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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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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

A Novel Manufacturing Process of Lightweight Automotive Seats (Integration of Additive Manufacturing and Reinforced Polymer Composite)

Lightweight automotive seats offer multiple benefits to original equipment manufacturers in terms of cost savings from various aspects, including less material usage, more integrated processes, and compliance with Corporate Average Fuel Economy Standards. Original equipment manufacturers have been focusing on innovative ways to produce light weight automotive seats. The commercially available automotive seats are currently made of multiple metal components combined through welding and fasteners. The use of additive manufacturing and composite structures is particularly useful for light weighting the automotive components. Additive manufacturing (AM) offers multiple advantages over traditional manufacturing processes such as freedom of design thereby enabling complex structural geometries, mass customization and waste minimization, and control over the fiber alignment through deposition in a predetermined pattern. Combining metal inserts with polymer composites through a novel manufacturing process allows design of lightweight and high-performance materials for automotive components. However, fabricating these metal polymer composite structures through traditional manufacturing processes limits their mechanical properties due to limited design freedom, lack of control over fiber orientation in composite parts, and poor interfacial bonding between the constituent materials. It is essential to develop a novel manufacturing process to enable high throughput production of lightweight automotive seats using metal and polymer composites. As such it is important to design the automotive seat suitable for manufacturing via this process and perform mechanical characterization on various subcomponents of the seat to ensure that the design and performance requirements provided by the auto manufacturer are met. The aim of this project is to develop a novel manufacturing technique to produce lightweight automotive seat by combining AM with conventional manufacturing processes. The car seat back panel will be designed via topology optimization and numerical simulations to minimize the overall weight while ensuring it meets all the performance requirements. The optimization of the seat back structure will be based on computational stress analysis to maximize the stiffness and minimize the weight. Materials currently used by Ford Motor Company will be adopted for a few subcomponents while the in-house composite materials will be used for the rest of the seat back. The composite and metallic materials will be tested to determine their mechanical properties as these are necessary for simulations. A novel manufacturing process will be developed to integrate AM metal inserts with discontinuous reinforced composite through large scale additive manufacturing and compression overmolding processes. The developed manufacturing technique will be used to fabricated various subcomponents suitable for the seat back design and mechanically tested to determine their properties. The manufacturing of the lightweight seat back design through this process involves integrated AM metal inserts with the composite structure for recliner connection. The manufacturing of the entire seat back which is lightweight through the novel manufacturing process will be discussed. The performance of the designed seat back will be investigated through numerical simulations and shown to meet all the requirements provided by the auto manufacturer. The final goal of developing a novel manufacturing process for lightweight automotive seats is met through design optimization of seat back, manufacturing of subcomponents, mechanical characterization, and validation through numerical simulations. The routes to achieve the final goal of the project and the depth in which they were investigated changed throughout the project due to personnel changes and the COVID-19 pandemic. The project resulted in the development of a novel manufacturing process to integrate metal inserts with tailored polymer composite preforms through overmolding. Leveraging this proven manufacturing process, a lightweight seat back was designed through topology optimization and numerical simulations. The designed seat back uses AM metal inserts and compression overmolding of tailored polymer composite preforms obtained via large scale additive manufacturing. The metal polymer composite structures fabricated through this process exhibited enhancement in stiffness and improved ductility upon testing. Overall, the project provided an alternative design and manufacturing technique for automotive seat back that enables weight saving while meeting the safety and performance requirements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1975

The Multimission Modular Spacecraft for the 80's

The challenge to NASA is to prepare for the missions of tomorrow with manpower and funding constraints of today. The Goddard Space Flight Center has met this challenge with the Multimission Modular Spacecraft (MMS). This spacecraft design has evolved over the past six years while studying various potential missions. The key to the concept of the MMS is modularity and flexibility to accept mission unique hardware with minimum impact on the basic spacecraft bus. Beyond this, it was imperative that this multiple mission bus be cost effective even though it would not be of an optimum design for many missions having minimum performance requirements. The MMS performance and cost will capture 34 of the 43 potential spacecraft missions which have been initially studied. Gamma Ray Explorer (GRE) will be the first mission to utilize the MMS.

