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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 sourcesNASA NTRSDOE OSTI
NASA NTRS1980

Coal gasification systems engineering and analysis. Appendix C: Alternate product facility designs

The study of the production of methane, methanol, gasoline, and hydrogen by an add-on facility to a Koppers-Totzek based MBG plant is presented. Applications to a Texaco facility are inferred by evaluation of delta effects from the K-T cases. The production of methane from an add-on facility to a Lurgi based MBG plant and the co-production of methane and methanol from a Lurgi based system is studied. Studies are included of the production of methane from up to 50 percent of the MBG produced in an integrated K-T based plant and the production of methane from up to 50 percent of the MBG produced from an integrated plant in which module 1 is based on K-T technology and modules 2, 3, and 4 are based on Texaco technology.

Source record↗
NASA NTRS2016

NASA's Space Launch System Transitions From Design To Production

NASA's Space Launch System (SLS) successfully completed its Critical Design Review (CDR) in 2015, a major milestone on the journey to an unprecedented era of exploration for humanity. CDR formally marked the program's transition from design to production phase just four years after the program's inception and the first such milestone for a human launch vehicle in 40 years. While challenges typical of a complex development program lie ahead, CDR evaluators concluded that the design is technically and programmatically sound and ready to press forward to Design Certification Review (DCR) and readiness for launch of Exploration Mission 1 (EM-1) in the 2018 timeframe. SLS is prudently based on existing propulsion systems, infrastructure and knowledge with a clear, evolutionary path as required by mission needs. In its initial configuration, designated Block 1, SLS will a minimum of 70 metric tons (t) (154,324 pounds) of payload to low Earth orbit (LEO). It will evolve to a 130 t (286,601 pound) payload capacity by upgrading its engines, boosters, and upper stage, dramatically increasing the mass and volume of human and robotic exploration while decreasing mission risk, increasing safety, and simplifying ground and mission operations. CDR was the central programmatic accomplishment among many technical accomplishments that will be described in this paper. The government/industry SLS team successfully test-fired a flight-like five-segment solid rocket motor, as well as seven hotfire development tests of the RS-25 core stage engine. The majority of the major test article and flight barrels, rings, and domes for the core stage liquid oxygen, liquid hydrogen, engine section, intertank, and forward skirt were manufactured at NASA's Michoud Assembly Facility in New Orleans, Louisiana. Renovations to the B-2 test stand for stage green run testing were completed at NASA's Stennis Space Center (SSC), near Bay St. Louis, Mississippi. Core stage test stands are reaching completion at NASA's Marshall Space Flight Center in Huntsville, Alabama. The modified Pegasus barge for core stage transportation from manufacturing to testing and launch sites was delivered to SSC. The Interim Cryogenic Propulsion System test article was also completed. This paper will discuss these and other technical and programmatic successes and challenges over the past year and provide a preview of work ahead before the first flight of this new capability.

Askins, Bruce R.↗
NASA NTRS2016

NASA's Space Launch Transitions: From Design to Production

NASA's Space Launch System (SLS) successfully completed its Critical Design Review (CDR) in 2015, a major milestone on the journey to an unprecedented era of exploration for humanity. CDR formally marked the program's transition from design to production phase just four years after the program's inception and the first such milestone for a human launch vehicle in 40 years. While challenges typical of a complex development program lie ahead, CDR evaluators concluded that the design is technically and programmatically sound and ready to press forward to Design Certification Review (DCR) and readiness for launch of Exploration Mission 1 (EM-1) in the 2018 timeframe. SLS is prudently based on existing propulsion systems, infrastructure and knowledge with a clear, evolutionary path as required by mission needs. In its initial configuration, designated Block I, SLS will a minimum of 70 metric tons (t) of payload to low Earth orbit (LEO). It can evolve to a 130 t payload capacity by upgrading its engines, boosters, and upper stage, dramatically increasing the mass and volume of human and robotic exploration while decreasing mission risk, increasing safety, and simplifying ground and mission operations. CDR was the central programmatic accomplishment among many technical accomplishments that will be described in this paper. The government/industry SLS team successfully test fired a flight-like five-segment solid rocket motor, as well as seven hotfire development tests of the RS-25 core stage engine. The majority of the major test article and flight barrels, rings, and domes for the core stage liquid oxygen, liquid hydrogen, engine section, intertank, and forward skirt were manufactured at NASA's Michoud Assembly Facility. Renovations to the B-2 test stand for stage green run testing were completed at NASA Stennis Space Center. Core stage test stands are rising at NASA Marshall Space Flight Center. The modified Pegasus barge for core stage transportation from manufacturing to testing and launch sites was delivered. The Interim Cryogenic Propulsion System test article was also completed. This paper will discuss these and other technical and programmatic successes and challenges over the past year and provide a preview of work ahead before the first flight of this new capability.

