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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

Influence of Design Variations on Systems Performance

High-risk aerospace components have to meet very stringent quality, performance, and safety requirements. Any source of variation is a concern, as it may result in scrap or rework. poor performance, and potentially unsafe flying conditions. The sources of variation during product development, including design, manufacturing, and assembly, and during operation are shown. Sources of static and dynamic variation during development need to be detected accurately in order to prevent failure when the components are placed in operation. The Systems' Health and Safety (SHAS) research at the NASA Ames Research Center addresses the problem of detecting and evaluating the statistical variation in helicopter transmissions. In this work, we focus on the variations caused by design, manufacturing, and assembly of these components, prior to being placed in operation (DMV). In particular, we aim to understand and represent the failure and variation information, and their correlation to performance and safety and feed this information back into the development cycle at an early stage. The feedback of such critical information will assure the development of more reliable components with less rework and scrap. Variations during design and manufacturing are a common source of concern in the development and production of such components. Accounting for these variations, especially those that have the potential to affect performance, is accomplished in a variety ways, including Taguchi methods, FMEA, quality control, statistical process control, and variation risk management. In this work, we start with the assumption that any of these variations can be represented mathematically, and accounted for by using analytical tools incorporating these mathematical representations. In this paper, we concentrate on variations that are introduced during design. Variations introduced during manufacturing are investigated in parallel work.

Tumer, Irem Y.↗
DOE OSTI2023

Design and additive manufacturing of optimized electrodes for energy storage applications

Supercapacitors exhibit fast charging/discharging ability and have attracted considerable attention within the automotive, aerospace, and telecommunication industries. Porous carbons, prized for their high electrical conductivity and high surface area, have been attractive candidates for supercapacitor electrodes. Moving to thick electrodes is one strategy to further increase energy density due to a higher volume fraction of active material. However, thick electrodes suffer from sluggish charged species transport, which is why thin electrodes are currently favored. In this work, we investigate the use of computational optimization and additive manufacturing to design and fabricate thick porous electrodes with improved performance. Electrode performance was maximized by designing their morphologies via topology optimization and printing by projection micro stereolithography (PμSL) using commercial resin (PR48). The PR48 resin was then pyrolyzed (PR48-P) to create the final conductive electrode. The optimized PR48-P electrodes exhibited 99% improvement in capacitance compared to control electrodes printed with cubic lattice morphologies. To further improve performance, we formulated a resin combining graphene oxide (GO) and trimethylolpropane triacrylate (TMPTA). Electrodes printed with 3 wt% GO in TMPTA exhibited improved capacitance retention after pyrolysis compared to the PR48-P electrodes. Finally, this work demonstrates the benefits of using topology optimization to design electrodes and material development to improve functional properties of 3D printable electrodes.

25 ENERGY STORAGE↗
DOE OSTI2022

Validation of Manufacturing Process Designs for Stamped Microchannel Recuperators

Microchannel recuperators can achieve high-efficiency power cycles and chemical reactions by recovering waste heat from hot turbine exhaust and chemical reaction streams. However, the industrial application of microchannel recuperators are restricted by the high cost of patterning and bonding. The objective of this study was thus to investigate new methods for producing microchannel recuperators for emerging markets. Based on greenfield cost estimates, process designs based on stamping, laser welding and vacuum brazing of 316L stainless steel laminae were found to be more economical than conventional photochemical machining and diffusion bonding. Subsequently, validation experiments were conducted to produce stamped microchannel components using cost model parameters. At a mass flow rate of 0.99 g/s, the test article made with laser welding was found to provide higher effectiveness than the test article produced using vacuum brazing. Preliminary investigations showed that residual stresses during laser welding of the laminae led to significant warpage, collapsing channels and making lamina-to-lamina fit up challenging. In contrast, the test article produced by vacuum brazing of stamped laminae showed no clogging and 4.6% and 10.5% channel height standard deviation for the cold and hot channels, respectively. Channel variation in the vacuum brazing sample was determined to be caused by misregistration of laminae during brazing. In future work, efforts are needed to choose cheaper, more ductile brazing foils as well as design a brazing fixture to improve lamina-to-lamina registration.