Bartlett, R. O.↗
NASA NTRS1993

Functional categories for future flight deck designs

With the addition of each new system on the flight deck, the danger of increasing overall operator workload while reducing crew understanding of critical mission information exists. The introduction of more powerful onboard computers, larger databases, and the increased use of electronic display media may lead to a situation of flight deck 'sophistication' at the expense of losses in flight crew capabilities and situational awareness. To counter this potentially negative impact of new technology, research activities are underway to reassess the flight deck design process. The fundamental premise of these activities is that a human-centered, systems-oriented approach to the development of advanced civil aircraft flight decks will be required for future designs to remain ergonomically sound and economically competitive. One of the initial steps in an integrated flight deck process is to define the primary flight deck functions needed to support the mission goals of the vehicle. This would allow the design team to evaluate candidate concepts in relation to their effectiveness in meeting the functional requirements. In addition, this would provide a framework to aid in categorizing and bookkeeping all of the activities that are required to be performed on the flight deck, not just activities of the crew or of a specific system. This could then allow for a better understanding and allocation of activities in the design, an understanding of the impact of a specific system on overall system performance, and an awareness of the total crew performance requirements for the design. One candidate set of functional categories that could be used to guide an advanced flight deck design are described.

Abbott, Terence S.↗
NASA NTRS2017

Development of a New Departure Aversion Standard for Light Aircraft

The Federal Aviation Administration (FAA) and European Aviation Safety Agency (EASA) have recently established new light aircraft certification rules that introduce significant changes to the current regulations. The changes include moving from prescriptive design requirements to performance-based standards, transferring many of the acceptable means of compliance out of the rules and into consensus standards. In addition, the FAA/EASA rules change the performance requirements associated with some of the more salient safety issues regarding light aircraft. One significant change is the elimination of spin recovery demonstration. The new rules now call for enhanced stall warning and aircraft handling characteristics that demonstrate resistance to inadvertent departure from controlled flight. The means of compliance with these changes in a safe, cost-effective manner is a challenging problem. This paper discusses existing approaches to reducing the likelihood of departure from controlled flight and introduces a new approach, dubbed Departure Aversion, which allows applicants to tailor the amount of departure resistance, stall warning, and enhanced safety equipment to meet the new proposed rules. The Departure Aversion approach gives applicants the freedom to select the most cost-effective portfolio for their design, while meeting the safety intent of the new rules, by ensuring that any combination of the selected approaches will be at a higher equivalent level of safety than today's status quo.

Borer, Nicholas K.↗
NASA NTRS2017

Development Specification for the Feedwater Supply Assembly (FSA), FSA-431 with Integrated Auxiliary Feedwater Supply Assembly (AFSA), FSA-531

The FSA with Integrated Aux FSA Specification establishes the requirements for design, performance, and testing of the FSA-431/FSA-531 assembly in compliance with CTSD-ADV-780, Development Specification for the Advanced EMU (AEMU) Portable Life Support System (PLSS). This section contains the technical design and performance requirements for the integrated assembly of the Feedwater Supply Assembly and Auxiliary Feedwater Supply Assembly for the Advanced EVA Development Portable Life Support Subsystem (PLSS).

Anchondo, Ian↗
NASA NTRS2014

TPSAS-NF1676L-19134-DND

Composite materials and structures are state-of-art enabling technology for modern aerospace vehicles, reducing weight and maintenance requirements, and increasing performance and reliability. Numerical-control manufacturing systems, including automated fiber placement (AFP), are widely used to fabricate these components. However, the challenging weight and performance requirements necessary for the next generation of aerospace vehicles will push the composites state-of-art even further, and require development of even more advanced materials, manufacturing, and structures technologies that are more affordable and more efficient. The Integrated Structural Assembly of Advanced Composites (ISAAC) system is intended to address many of NASA's critical research needs in the field of advanced composites. The baseline ISAAC system, combining a commercial robot with multiple degrees of freedom, a tool changer interface, and a special-purpose AFP end effector, will enable very precise and accurate additive manufacturing of composite structures. One promising area of research enabled by the ISAAC system is advanced composite tow-steered structures that have tailored structural load paths. Several examples are presented that describe these tow-steered composite structures in more detail.

Brian K Stewart↗
NASA NTRS2023

ICESat-2/ATLAS at 4 Years: Instrument Performance and Projected Life

NASA’s ICESat-2 mission launched in September 2018 carrying a single instrument, the Advanced Topographic Laser Altimeter System (ATLAS). ATLAS uses a high-repetition-rate, low-pulse-energy laser with its output split into six beams and a photon-counting receiver to measure Earth surface elevation with centimeter-level precision, repeating its ground track every 91 days. During more than four years of on-orbit operation, ATLAS has met or exceeded its lifetime and performance requirements. We present performance measurements, trends and projections for several instrument parameter, including transmitted laser pulse energy, receiver sensitivity, the instrument’s impulse response, transmitter/receiver alignment, dead-time behavior, and elevation measurement performance. The laser energy setting was increased in September 2023, for the first time, to maintain ranging performance at its early mission level. The trends in instrument parameters indicate capability to continue on-orbit operation of ATLAS for many years into the future.

