water wash conditions. SS had little corrosion at this lower temperature. Performance of siderite (FeCO3) protective films on CS was studied at representative stripper conditions on the bench-scale. Siderite films can deposit on the surface of CS in CO2-loaded PZ solution at temperatures >100 °C and protect CS from corrosion. The protection may fail in degraded PZ. Ethylenediamine (EDA) is one of the major contributors for the loss of film protectiveness or can be the surrogate for the effect of PZ degradation on siderite film protection. A link between protectiveness and the apparent density of siderite films was discovered. The apparent density of siderite films decreases with increasing flow velocity and decreasing CO2 loading, resulting in higher corrosion of CS.

Liu, Ching-Ting↗

DOE OSTI2025

Additive manufacturing of amorphous metal soft magnetic composites

Soft magnet alloys are used as magnetic cores for electric motors, transformers, wind turbines and other power generation systems. Soft magnetic cores are expensive and time consuming to manufacture in the complex shapes required for next-generation devices using conventional press and sinter powder metallurgy. The objective of this effort is to additively manufacture high performance soft magnets, with reduced cost and reduced material waste and 10x lower energy (core) loss at the high operating frequencies of many electric machines. Laser powder bed fusion additive manufacturing is used as the fabrication method. Electrical steel and amorphous alloys atomized powders are used as a feedstock materials. Magnetic cores are printed in topology optimized structures such as the Hilbert curve because this has been shown to reduce energy losses by minimizing the eddy currents that circulate within the magnet at high frequencies. In our project, we succeed in printing FeSi 3.5wt% and FeSi 6.5wt% electrical steels, and iron-based soft magnetic amorphous alloys in the shape of Hilbert and Peano curve topology optimized structures. We found that the Peano curve has a higher cut-off frequency than the Hilbert curve, and that amorphous alloys have high cut-off frequencies and higher mechanical hardness than electrical steels. Processing conditions such as laser power, scan speed, and hatching pattern were optimized to achieve high density prints, and optimize magnetic performance. We find that the printing of amorphous alloy soft magnetic cores may be technoeconomically feasible for large scale applications such as transformers, for which supply chain issues and the labor costs of manual fabrication of magnetic cores is prohibitive in some cases.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Reported Energy and Cost Savings from the DOE ESPC IDIQ Program: FY 2024

Energy Savings Performance Contracts (ESPCs)are a contractual mechanism that allow a federal agency to procure energy savings and facility improvements without upfront capital costs to reduce costs and resiliency. ESPCs are covered under FAR Part 23.2, and 42 USC § 8287. Section 8287(a)(2)(A) of Title 42 of the U.S. Code requires that each energy savings performance contract (ESPC) undergo an annual energy audit, resulting in a separate audit report for every project. The objective of the present report is to compile and analyze all annual ESPC audit reports issued between October 1, 2023, and September 30, 2024, for projects awarded under Generations 1, 2, and 3 of DOE’s ESPC IDIQ contracts. During this period, 205 measurement and verification (M&V) reports were produced for 200 projects; the total number of reports exceeds the number of projects because some projects generated more than one report(for example, a few projects measure savings twice per year and produce two audit reports annually, each covering a different six-month period). By aggregating the results from these individual audits, the report determines the portfolio-wide realization rate of energy and cost savings for all active ESPC projects awarded under DOE’s IDIQ program. For all 205audit reports, sufficient information was available to compare project-level estimated, reported, and guaranteed cost savings. Reported cost savings accounted for ESCO verified savings per each project’s M&V plan. The total reported cost savings for the period addressed were $\$$647.8million,compared with the total guaranteed cost savings of $\$$601.6million. On average across the reported projects: •ESPC contractors guaranteed 92.8% of the estimated cost savings• projects reported achieving 100.0% of the estimated cost savings• projects reported achieving 107.7% of the guaranteed cost savings. The M&V performed for the period indicated adjustments for government operations and maintenance impacts to savings amount to$\$$43.9millionandcould be restored with the original operational parameters for impacted projects. Accounting for this potential cost savings impact, these projects still realized 100.4% of the guaranteed cost savings. The information on estimated and reported energy savings was collected and compared for all 205of the reports examined. Based on site energy, estimated savings totaled 14.88million MMBtu, and reported savings were 15.33million MMBtu; 3.1% greater than the estimated energy savings. All of the reports examined contained sufficient information to calculate source energy savings. Based on site-adjusted source energy, total estimated energy savings were 20.90 million MMBtu, and reported savings were 21.22million MMBtu, 101.5% of the estimated energy savings. For water savings, the estimated savings were 11,539,055 kGal and the reported savings were 13,315,930 kGal. This means 1,776,875 kGal more water was saved than estimated, which is about 15% higher than the estimate. These results indicate that, overall, the reported energy savings slightly exceeded the estimated values, while estimated water savings significantly exceeded estimated values, suggesting that the projects achieved greater cost savings than originally projected. The total annual expense for the ESCOs to perform annual M&V audits and reporting was $\$$10.02million. Through this effort, $\$$647.8 million in annual cost savings was verified. The M&V results indicated that $\$$43.9 million of these verified savings reflected adjustments due to government operations A-6and maintenance impacts, which could be restored under the original operational parameters for the affected projects. These findings show the value of M&V that only costs 1.7%of the guaranteed cost savings to ensure guarantees are met.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Reported Energy and Cost Savings from the DOE ESPC IDIQ Program: FY 2024