42 ENGINEERING↗
DOE OSTI2023

Accelerating Additive Manufacturing Process Design for Energy Conversion Materials using In-situ Sensing and Machine Learning

One promising candidate for manufacturing of the bismuth Telluride thermoelectric legs is laser powder bed fusion (LPBF) additive Manufacturing (AM). AM processing parameters highly influence the material properties, however current processing parameter development methods in AM are costly and time consuming. In-situ sensors allow for the capture of physically relevant process information on a layer-by-layer basis and will be used to aide process development. To optimize the AM process for the best thermoelectric performance, process variables, in-situ process sensor data and ex-situ material characterization data are collected. Several different interpretable machine learning (ML) approaches are used, and the performance of each method are assessed. Significant input process variables include laser focus, hatch spacing and laser power. The best performing models are used to determine the manufacturing parameters that maximize the power factor. AM of bismuth telluride material provides the ability to create complex geometries enabling more efficient energy conversion.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

Multi-Scale Design And Advanced Manufacturing Of Seismic Metamaterials (CRADA Final Report)

As part of the Cyclotron Road program, METAseismic sought to investigate a multi-scale approach, both in terms of manufacturing and design, for seismic metamaterials with applications in the energy sector. Specifically, this project explored the feasibility of using nanofabrication to enable the incorporation of 3D nanostructured components into a mechanical metamaterial. These components were explored to increase the seismic resilience of our infrastructure to earthquakes, with the final aim of providing customized levels of protection for its components. This was envisioned as the base of a multi-scale design approach that consisted of using a multiplicity of metamaterial architectures ranging from the nano- to the meso-scale to address the stringent seismic design objectives of electric-power equipment.

36 MATERIALS SCIENCE↗
NASA NTRS1978

Key issues in application of composites to transport aircraft

The application of composite materials to transport aircraft was identified and reviewed including the major contributing disciplines of design, manufacturing, and processing. Factors considered include: crashworthiness considerations (structural integrity, postcrash fires, and structural fusing), electrical/avionics subsystems integration, lightning, and P-static protection design; manufacturing development, evaluation, selection, and refining of tooling and curing procedures; and major joint design considerations. Development of the DC-10 rudder, DC-10 vertical stabilizer, and the DC-9 wing study project was reviewed. The Federal Aviation Administration interface and the effect on component design of compliance with Federal Aviation Regulation 25 Composite Guidelines are discussed.

Stone, M.↗
NASA NTRS1995

Integrated design and manufacturing for the high speed civil transport (a combined aerodynamics/propulsion optimization study)

This report documents the efforts of a Georgia Tech High Speed Civil Transport (HSCT) aerospace student design team in completing a design methodology demonstration under NASA's Advanced Design Program (ADP). Aerodynamic and propulsion analyses are integrated into the synthesis code FLOPS in order to improve its prediction accuracy. Executing the integrated product and process development (IPPD) methodology proposed at the Aerospace Systems Design Laboratory (ASDL), an improved sizing process is described followed by a combined aero-propulsion optimization, where the objective function, average yield per revenue passenger mile ($/RPM), is constrained by flight stability, noise, approach speed, and field length restrictions. Primary goals include successful demonstration of the application of the response surface methodolgy (RSM) to parameter design, introduction to higher fidelity disciplinary analysis than normally feasible at the conceptual and early preliminary level, and investigations of relationships between aerodynamic and propulsion design parameters and their effect on the objective function, $/RPM. A unique approach to aircraft synthesis is developed in which statistical methods, specifically design of experiments and the RSM, are used to more efficiently search the design space for optimum configurations. In particular, two uses of these techniques are demonstrated. First, response model equations are formed which represent complex analysis in the form of a regression polynomial. Next, a second regression equation is constructed, not for modeling purposes, but instead for the purpose of optimization at the system level. Such an optimization problem with the given tools normally would be difficult due to the need for hard connections between the various complex codes involved. The statistical methodology presents an alternative and is demonstrated via an example of aerodynamic modeling and planform optimization for a HSCT.

