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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sources NASA NTRS DOE OSTI

NASA NTRS2014

Human Integration Design Processes (HIDP)

The purpose of the Human Integration Design Processes (HIDP) document is to provide human-systems integration design processes, including methodologies and best practices that NASA has used to meet human systems and human rating requirements for developing crewed spacecraft. HIDP content is framed around human-centered design methodologies and processes in support of human-system integration requirements and human rating. NASA-STD-3001, Space Flight Human-System Standard, is a two-volume set of National Aeronautics and Space Administration (NASA) Agency-level standards established by the Office of the Chief Health and Medical Officer, directed at minimizing health and performance risks for flight crews in human space flight programs. Volume 1 of NASA-STD-3001, Crew Health, sets standards for fitness for duty, space flight permissible exposure limits, permissible outcome limits, levels of medical care, medical diagnosis, intervention, treatment and care, and countermeasures. Volume 2 of NASASTD- 3001, Human Factors, Habitability, and Environmental Health, focuses on human physical and cognitive capabilities and limitations and defines standards for spacecraft (including orbiters, habitats, and suits), internal environments, facilities, payloads, and related equipment, hardware, and software with which the crew interfaces during space operations. The NASA Procedural Requirements (NPR) 8705.2B, Human-Rating Requirements for Space Systems, specifies the Agency's human-rating processes, procedures, and requirements. The HIDP was written to share NASA's knowledge of processes directed toward achieving human certification of a spacecraft through implementation of human-systems integration requirements. Although the HIDP speaks directly to implementation of NASA-STD-3001 and NPR 8705.2B requirements, the human-centered design, evaluation, and design processes described in this document can be applied to any set of human-systems requirements and are independent of reference missions. The HIDP is a reference document that is intended to be used during the development of crewed space systems and operations to guide human-systems development process activities.

Boyer, Jennifer↗

NASA NTRS1980

Case study: Lockheed-Georgia Company integrated design process

A case study of the development of an Integrated Design Process is presented. The approach taken in preparing for the development of an integrated design process includes some of the IPAD approaches such as developing a Design Process Model, cataloging Technical Program Elements (TPE's), and examining data characteristics and interfaces between contiguous TPE's. The implementation plan is based on an incremental development of capabilities over a period of time with each step directed toward, and consistent with, the final architecture of a total integrated system. Because of time schedules and different computer hardware, this system will not be the same as the final IPAD release; however, many IPAD concepts will no doubt prove applicable as the best approach. Full advantage will be taken of the IPAD development experience. A scenario that could be typical for many companies, even outside the aerospace industry, in developing an integrated design process for an IPAD-type environment is represented.

Waldrop, C. T.↗

NASA NTRS1980

Future integrated design process

The design process is one of the sources used to produce requirements for a computer system to integrate and manage product design data, program management information, and technical computation and engineering data management activities of the aerospace design process. Design activities were grouped chronologically and explored for activity type, activity interface, data quantity, and data flow. The work was based on analysis of the design process of several typical aerospace products, including both conventional and supersonic airplanes and a hydrofoil design. Activities examined included research, preliminary design, detail design, manufacturing interface, product verification, and product support. The design process was then described in an IPAD environment--the future.

Meyer, D. D.↗

DOE OSTI2023

Integration Process Design and Balance of Plant [Slides]

Requirements to Design Agencies provided primarily via Facility Design Description and System Design Descriptions for 226-F Facility and Task Requirements & Criteria (TR&C) Document for HFTOC.

42 ENGINEERING↗

DOE OSTI2013

PAREX, A numerical Code for process design and integration

The modeling approach for process design is illustrated in this paper by the work done to qualify the PAREX code to design the flow sheet of a uranium/plutonium splitting operation in a pulsed column. The different flow sheet experimentations are presented along with the simulation results. The qualified code has been successfully used to design the flow sheet of this operation in the first purification cycle of UP2-800 plant at La Hague. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2019

Computational Materials Techniques for Thermal Protection Solutions: Materials and Process Design

Integrated computational materials techniques that span the atomistic and continuum scales have the potential to aid the design and manufacturing of thermal protection materials. Two cases demonstrating the practical application of these methods are discussed. Case one examines the selection of a high temperature coating for carbon/carbon, with the target application being a solar thermal propulsion heat exchanger. The performance of various refractory metal and metal-carbide coatings is characterized considering extreme thermal (3500 K) and chemical (hydrogen flows) conditions. The recession rate, hydrogen leakage, and likelihood of mechanical failure are characterized and provide directions for further experimental investigation. Case two examines the process optimization of a heat shield material composed of a woven silica fiber preform and cyanate ester resin. Frequently, internal voids were found to be present in this composite after the resin infusion and curing stages of manufacturing. Using the manufacturing conditions, computations indicate that both water adsorption and resin cure shrinkage are contributing factors to void formation. The results suggest an alternative process configuration for curing that would mitigate voids.