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS1988

Space transportation - Options and opportunities

The development space transportation options to earth orbit and beyond are summarized. The performance of available launch systems is reviewed, including the Scout, Delta, Long March 3, Atlas Centaur, Ariane 3, Titan 34D, Proton, the Japanese M-3S-II, N-1, and H-1, and the Space Shuttle. Launch vehicle which are planned or are under development are examined, including the Conestoga, Industrial Launch Vehicle, Titan II, Delta II, H-II, Ariane 5, Titan IV, and the NASA/DOD Heavy Lift Launch Vehicle. Also, issues pertinent to the development of space transportation vehicles are considered, such as reliability, reduced unit cost, reduced lead time, and improved payload accommodations.

Loftus, J. P., Jr.↗

NASA NTRS1992

Functional implications of component commonality in operational systems

The application of commonality in a system represents an attempt to reduce costs by reducing the number of unique components. Research in this area has primarily addressed a significant benefit of commonality, the reduction of parts inventories in assemble-to-order manufacturing systems. Likewise, in an operational system subject to component failures, spares inventories are reduced through the increased commonality of components. However, commonality tends to degrade system performance parameters, a degradation that can preclude commonality in resource-constrained systems such as spacecraft. The functional impacts of component commonality on a system is addressed in a manner that allows inclusion in a commonality analysis.

Thomas, Lawrence D.↗

NASA NTRS1996

Computer-Aided Process Model For Carbon/Phenolic Materials

Computer program implements thermochemical model of processing of carbon-fiber/phenolic-matrix composite materials into molded parts of various sizes and shapes. Directed toward improving fabrication of rocket-engine-nozzle parts, also used to optimize fabrication of other structural components, and material-property parameters changed to apply to other materials. Reduces costs by reducing amount of laboratory trial and error needed to optimize curing processes and to predict properties of cured parts.

Letson, Mischell A.↗

NASA NTRS2000

Putting ROSE to Work: A Proposed Application of a Request-Oriented Scheduling Engine for Space Station Operations

Scheduling engines are found at the core of software systems that plan and schedule activities and resources. A Request-Oriented Scheduling Engine (ROSE) is one that processes a single request (adding a task to a timeline) and then waits for another request. For the International Space Station, a robust ROSE-based system would support multiple, simultaneous users, each formulating requests (defining scheduling requirements), submitting these requests via the internet to a single scheduling engine operating on a single timeline, and immediately viewing the resulting timeline. ROSE is significantly different from the engine currently used to schedule Space Station operations. The current engine supports essentially one person at a time, with a pre-defined set of requirements from many payloads, working in either a "batch" scheduling mode or an interactive/manual scheduling mode. A planning and scheduling process that takes advantage of the features of ROSE could produce greater customer satisfaction at reduced cost and reduced flow time. This paper describes a possible ROSE-based scheduling process and identifies the additional software component required to support it. Resulting changes to the management and control of the process are also discussed.

Jaap, John↗