Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Quality by Design”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 415 records · Page 23

Optical testing cryogenic thermal vacuum facility

The construction of a turnkey cryogenic vacuum test facility was recently completed. The facility will be used to measure and record the surface profile of large diameter and 540 kg optics under simulated space conditions. The vacuum test chamber is a vertical stainless steel cylinder with a 3.5 diameter and a 7 m tangent length. The chamber was designed to maximize optical testing quality by minimizing the vibrations between the laser interferometer and the test specimen. This was accomplished by designing the chamber for a high natural frequency and vibration isolating the chamber. An optical test specimen is mounted on a movable presentation stage. During thermal vacuum testing, the specimen may be positioned to + or - 0.00025 cm accuracy with a fine adjustment mechanism. The chamber is evacuated by a close coupled Roots-type blower and rotary vane pump package and two cryopumps. The chamber is equipped with an optically dense gaseous nitrogen cooled thermal shroud. The thermal shroud is used to cool or warm the optical test specimen at a controlled rate. A control system is provided to automatically evacuate the chamber and cooldown the test specimen to the selected control temperature.

Dohogne, Patrick W.↗

CFD modeling of non-catalytic, partial-oxidation engine reformer for flare mitigation

Flaring associated natural gas is commonly employed in the oil and gas industry to reduce methane (CH 4 ) emissions but generates carbon dioxide (CO 2 ) and harmful pollutants, significantly contributing to air pollution and posing risks to public health. To mitigate this impact, M2X Energy Inc. has developed a small-scale, modular gas-to-methanol system. This system features an engine reformer that performs fuel-rich partial oxidation of wellhead gas to produce syngas—a mixture of carbon monoxide (CO) and hydrogen (H 2 )—followed by a downstream reactor for methanol synthesis. This study focused on computational fluid dynamics (CFD) modeling of the engine reformer to simulate partial oxidation chemistry, predict the rich-burn operating limit, and assess syngas quality, ultimately aiding in design and operational optimization. The CFD model, developed within a Reynolds-Averaged Navier-Stokes (RANS) turbulence framework, incorporated sub-models for turbulent combustion, a chemical mechanism with polycyclic aromatic hydrocarbon (PAH) pathways, and soot emissions to accurately capture the fuel-rich, turbulent jet ignition and combustion processes. Model validation against experimental data showed good agreement across pre- and main-chamber pressures, apparent heat release rates, and exhaust gas concentrations of key species (H 2 , CO, CO 2 , CH 4 ) for varying intake equivalence ratios. Here, the model identified a rich-burn operating limit near a fuel-air equivalence ratio of 2.35, consistent with experimental observations. Furthermore, syngas quality analysis revealed that extending the rich-burn limit through engine reformer optimization could enhance syngas production, contributing to higher methanol synthesis efficiency.

Computational Fluid Dynamics↗

Quality assurance procedures for environmental control and monitoring in plant growth facilities. Report of the North Central Regional 101 Committee on Growth Chamber Use

This report includes procedures for ensuring the quality of the environment provided for plant growth in controlled environment facilities. Biologists and engineers may use these procedures for ensuring quality control during experiments or for ensuring quality control in the design of plant growth facilities. Environmental monitoring prior to and during experiments is included in these procedures. Specific recommendations cover control, acquisition, and calibration for sensor types for the separate parameters of radiation (light), temperature, humidity, carbon dioxide, and air movement.

NASA Discipline Number 61-10↗

Evaluating Core Quality for a Mars Sample Return Mission

Sample return missions, including the proposed Mars Sample Return (MSR) mission, propose to collect core samples from scientifically valuable sites on Mars. These core samples would undergo extreme forces during the drilling process, and during the reentry process if the EEV (Earth Entry Vehicle) performed a hard landing on Earth. Because of the foreseen damage to the stratigraphy of the cores, it is important to evaluate each core for rock quality. However, because no core sample return mission has yet been conducted to another planetary body, it remains unclear as to how to assess the cores for rock quality. In this report, we describe the development of a metric designed to quantitatively assess the mechanical quality of any rock cores returned from Mars (or other planetary bodies). We report on the process by which we tested the metric on core samples of Mars analogue materials, and the effectiveness of the core assessment metric (CAM) in assessing rock core quality before and after the cores were subjected to shocking (g forces representative of an EEV landing).