thermal protection↗

NASA NTRS2018

Computational Materials Techniques for Thermal Protection Solutions: Materials and Process Design

Haskins, Justin↗

NASA NTRS2019

Computational Materials Techniques for Thermal Protection Solutions: Materials and Process Design

Integrated computational materials techniques that span the atomistic and continuum scales have the potential to aid the design and manufacturing of thermal protection materials. Two cases demonstrating the practical application of these methods are discussed. Case one examines the selection of a high temperature coating for carbon/carbon, with the target application being a solar thermal propulsion heat exchanger. The performance of various refractory metal and metal-carbide coatings is characterized considering extreme thermal (3500 degrees Kelvin) and chemical (hydrogen flows) conditions. The recession rate, hydrogen leakage, and likelihood of mechanical failure are characterized and provide directions for further experimental investigation. Case two examines the process optimization of a heat shield material composed of a woven silica fiber preform and cyanate ester resin. Frequently, internal voids were found to be present in this composite after the resin infusion and curing stages of manufacturing. Using the manufacturing conditions, computations indicate that both water adsorption and resin cure shrinkage are contributing factors to void formation. The results suggest an alternative process configuration for curing that would mitigate voids.

Thermal Protection↗

DOE OSTI2019

A Bi-Level Formulation And Solution Method For The Integration Of Process Design And Scheduling

Design and operation decisions of manufacturing plants can often be expressed within a hierarchical structure, where optimal decisions at lower operating level provide constraints for the decision raking at a higher decision level. In this work, we are addressing the case of a hierarchical design and scheduling optimization problem. The integration of design and scheduling decisions can play a big role in designing economically profitable plants and improving their operational performance. This problem can be expressed as a bi-level problem, where design related decisions occur at the upper level and operational scheduling decisions at the lower level. Since discrete decisions are involved in both optimization levels, the resulting formulation typically corresponds to bi-level mixed-integer programming problems (B-MIP). The solution of B-MIP problems is very challenging, and typically requires the use of global optimization techniques, with many algorithms not able to guarantee feasibility. To overcome the challenges in solving this class of problems we propose the use of a multi-parametric based algorithm for the solution of bi-level mixed-integer linear and quadratic programming problems, capable of providing the exact and global solution. The main idea of this approach is to treat the lower scheduling problem as a multi-parametric programming problem in which the design decisions are considered as parameters. Here, the resulting parametric solutions can then be substituted into the upper level design problem, which can be solved as a set of single-level deterministic programming problems. Through the developed formulation and algorithm we are able to supply the decision makers with the exact solution of the integrated design and scheduling problem.

42 ENGINEERING↗

NASA NTRS2001

Launch Vehicle Design Process: Characterization, Technical Integration, and Lessons Learned

Engineering design is a challenging activity for any product. Since launch vehicles are highly complex and interconnected and have extreme energy densities, their design represents a challenge of the highest order. The purpose of this document is to delineate and clarify the design process associated with the launch vehicle for space flight transportation. The goal is to define and characterize a baseline for the space transportation design process. This baseline can be used as a basis for improving effectiveness and efficiency of the design process. The baseline characterization is achieved via compartmentalization and technical integration of subsystems, design functions, and discipline functions. First, a global design process overview is provided in order to show responsibility, interactions, and connectivity of overall aspects of the design process. Then design essentials are delineated in order to emphasize necessary features of the design process that are sometimes overlooked. Finally the design process characterization is presented. This is accomplished by considering project technical framework, technical integration, process description (technical integration model, subsystem tree, design/discipline planes, decision gates, and tasks), and the design sequence. Also included in the document are a snapshot relating to process improvements, illustrations of the process, a survey of recommendations from experienced practitioners in aerospace, lessons learned, references, and a bibliography.