Askins, Bruce↗
DOE OSTI2023

Disruptive Photovoltaic Technologies Can Accelerate Global Decarbonization

This contribution explores PV manufacturing capacity expansion trajectories needed to achieve the goal of global decarbonization assuming that investors make financially rational decisions avoiding stranded production assets while still effectively exploiting experience curve benefits in both manufacturing process and product design. Substantial production cost savings and timely decarbonization risk mitigation could accrue by adoption and scaling of high efficiency multijunction device architectures and thin film direct bandgap semiconductor technologies that provide lower manufacturing capital intensity. We demonstrate that there is a $1-2 trillion market opportunity for such disruptive technologies while also providing hundreds of billions of dollars of cost savings to reach total decarbonization.

decarbonization↗
DOE OSTI2022

Design of Production PIP-II SSR1 Cavities

The testing and manufacturing process of the PIP-II Single Spoke Resonators Type 1 (SSR1) prototype jacketed cavity presented opportunities for refinement of the production series. Experience from the prototype cavity and the design of other cavities at Fermilab were used. The mechanical design of the production jacketed cavity has been modified from the prototype design to allow for improvements in overall performance, structural behavior, and manufacturability of the weld joints.

43 PARTICLE ACCELERATORS↗
NASA NTRS1977

Use of human engineering standards in design

Results are presented for a research study intended to assess the impact of present human engineering standards on product design. The approach consisted of three basic steps: a comparison of two display panels to determine if, in fact, products designed to the same standards are truly standardized; a review of two existing standards to determine how well their information can be used to solve design problems; and a survey of human factors specialists to assess their opinions about standards. It is shown that standards have less than the desired influence on product design. This is evidenced by a lack of standardization between hardware designed under common standards, by deficiencies within the standards that detract from their usefulness and encourage users to ignore them, and by the respondents of the survey who consider standards less valuable than other reference sources for design implementation. Recommendations aimed at enhancing the use of standards are set forth.

Rogers, J. G.↗
NASA NTRS1979

Development of integrated programs for Aerospace-vehicle Design (IPAD): Product program management systems

The Integrated Programs for Aerospace Vehicle Design (IPAD) is a computing system to support company-wide design information processing. This document presents a brief description of the management system used to direct and control a product-oriented program. This document, together with the reference design process (CR 2981) and the manufacture interactions with the design process (CR 2982), comprises the reference information that forms the basis for specifying IPAD system requirements.

Isenberg, J. M.↗
DOE OSTI2021

Design and production of the high voltage electrode grids and electron extraction region for the LZ dual-phase xenon time projection chamber

The dual-phase xenon time projection chamber (TPC) is a powerful tool for direct-detection experiments searching for WIMP dark matter, other dark matter models, and neutrinoless double-beta decay. Successful operation of such a TPC is critically dependent on the ability to hold high electric fields in the bulk liquid, across the liquid surface, and in the gas. Careful design and construction of the electrodes used to establish these fields is therefore required. We present the design and production of the LUX-ZEPLIN (LZ) experiment's high-voltage electrodes, a set of four woven mesh wire grids. Grid design drivers are discussed, with emphasis placed on design of the electron extraction region. Here, we follow this with a description of the grid production process and a discussion of steps taken to validate the LZ grids prior to integration into the TPC.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Solar-Thermal Ammonia Production: System Design and Technoeconomic Analysis [Slides]

CO 2 -neutral ammonia production with concentrated solar technology is theoretically possible based on advanced solar thermochemical looping technology. The parametric analysis points to the re-oxidation temperature and the H 3 yield as the most influential parameters in the energy balance. The cycle time and the nitride cost are the most influential parameters on the CAPEX. The techno-economics analysis shows the potential of the plant to achieve a target price <125 $\$$/tonne.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1988

The Transportable Applications Environment - An interactive design-to-production development system

An account is given of the design philosophy and architecture of the Transportable Applications Environment (TAE), an executive program binding a system of applications programs into a single, easily operable whole. TAE simplifies the job of a system developer by furnishing a stable framework for system-building; it also integrates system activities, and cooperates with the host operating system in order to perform such functions as task-scheduling and I/O. The initial TAE human/computer interface supported command and menu interfaces, data displays, parameter-prompting, error-reporting, and online help. Recent extensions support graphics workstations with a window-based, modeless user interface.