Baecher, Juergen↗
DOE OSTI2024

Rapid Design and Manufacturing of High-Performance Materials for Turbine Blades

This research demonstrated the concept of carbide precipitation-strengthened refractory high entropy alloys (RHEA). The advantage of a precipitation strengthened alloy is all phases are in thermodynamic equilibrium promoting microstructural stability, and consequently retention of properties at elevated temperatures. Additionally, as with any precipitation strengthened – or age hardened - alloy, components can be heat-treated after manufacturing to manipulate the microstructure and optimize properties for performance. This is an advantage of the precipitation strengthened alloys over composites and ceramics materials, where the microstructure and properties are essentially fixed upon the initial materials manufacturing stage. High throughput (HT), multi-scale computer modeling was used to identifying novel RHEA compositions with desired characteristics needed for precipitation strengthening. Designs were validated by producing small ingots via are melting. The results showed that carbides precipitated and consequently, the strength of the alloys (measured in compression) increased after heat-treatment, which is the desired effect. The project also demonstrated the feasibility of producing articles from RHEA by additive manufacturing (AM). Electron beam melting (EBM) and laser direct energy deposition (L-DED) additive manufacturing methods, were explored with various processing parameters were interrogated for both methods. Sound (crack-free and dense) precipitation strengthened RHEA samples were produced via EDM AM, demonstrating the feasibility of the concept.

36 MATERIALS SCIENCE↗
NASA NTRS1970

Design and Manufacture of Wheels for A Dual-Mode (Manned - Automatic) Lunar Surface Roving Vehicle. Volume 1: Detailed Technical Report

The concept development, testing, evaluation, and the selection of a final wheel design concept for a dual-mode lunar surface vehicle (DLRV) is detailed. Four wheel configurations were fabricated (one open wheel and three closed wheel) (and subjected to a series of soft soil, mechanical, and endurance tests. Results show that the open wheel has lower draw-bar pull (slope climbing) capability in loose soil due to its higher ground pressure and tendency to dig in at high wheel slip. Endurance tests indicate that a double mesh, fully enclosed wheel can be developed to meet DLRV life requirements. There is, however, a 1.0 to 1.8 lb/wheel weight penalty associated with the wheel enclosure. Also the button cleats used as grousers for the closed-type wheels result in local stress concentration and early fatigue failure of the wire mesh. Load deflection tests indicate that the stiffness of the covered wheel increased by up to 50% after soil bin testing, due to increased friction between the fabric and the wire mesh caused by the sand. No change in stiffness was found for the open wheel. The single woven mesh open wheel design with a chevron tread is recommended for continued development

Source record↗
NASA NTRS2012

Woven TPS - A New Approach to TPS Design and Manufacturing

NASA's Office of the Chief Technologist (OCT) Game Changing Division recently funded an effort to advance a Woven TPS (WTPS) concept. WTPS is a new approach to producing TPS materials that uses precisely engineered 3D weaving techniques to customize material characteristics needed to meet specific missions requirements for protecting space vehicles from the intense heating generated during atmospheric entry. Using WTPS, sustainable, scalable, mission-optimized TPS solutions can be achieved with relatively low life cycle costs compared with the high costs and long development schedules currently associated with material development and certification. WTPS leverages the mature state-of-the-art weaving technology that has evolved from the textile industry to design TPS materials with tailorable performance by varying material composition and properties via the controlled placement of fibers within a woven structure. The resulting material can be designed to perform optimally for a wide range of entry conditions encompassing NASAs current and future mission needs. WTPS enables these optimized TPS designs to be translated precisely into mission-specific, manufactured materials that can substantially increase the efficiency, utility, and robustness of heat shield materials compared to the current state-of-the-art material options. By delivering improved heat shield performance and affordability, this technology will impact all future exploration missions, from the robotic in-situ science missions to Mars, Venus and Saturn to the next generation of human missions. WTPS can change the way NASA develops, certifies, and integrates TPS into mission life cycles - instead of being a mission constraint, TPS will become a mission enabler. It is anticipated that WTPS will have direct impact on SMD, HEOMD and OCT and will be of interest for DoD and COTS applications. This presentation will overview the WTPS concept and present some results from initial testing completed.