Anthony J. Martino↗
NASA NTRS1998

Composing, Analyzing and Validating Software Models

This research has been conducted at the Computational Sciences Division of the Information Sciences Directorate at Ames Research Center (Automated Software Engineering Grp). The principle work this summer has been to review and refine the agenda that were carried forward from last summer. Formal specifications provide good support for designing a functionally correct system, however they are weak at incorporating non-functional performance requirements (like reliability). Techniques which utilize stochastic Petri nets (SPNs) are good for evaluating the performance and reliability for a system, but they may be too abstract and cumbersome from the stand point of specifying and evaluating functional behavior. Therefore, one major objective of this research is to provide an integrated approach to assist the user in specifying both functionality (qualitative: mutual exclusion and synchronization) and performance requirements (quantitative: reliability and execution deadlines). In this way, the merits of a powerful modeling technique for performability analysis (using SPNs) can be combined with a well-defined formal specification language. In doing so, we can come closer to providing a formal approach to designing a functionally correct system that meets reliability and performance goals.

Sheldon, Frederick T.↗
NASA NTRS2006

The Constellation-X Reflection Grating Spectrometer

The Reflection Grating Spectrometer on the Constellation-X mission will provide high sensitivity, high-resolution spectra in the soft x-ray band. The RGS performance requirements are specified as a resolving power of greater than 300 and an effective area of greater than 1000 sq cm across most of the 0.25 to 2.0 keV band. These requirements are driven by the science goals of the mission. We will describe the performance requirements and goals, the reference design of the spectrometer, and examples of science cases where we expect data from the RGS to significantly advance our current understanding of the universe.

Allen, Jean C.↗
NASA NTRS2010

Multi-Stage ADRs for Current and Future Astronomy Missions: Performance and Requirements for Cryogen-Free Operation

The cooling requirements for current (e.g. Astro-H) and future (e.g. IXO and ASP) astronomy missions pose significant challenges for the sub-Kelvin Cooler. In particular, the use of large detector arrays increases the cooling power needed, and the variety of cryocoolers that can be used for pre-cooling greatly expands the range of temperatures at which the sub-Kelvin cooler can be designed to reject heat. In most cases, there is also a need for a stable higher temperature stage for cooling amplifiers or telescope components. NASA/GSFC is currently building a 3-stage ADR for the Astro-H mission, and is developing a 5-stage ADR suitable for IXO and ASP, as well as many other missions in the early planning stages. The architecture of these ADRs allows them to be adapted rather easily for different cooling requirements and to accommodate different cryocooler capabilities (operating temperature and cooling power). This paper will discuss the performance of these ADRs, which operate in both continuous, and single-shot cooling modes, and the minimum cryocooler capabilities needed to meet the requirements of future missions.

Shirron, Peter↗
NASA NTRS1988

Hybrid deployable support truss designs for LDR

Concepts for a 20-meter diameter Large Deployable Reflector (LDR) deployable truss backup structure, and analytical predictions of its structural characteristics are discussed. The concept shown is referred to as the SIXPAC; It is a combination of the PACTRUSS concept and a single-fold beam, which would make up the desired backup structure. One advantage of retaining the PACTRUSS concept is its packaging density and its capability for synchronous deployment. Various 2-meter hexagonal panel arrangements are possible for this Hybrid PACTRUSS structure depending on the panel-to-structure attachment strategies used. Static analyses of the SIXPAC using various assumptions for truss designs and panel masses of 10 kg sq meters were performed to predict the tip displacement of the structure when supported at the center. The tip displacement ranged from 0.20 to 0.44 mm without the panel mass, and from 0.9 to 3.9 mm with the panel mass (in a 1-g field). The data indicate that the structure can be adequately ground tested to validate its required performance in space, assuming the required performance in space is approximately 100 microns. The static displacement at the tip of the structure when subjected to an angular acceleration of 0.001 rad/sec squared were estimated to range from 0.8 to 7.5 microns, depending on the type of truss elements.