Perkins, Dorothy C.↗
NASA NTRS1992

Applications of a damage tolerance analysis methodology in aircraft design and production

Objectives of customer mandated aircraft structural integrity initiatives in design are to guide material selection, to incorporate fracture resistant concepts in the design, to utilize damage tolerance based allowables and planned inspection procedures necessary to enhance the safety and reliability of manned flight vehicles. However, validated fracture analysis tools for composite structures are needed to accomplish these objectives in a timely and economical manner. This paper briefly describes the development, validation, and application of a damage tolerance methodology for composite airframe structures. A closed-form analysis code, entitled SUBLAM was developed to predict the critical biaxial strain state necessary to cause sublaminate buckling-induced delamination extension in an impact damaged composite laminate. An embedded elliptical delamination separating a thin sublaminate from a thick parent laminate is modelled. Predicted failure strains were correlated against a variety of experimental data that included results from compression after impact coupon and element tests. An integrated analysis package was developed to predict damage tolerance based margin-of-safety (MS) using NASTRAN generated loads and element information. Damage tolerance aspects of new concepts are quickly and cost-effectively determined without the need for excessive testing.

Woodward, M. R.↗
NASA NTRS2006

A Comparison of Functional Models for Use in the Function-Failure Design Method

When failure analysis and prevention, guided by historical design knowledge, are coupled with product design at its conception, shorter design cycles are possible. By decreasing the design time of a product in this manner, design costs are reduced and the product will better suit the customer s needs. Prior work indicates that similar failure modes occur with products (or components) with similar functionality. To capitalize on this finding, a knowledge base of historical failure information linked to functionality is assembled for use by designers. One possible use for this knowledge base is within the Elemental Function-Failure Design Method (EFDM). This design methodology and failure analysis tool begins at conceptual design and keeps the designer cognizant of failures that are likely to occur based on the product s functionality. The EFDM offers potential improvement over current failure analysis methods, such as FMEA, FMECA, and Fault Tree Analysis, because it can be implemented hand in hand with other conceptual design steps and carried throughout a product s design cycle. These other failure analysis methods can only truly be effective after a physical design has been completed. The EFDM however is only as good as the knowledge base that it draws from, and therefore it is of utmost importance to develop a knowledge base that will be suitable for use across a wide spectrum of products. One fundamental question that arises in using the EFDM is: At what level of detail should functional descriptions of components be encoded? This paper explores two approaches to populating a knowledge base with actual failure occurrence information from Bell 206 helicopters. Functional models expressed at various levels of detail are investigated to determine the necessary detail for an applicable knowledge base that can be used by designers in both new designs as well as redesigns. High level and more detailed functional descriptions are derived for each failed component based on NTSB accident reports. To best record this data, standardized functional and failure mode vocabularies are used. Two separate function-failure knowledge bases are then created aid compared. Results indicate that encoding failure data using more detailed functional models allows for a more robust knowledge base. Interestingly however, when applying the EFDM, high level descriptions continue to produce useful results when using the knowledge base generated from the detailed functional models.

Stock, Michael E.↗
NASA NTRS2016

Leadership Development Program Final Project

TOSC is NASA's prime contractor tasked to successfully assemble, test, and launch the EM1 spacecraft. TOSC success is highly dependent on design products from the other NASA Programs manufacturing and delivering the flight hardware; Space Launch System(SLS) and Multi-Purpose Crew Vehicle(MPCV). Design products directly feed into TOSC's: Procedures, Personnel training, Hardware assembly, Software development, Integrated vehicle test and checkout, Launch. TOSC senior management recognized a significant schedule risk as these products are still being developed by the other two (2) programs; SVE and ACE positions were created.

Design products required for Engineering↗
DOE OSTI2026

TRIZ-Based Design Improvement for Facilitating Transmission Control Unit Remanufacturing

Design for Remanufacturing (DfRem) centers on enhancing product design and operations to facilitate remanufacturing while increasing both economic and environmental sustainability. DfRem requires a comprehensive understanding of product characteristics, production conditions, and operational constraints. Thus, DfRem requires a systematic methodology to identify and implement alternative designs. Among many critical steps in remanufacturing, disassembly is essential because it directly supports remanufacturing by separation of product components for cleaning, inspection, and other subsequent process steps. This study proposes a TRIZ-based framework to improve product design for disassembly in support of remanufacturing. The framework is applied to a transmission control unit (TCU) case study. The current TCU design prevents remanufacturing due to the sealant-based component joinery, which complicates disassembly and risks damaging the printed circuit board (PCB). After defining technical contradictions for the TCU product design and reviewing the suggested TRIZ principles to solve the conflicts, a cantilever snap-fit design alternative is developed. The economic feasibility of the snap-fit design is assessed by comparing the current and snap-fit design costs for three life cycles. The cost analysis demonstrates that the cost of the snap-fit design remains the same as the current design. Additionally, the snap-fit design offers substantial cost savings for three life cycles compared to the current design. We demonstrate how snap-fit design supports both environmental and economic sustainability.