Feldman, Jay↗
NASA NTRS1992

Characterization and manufacture of braided composites for large commercial aircraft structures

Braided composite materials, one of the advanced material forms which is under investigation in Boeing's ATCAS program, have been recognized as a potential cost-effective material form for fuselage structural elements. Consequently, there is a strong need for more knowledge in the design, manufacture, test, and analysis of textile structural composites. The overall objective of this work is to advance braided composite technology towards applications to a large commercial transport fuselage. This paper summarizes the mechanics of materials and manufacturing demonstration results which have been obtained in order to acquire an understanding of how braided composites can be applied to a commercial fuselage. Textile composites consisting of 1D, 2D triaxial, and 3D braid patterns with thermoplastic and two RTM resin systems were investigated. The structural performance of braided composites was evaluated through an extensive mechanical test program. Analytical methods were also developed and applied to predict the following: internal fiber architectures, stiffnesses, fiber stresses, failure mechanisms, notch effects, and the entire history of failure of the braided composites specimens. The applicability of braided composites to a commercial transport fuselage was further assessed through a manufacturing demonstration. Three foot fuselage circumferential hoop frames were manufactured to demonstrate the feasibility of consistently producing high quality braided/RTM composite primary structures. The manufacturing issues (tooling requirements, processing requirements, and process/quality control) addressed during the demonstration are summarized. The manufacturing demonstration in conjunction with the mechanical test results and developed analytical methods increased the confidence in the ATCAS approach to the design, manufacture, test, and analysis of braided composites.

Fedro, Mark J.↗
NASA NTRS1980

Manufacturing cost/design system: A CAD/CAM dialogue

The development of the Manufacturing Cost/Design System (MC/DS) will provide the aerospace design engineer a tool with which to perform heretofore impractical design manufacturing cost tradeoffs. The Air Force Integrated Computer Aided Manufacturing (ICAM) Office has initiated the development and demonstration of an MC/DS which, when fully implemented, will integrate both design and manufacturing data bases to provide real time visibility into the manufacturing costs associated with various design options. The first release of a computerized system will be made before the end of 1981.

Loshigian, H. H.↗
NASA NTRS1998

Design and Manufacture of Wood Blades for Windtunnel Fans

Many windtunnels use wooden fan blades, however, because of their usual long life (often in excess of 50 years) wooden blades typically do not have to be replaced very often; therefore, the expertise for designing and building wooden windtunnel fan blades is being lost. The purpose of this report is to document the design and build process so that when replacement blades are eventually required some of the critical information required is available. Information useful to fan-blade designers, fabricators, inspectors, and windtunnel operations personnel is included. Fixed pitch and variable pitch fans as well as fans which range in size from a few feet in diameter to over 40 ft. in diameter are described. Woods, adhesives, and coverings are discussed.