Blair, J. C.↗

DOE OSTI2022

Design, Processing, and Integration of Pouch-Format Cell for High-Energy Lithium-Sulfur Batteries

This project objective was to develop and demonstrate a lithium-sulfur (Li-S) battery in a pouch-format cell capable of achieving an energy density ≥ 500 Wh/kg while achieving a 1,000 cycle life. The research focused on cell optimization and fabrication addressing different technical barriers and challenges including: 1) thin lithium anode optimization; 2) current collector and tab attachment design; 3) cathode porosity control; 4) electrolyte to sulfur ratio control; 5) cell design; and 6) cell fabrication. The project developed and demonstrated various technologies to address these technical barriers and challenges. The project demonstrated a thin lithium anode by vapor deposition, a collector design and validation of laser welding of tab attachment method, a cathode porosity control strategy by binder optimization, a calendaring process control and surface/interface treatment, and an electrolyte to sulfur ratio control with influence on cell energy density. The sulfur cathode was optimized by tuning the formulation, optimizing the calendaring process, and introducing a novel electrode fabrication process. To address the electrolyte performance issue, the electrolyte optimization was achieved with additive and formulation tuning and the introduction of a dual-phase electrolyte system. In addition to the demonstration of the optimized electrode with a novel fast-curing coating process and dual-phase electrolyte, a coating separator was further developed to address the polysulfide shuttling issue. The resulting new cell design with these optimized cell components was demonstrated in the 1 Ah pouch cell with medium sulfur loading and moderate porosity (~ 4.5 mAh cm-2, 65% porosity) and showed an energy density of > 400 Wh/kg (with E/S ratio of 2.8). The Li-SPAN cell configuration was also evaluated in combination with a new dual-phase electrolyte system. Initial coin cell performance demonstrated cycle stability of >300 cycles with an estimated energy density of 300 Wh/kg at the pouch format level. The corresponding 1 Ah pouch format SPAN cells with the new polymer electrolyte were developed which has shown a stable capacity at 800-900 mAh for ~40 cycles so far.

25 ENERGY STORAGE↗

NASA NTRS2008

Ares Project Overview - Quality in Design

This presentation introduces the audience to the overall goals of the Ares Project, which include providing human access to low-Earth orbit, the Moon, and beyond. The presentation also provides an overview of with the vehicles that will execute those goals and progress made on the vehicles to date. The briefing will provide an introduction to Lean, Six Sigma, and Kaizen practices Ares will use to improve the overall effectiveness and quality of its efforts. Finally, the briefing includes a summary of Safety and Mission Assurance practices being implemented within[Ares to ensure safety and quality early in the design process. Integrating Safety and Mission Assurance in Design: This presentation describes how the Ares Projects are learning from the successes and failures of previous launch systems in order to maximize safety and reliability while maintaining fiscal responsibility. The Ares Projects are integrating Safer T and Mission Assurance into design activities and embracing independent assessments by Quality experts in thorough reviews of designs and processes. Incorporating Lean thinking into the design process, Ares is also streamlining existing processes and future manufacturing flows which will yield savings during production. Understanding the value of early involvement of Quality experts, the Ares Projects are leading launch vehicle development into the 21st century.

Cianciola, Chris↗

NASA NTRS1993

Model reduction in integrated controls-structures design

It is the objective of this paper to present a model reduction technique developed for the integrated controls-structures design of flexible structures. Integrated controls-structures design problems are typically posed as nonlinear mathematical programming problems, where the design variables consist of both structural and control parameters. In the solution process, both structural and control design variables are constantly changing; therefore, the dynamic characteristics of the structure are also changing. This presents a problem in obtaining a reduced-order model for active control design and analysis which will be valid for all design points within the design space. In other words, the frequency and number of the significant modes of the structure (modes that should be included) may vary considerably throughout the design process. This is also true as the locations and/or masses of the sensors and actuators change. Moreover, since the number of design evaluations in the integrated design process could easily run into thousands, any feasible order-reduction method should not require model reduction analysis at every design iteration. In this paper a novel and efficient technique for model reduction in the integrated controls-structures design process, which addresses these issues, is presented.

Maghami, Peiman G.↗

NASA NTRS1994

Experimental validation of an integrated controls-structures design methodology for a class of flexible space structures

This paper describes the first experimental validation of an optimization-based integrated controls-structures design methodology for a class of flexible space structures. The Controls-Structures-Interaction (CSI) Evolutionary Model, a laboratory test bed at Langley, is redesigned based on the integrated design methodology with two different dissipative control strategies. The redesigned structure is fabricated, assembled in the laboratory, and experimentally compared with the original test structure. Design guides are proposed and used in the integrated design process to ensure that the resulting structure can be fabricated. Experimental results indicate that the integrated design requires greater than 60 percent less average control power (by thruster actuators) than the conventional control-optimized design while maintaining the required line-of-sight performance, thereby confirming the analytical findings about the superiority of the integrated design methodology. Amenability of the integrated design structure to other control strategies is considered and evaluated analytically and experimentally. This work also demonstrates the capabilities of the Langley-developed design tool CSI DESIGN which provides a unified environment for structural and control design.