42 ENGINEERING↗
DOE OSTI2024

A novel design optimization framework to sustain remanufacturability

The ever-increasing global carbon emissions have urged the need for environmentally conscious/sustainable product design, for which the design for remanufacturing (DfRem) is one potential approach. DfRem targets at designing products that have multiple life cycles, thus significantly reducing raw material usage, energy consumption, and carbon emissions. In this paper, we develop a three-stage framework that consists of (1) systematic design space exploration and a multi-objective optimization formulation to minimize the likelihood of failure causes (such as fatigue and wear) and environmental footprint, (2) topology optimization to further reduce material usage without significantly affecting the load-carrying capability of the product, and (3) post-topology optimization design verification to ensure the proposed design satisfies all design constraints. The environmental impact can be assessed at varying comprehensiveness levels (e.g., design and manufacturing phase, use phase) and in terms of carbon or GHG emission, energy use, and waste generation. Because the novel design framework predominantly adjusted the geometry, we focused on mass-based change and energy savings due to sustained remanufacturability. The multi-objective optimization formulation in the first step results in a Pareto optimal set of possible design solutions that the designer can use for the second step. Finally, we demonstrate the utility of this framework through a case study of an engine cylinder head subjected to thermo-mechanical loads, where we find that about 5% of the product mass can be conserved with only about a 3% increase in surface area that has a fatigue life less than 10,000 cycles.

42 ENGINEERING↗
NASA NTRS2016

Systems Engineering and Management Applications of ISO 9001:2015 for Government

The manufacturing segment of the business world is busy assessing the impact of ISO 9001:2015, and updating their management systems to meet the required compliance date. What does the new revision mean for government agencies that deliver large engineering projects rather than mass production? In fact, the standard, especially the new revision, can be used quite readily for government agencies, or applied to specific projects, once it is understood in terms of the similarities with systems engineering and project management. From there it can be extrapolated to "mission realization" systems, and a Quality Management System (QMS) is a logical result that can bring order to processes and systems that likely already exist in some fashion. ISO 9001:2015 is less product-oriented than previous versions. It can be more broadly applied to public organizations as well as private; and to services (missions) as well as products. The emphasis on risk management in the revised standard provides the needed balance for weighing decisions with respect to cost, schedule, technical, safety, and regulatory compliance; so if this is not part of agency governance already, this is a good place to start, especially for large engineering projects. The Systems Engineering standard used for this analysis is from NASA's NPR 7123.1 NASA Systems Engineering Processes and Requirements; however, those who are more familiar with ISO/IEC 26702 Systems Engineering-application and management of the systems engineering process, or SAE/EIA 632 Processes for Engineering a System will also recognize the similarities. In reality, the QMS outlined by ISO 9001 reinforces the systems engineering processes, and serves to ensure that they are adequately implemented, although most of the ISO 9001 literature emphasizes the production and process aspects of the standard. Rather than beginning with ISO 9001and getting lost in the vocabulary, it is useful to begin with the systems engineering lifecycle. Identification of stakeholder expectations, identifying solutions, creating specific product or service designs, production of the product or service, delivery to the public, and the associated management, planning, and control processes, are a familiar place to begin thinking of the overall system of identifying, designing, and competing a project or mission. Lining up this lifecycle with the ISO requirements (see Figure 1) illustrates how a quality management system is concerned with the same processes, and provides a governance and assurance function. If implemented properly, there are cost savings resulting from less rework, repair, reprocessing, failures, misplaced documents, and similar types of deficiencies1. Starting with an organization's systems engineering processes allows the organization to use their own terminology for a QMS plan, and tailor the plan to their own project or organization, so that it is more easily developed, understood, and implemented.

Shepherd, Christena C.↗
DOE OSTI2023

Development of the generation III (ATR generation I) Plutonium-238 production target design

A domestic supply chain to produce 238 Pu fuel for radioisotope thermoelectric generators is critical for enabling future space exploration. A multi-laboratory effort has worked to establish a common target design to efficiently produce 238 Pu in two research reactors. This approach ensures that the annual production goals set forth by NASA are met, while also establishing redundant production capabilities. Here, this paper describes the effort to develop the common target design as well as considerations for future applications for the irradiation platform.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