Hedgepeth, J.↗
NASA NTRS1993

Integrated flight/propulsion control - Subsystem specifications for performance

A procedure is presented for calculating multiple subsystem specifications given a number of performance requirements on the integrated system. This procedure applies to problems where the control design must be performed in a partitioned manner. It is based on a structured singular value analysis, and generates specifications as magnitude bounds on subsystem uncertainties. The performance requirements should be provided in the form of bounds on transfer functions of the integrated system. This form allows the expression of model following, command tracking, and disturbance rejection requirements. The procedure is demonstrated on a STOVL aircraft design.

Neighbors, W. K.↗
NASA NTRS2017

Calibration and Performance Measurements for the NASA Deep Space Network Aperture Enhancement Project (DAEP)

The NASA Deep Space Network (DSN) has recently constructed two new 34-meter antennas at the Canberra Deep Space Communications Complex (CDSCC). These new antennas are part of the larger DAEP project to add six new 34-meter antennas to the DSN, including two in Madrid, three in Canberra and one in Goldstone (California). The DAEP project included development and implementation of several new technologies for the S, X, Ka (26 GHz) and Ka (32 GHz) -band uplink and downlink electronics, as previously reported. The electronics upgrades were driven by several different considerations, including parts obsolescence, cost reduction, improved reliability and maintainability, and capability to meet future performance requirements. The new antennas are required to support TT&C links for all of the NASA deep-space spacecraft, as well as for several international partners. Some of these missions, such as Voyager 1 and 2, have very limited link budgets, which results in demanding requirements for system G/T performance. These antennas are also required to support radio science missions with several spacecraft, which dictate some demanding requirements for spectral purity, amplitude stability and phase stability for both the uplink and downlink electronics. After completion of these upgrades, a comprehensive campaign of tests and measurements took place to characterize the electronics and calibrate the antennas. Radiometric measurement techniques were applied to characterize, calibrate, and optimize the performance of the antenna parameters. These included optical and RF high-resolution holographic and total power radiometry techniques. These techniques, which are described in the article, resulted in the highest antenna aperture efficiency in the DSN, of 66% achieved, at the highest operating frequency of the antenna, which is Ka-Band (32-GHz). The other measurements and results described include antenna noise temperature, photogrammetry and holography alignment of antenna panels, beam-waveguide mirrors, and subreflector, antenna aperture efficiencies and G/T versus frequency, and antenna pointing models. The first antenna (DSS-35) was entered into operations in October, 2014 and the 2nd antenna (DSS-36) in October, 2016. This paper describes the measurement techniques and results of the testing and calibration for both antennas, along with the driving requirements.

Rochblatt, David J.↗
NASA NTRS2018

Initial Jitter Analysis of Lynx, A Proposed Future Large Astrophysics Facility

Lynx, formerly known as the X-Ray surveyor, is one of the large strategic mission concepts being studied for input into the 2020 Astrophysics Decadal Survey. Lynx is the first future X-ray mission concept planning to match Chandra's angular-resolution and will combine this with very high throughput, large field of view, and high-resolution spectroscopy for point-like and extended sources. These ambitious performance requirements clearly merit early detailed engineering to demonstrate feasibility. An on-going structural dynamic analysis is being performed on the Lynx structural design to predict dynamic responses, jitter, to expected on-board vibrational disturbances. Applicable disturbance sources include a cryogenic pump, and six reaction wheels. The structural design, disturbances, analysis, and results are presented. Ultimately, responses will be compared to Lynx performance requirements as they relate to a system error budget.

Knight, J. Brent↗
NASA NTRS1988

Formulation and verification of frequency response system identification techniques for large space structures

For the past several years much effort has been given to the development of techniques for designing control systems for large space structures (LSS's). The main objective of these efforts has been to develop a LSS control methodology that produces designs that meet strenuous performance requirements and are robust to model inaccuracies. Unfortunately, performance and robustness are conflicting requirements. Because LSS's can not be fully tested on ground, it has become an accepted fact that the design of LSS control systems to meet performance requirements can not be completed until the LSS is placed on-orbit and tested and an accurate model is extracted from on-orbit test results. Modern MIMO sampled-data frequency response design techniques are viable candidates for designing LSS control systems. First, this paper presents techniques for performing MIMO system identification (ID) from test data. Then, techniques for improving the performance of the system ID process in the presence of noise are presented. Finally, practical utility of the system ID approaches are validated by the presentation of results obtained from application on the LSS Ground Test Facility at Marshall Space Flight Center.