Richardson, S. E.↗
DOE OSTI2024

Design and Manufacturing of High Performance, Reduced Charge Heat Exchangers

Air-to-fluid heat exchangers (HXs) play a critical role as the main heat transfer component in Heating, Ventilation, Air-Conditioning, and Refrigeration (HVAC&R) systems. However, their airside thermal resistance significantly inhibits their overall performance. Furthermore, these HXs must be continually more compact to meet the latest refrigerant charge limits to reduce emissions. Recent literature suggests that traditional HX geometries (e.g., round or flat tubes with fins), have reached their limits, and more sophisticated shape- and topology-optimized designs are required to achieve the next jump in performance. This research sheds light on the next generation of air-to-refrigerant HXs and aims to address several practical issues to commercialization such as novelty challenges (improved performance for significant charge reduction; modeling expertise & time investment), manufacturing challenges (non-round tube manufacturing; tube-header integration; product qualification, e.g., burst pressure testing, extreme operational environment, etc.), and operational challenges (flow maldistribution, fouling & wetting, noise & vibration). For example, a >20% improvement on one (or more) HX-level performance metrics (e.g., envelope volume, airside pressure drop, face area, capacity, refrigerant charge, weight, cost, etc.) must be achieved before a HX design is considered for commercialization. We present a new, comprehensive and experimentally validated air-to-refrigerant HX optimization framework with simultaneous thermal-hydraulic performance and mechanical strength considerations for novel, non-round, shape- and topology-optimized tubes capable of optimizing single and two-phase HX designs for any refrigerant choice and performance requirement with significant engineering time savings compared to conventional design practices. The framework was exercised for a wide range of applications and refrigerants, resulting in HXs which achieved greater than 20% improved performance, 20% reductions in size, and 25% reductions in refrigerant charge. To enable non-round tube bundle use in next generation HVAC&R equipment, novel manufacturing techniques were investigated, including the development of conventional manufacturing methods for small diameter, non-round tubes and novel tube-header integration strategies. In total, ten HX prototypes were manufactured, nine using conventional methods directly attributed to this project and one using advanced additive manufacturing methods. The five-year manufacturing feasibility of the proposed HXs was found to have a good outlook. The non-round tube HX simulated performance was validated through comprehensive experimental testing, including nine in-house component-level tests, one independent component-level test at an industry partner laboratory, and in-house system-level tests of using a commercially-available, residential packaged A/C unit which was retrofitted with a non-round tube prototype HX. It was found that HX designs proposed by the new framework can successfully predict experimental thermal-hydraulic performance within ±10-20% the first time with no manual design changes, eliminating the need for time-consuming and expensive prototyping efforts. This work will accelerate design and time to market for next generation HXs while simultaneously facilitating industry transition to new refrigerants at lower charge.

42 ENGINEERING↗
NASA NTRS1980

IPAD: Integrated Programs for Aerospace-Vehicle Design

The conference was organized to promote wider awareness of the IPAD program and its coming impact on American industry. The program focuses on technology issues that are critical to computer aided design manufacturing. Included is a description of a representative aerospace design process and its interface with manufacturing, the design of a future IPAD integrated computer aided design system, results to date in developing IPAD products and associated technology, and industry experiences and plans to exploit these products.

Source record↗
NASA NTRS1979

Space Telescope fine guidance - A design for manufacturability

The NASA Space Telescope (ST) is a 2.4-m aperture, f/24 Ritchey-Chretien telescope coupled to five on-board astronomical scientific packages. The very accurate line-of-sight stability required by ST during operating periods of up to 24 hours is maintained by the Pointing Control System whose optical system, the Fine Guidance Subsystem (FGS), is described. The Pointing Control System includes three identical FGSs, any two of which provide line-of-sight stabilization by tracking guide stars while the third performs astrometry. The optical system for the ST FGS performs the field aberration correction within the FGS near a pupil plane measuring only 52.7 mm. The design is simple and easily corrected, and offers substantial advantages over the traditional approach in terms of manufacturability.

Friedman, I.↗
NASA NTRS1991

Design and manufacturing concepts for thermoplastic structures

Results to date on the application of two manufacturing techniques, fiber placement and single diaphragm/coconsolidation, to produce cost-effective, thermoplastic composite (TPC), primary fuselage structure are presented. Applications relative to fuselage upper cover structure indicate potential cost savings relative to conventional approaches. Progress is also presented on efforts concerned with other design details which take advantage of thermoplastic composites such as fastener less stiffener/frame attachments. In addition, results are presented on the development and verification testing of a composite lug analysis program which incorporates through-the-thickness effects.

Renieri, Michael P.↗
NASA NTRS1992

Integrating aerodynamic surface modeling for computational fluid dynamics with computer aided structural analysis, design, and manufacturing

This presentation will discuss the development of a NASA Geometry Exchange Specification for transferring aerodynamic surface geometry between LeRC systems and grid generation software used for computational fluid dynamics research. The proposed specification is based on a subset of the Initial Graphics Exchange Specification (IGES). The presentation will include discussion of how the NASA-IGES standard will accommodate improved computer aided design inspection methods and reverse engineering techniques currently being developed. The presentation is in viewgraph format.

Thorp, Scott A.↗