Maghami, Peiman G.↗

NASA NTRS1997

Integrated Controls-Structures Design Methodology: Redesign of an Evolutionary Test Structure

An optimization-based integrated controls-structures design methodology for a class of flexible space structures is described, and the phase-0 Controls-Structures-Integration evolutionary model, a laboratory testbed at NASA Langley, is redesigned using this integrated design methodology. The integrated controls-structures design is posed as a nonlinear programming problem to minimize the control effort required to maintain a specified line-of-sight pointing performance, under persistent white noise disturbance. Static and dynamic dissipative control strategies are employed for feedback control, and parameters of these controllers are considered as the control design variables. Sizes of strut elements in various sections of the CEM are used as the structural design variables. Design guides for the struts are developed and employed in the integrated design process, to ensure that the redesigned structure can be effectively fabricated. The superiority of the integrated design methodology over the conventional design approach is demonstrated analytically by observing a significant reduction in the average control power needed to maintain specified pointing performance with the integrated design approach.

Maghami, Peiman G.↗

DOE OSTI2024

Strategies for connecting whole-building LCA to the low-carbon design process

Abstract Decarbonization is essential to meeting urgent climate goals. With the building sector in the United States accounting for 35% of total U.S. carbon emissions, reducing environmental impacts within the built environment is critical. Whole-building life cycle analysis (WBLCA) quantifies the impacts of a building throughout its life cycle. Despite being a powerful tool, WBLCA is not standard practice in the integrated design process. When WBLCA is used, it is typically either speculative and based on early design information or conducted only after design completion as an accounting measure, with virtually no opportunity to impact the actual design. This work proposes a workflow for fully incorporating WBLCA into the building design process in an iterative, recursive manner, where design decisions impact the WBLCA, which in turn informs future design decisions. We use the example of a negative-operational carbon modular building seeking negative upfront embodied carbon using bio-based materials for carbon sequestration as a case study for demonstrating the utility of the framework. Key contributions of this work include a framework of computational processes for conducting iterative WBLCA, using a combination of an existing building WBLCA tool (Tally) within the building information modeling superstructure (Revit) and a custom script (in R) for materials, life cycle stages, and workflows not available in the WBLCA tool. Additionally, we provide strategies for harmonizing the environmental impacts of novel materials or processes from various life cycle inventory sources with materials or processes in existing building WBLCA tool repositories. These strategies are useful for those involved in building design with an interest in reducing their environmental impact. For example, this framework would be useful for researchers who are conducting WBLCAs on projects that include new or unusual materials and for design teams who want to integrate WBLCA more fully into their design process in order to ensure the building materials are consciously chosen to advance climate goals, while still ensuring best performance by traditional measures.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1990

Eigensensitivity in integrated design

An application of eigensensitivity analysis to the control-structure integrated design process is presented with an emphasis placed on computational efficiency improvement of the overall design optimization process. The computational efficiency of eigenvalue/vector sensitivity analysis is demonstrated using the Earth Pointing Satellite in the context of a control-structure integrated design program. Results for a 2 percent design variable perturbation with and without the effects of the actuator mass show a 42 and 52 percent reduction in CPU time, respectively.

Kenny, Sean P.↗

NASA NTRS1980

Integration of design information

The overall concepts of the integrated programs for aerospace-vehicle design (IPAD) from the user's viewpoint are discussed. Also a top-level view of what the user requires from such a system is provided, and the interactions between the system and user are described. The four major components discussed are design process; data storage, management and manipulation; user interface; and project management. Although an outgrowth of aerospace production experience, the basic concepts discussed, and especially their emphasis on integration, are considered applicable to all problem solving. Thus, these concepts may offer a broad base for exploitation by industry in general. This is the first in a set of three papers, the other two being Future Integrated Design Process, by D. D. Mayer, and Requirements for Company-Wide Management of Engineering Information, by J. W. Southall. In addition to tying the three together, how project management can be handled in a computing environment and also the user interface needs are discussed in detail.

Anderton, G. L.↗