Mitchell, Jerrel R.↗
NASA NTRS1975

Redundant actuator development program

Two concepts of redundant secondary actuator mechanization, applicable to future advanced flight control systems, were studied to quantitatively assess their design applicability to an AST. The two actuator concepts, a four-channel, force summed system and a three-channel, active/standby system have been developed and evaluated through analysis, analog computer simulation, and piloted motion simulation. The quantitative comparison of the two concepts indicates that the force summed concept better meet performance requirements, although the active/standby is superior in other respects. Both concepts are viable candidates for advanced control application dependent on the specific performance requirements.

Chenoweth, C. C.↗
DOE OSTI2025

LAMP Technical Readiness Evaluation Report

An internal preliminary evaluation of Critical Technology Elements (CTEs) for the LANSCE Modernization Project (LAMP) was completed in 2023. This included determining corresponding Technical Readiness Levels (TRLs) for all subsystems using the criteria of DOE G 413.3-4A, Technical Readiness Assessment Guide. This revised report includes a summary of the recent design modifications required to meet the project Key Performance Requirements (KPPs), some of which may reduce technical risk to the project. These recent design modifications include: • Further optimization of the low-energy and medium-energy beam transport regions (LEBT and MEBT, respectively), including relocation of various functional elements (ie choppers, kickers, and bunchers). • An additional H - ion source to separate ion-source function based on beam delivery requirements. • A high-repetition-rate pulsed kicker magnet to select/merge the two H ion beams into a common low-energy beam transport. • Modification and further optimization to a more conventional RFQ design. Performance of the RFQ has been optimized to deliver the required three types of beams while meeting the project KPPs. • The addition of a second chopper in the medium-energy beam transport (MEBT) line to reduce the required pulser voltages. The scope of the evaluation was limited to the project Work Breakdown Structure (WBS) elements as defined for the RFQ Injector and Drift Tube Linac (DTL) systems only. Integration of Instrumentation and Controls (I&C) and Safety Systems was not considered, although specific technologies as related to the RFQ and DTL systems were included. Other elements of the project such as Shielding, System Design, Technical Management, and additional facility integration needed to enable off-line testing and pre-installation commissioning were also not evaluated. Each technical subsystem element was evaluated for technical readiness, however, not all were found to meet the criteria for a CTE. Three subsystem elements were determined to meet the CTE criteria. Their associated TRLs are summarized in the table below. These subsystem elements of the project have the lowest technical readiness due to either being new, novel or modified, requiring additional R&D before being capable of meeting the project Key Performance Parameters (KPPs) and subsystem requirements, or present technology exists but has not yet been demonstrated in a relevant environment. All other subsystems were determined to have a TRL of 8, indicating that actual operating systems exist having similar performance requirements as needed for LAMP. Details of the technical readiness evaluation for each subsystem is given in the following sections of this report.

43 PARTICLE ACCELERATORS↗
NASA NTRS2005

Rotary Drum Separator and Pump for the Sabatier Carbon Dioxide Reduction System

A trade study conducted in 2001 selected a rotary disk separator as the best candidate to meet the requirements for an International Space Station (ISS) Carbon Dioxide Reduction Assembly (CRA). The selected technology must provide micro-gravity gasfliquid separation and pump the liquid from 10 psia at the gasfliquid interface to 18 psia at the wastewater bus storage tank. The rotary disk concept, which has pedigree in other systems currently being built for installation on the ISS, failed to achieve the required pumping head within the allotted power. The separator discussed in this paper is a new design that was tested to determine compliance with performance requirements in the CRA. The drum separator and pump @SP) design is similar to the Oxygen Generator Assembly (OGA) Rotary Separator Accumulator (RSA) in that it has a rotating assembly inside a stationary housing driven by a integral internal motor. The innovation of the DSP is the drum shaped rotating assembly that acts as the accumulator and also pumps the liquid at much less power than its predecessors. In the CRA application, the separator will rotate at slow speed while accumulating water. Once full, the separator will increase speed to generate sufficient head to pump the water to the wastewater bus. A proof-of- concept (POC) separator has been designed, fabricated and tested to assess the separation efficiency and pumping head of the design. This proof-of-concept item was flown aboard the KC135 to evaluate the effectiveness of the separator in a microgravity environment. This separator design has exceeded all of the performance requirements. The next step in the separator development is to integrate it into the Sabatier Carbon Dioxide Reduction System. This will be done with the Sabatier Engineering Development Unit at the Johnson Space Center.

Holder, Don↗