Mars samples↗

Color matrix display simulation based upon luminance and chromatic contrast sensitivity of early vision

This paper describes the design and operation of a new simulation model for color matrix display development. It models the physical structure, the signal processing, and the visual perception of static displays, to allow optimization of display design parameters through image quality measures. The model is simple, implemented in the Mathematica computer language, and highly modular. Signal processing modules operate on the original image. The hardware modules describe backlights and filters, the pixel shape, and the tiling of the pixels over the display. Small regions of the displayed image can be visualized on a CRT. Visual perception modules assume static foveal images. The image is converted into cone catches and then into luminance, red-green, and blue-yellow images. A Haar transform pyramid separates the three images into spatial frequency and direction-specific channels. The channels are scaled by weights taken from human contrast sensitivity measurements of chromatic and luminance mechanisms at similar frequencies and orientations. Each channel provides a detectability measure. These measures allow the comparison of images displayed on prospective devices and, by that, the optimization of display designs.

Martin, Russel A.↗

Development of a Model Following Control Law for Inflight Simulation and Flight Controls Research

The U.S. Army and NASA are currently developing the Rotorcraft Aircrew Systems Concepts Airborne Laboratory (RASCAL) at the Ames Research Center. RASCAL, shown in Figure 1, is a UH-60, which is being modified in a phased development program to have a research fly-by-wire flight control system, and an advanced navigation research platform. An important part of the flight controls and handling qualities research on RASCAL will be an FCS design for the aircraft to achieve high bandwidth control responses and disturbance rejection characteristics. Initially, body states will be used as feedbacks, but research into the use of rotor states will also be considered in later stages to maximize agility and maneuverability. In addition to supporting flight controls research, this FCS design will serve as the inflight simulation control law to support basic handling qualities, guidance, and displays research. Research in high bandwidth controls laws is motivated by the desire to improve the handling qualities in aggressive maneuvering and in severely degraded weather conditions. Naturally, these advantages will also improve the quality of the model following, thereby improving the inflight simulation capabilities of the research vehicle. High bandwidth in the control laws provides tighter tracking allowing for higher response bandwidths which can meet handling qualities requirements for aggressive maneuvering. System sensitivity is also reduced preventing variations in the response from the vehicle due to changing flight conditions. In addition, improved gust rejection will result from this reduced sensitivity. The gust rejection coupled with a highly stable system will make more precise maneuvering and pointing possible in severely degraded weather conditions. The difficulty in achieving higher bandwidths from the control laws in the feedback and in the responses arises from the complexity of the models that are needed to produce a satisfactory design. In this case, high quality models that include rotor dynamics in a physically meaningful context must be available. A non-physical accounting of the rotor, such as lumping the effect as a time delay, is not likely to produce the desired results. High order simulation models based on first principals are satisfactory for the initial design phase in order to work out the control law design concept and get an initial set of gains. These models, however, have known deficiencies, which must be resolved in the final control law design. The error in the pitch-roll cross coupling is one notable deficiency that even sophisticated rotorcraft models including complex wake aerodynamics have yet to capture successfully. This error must be accounted for to achieve the desired decoupling. The approach to design the proposed inflight simulation control law is based on using a combination of simulation and identified models. The linear and nonlinear higher order models were used to develop an explicit model following control structure. This structure was developed to accommodate the design of control laws compliant to many of the quantitative requirements in ADS-33C. Furthermore, it also allows for control law research using rotor-state feedback and other design methodologies such as Quantitative Feedback and H-Infinity. Final gain selection will be based on higher order identified models which include rotor degrees of freedom.

Takahashi, Mark↗

On the Development of a Computing Infrastructure that Facilitates IPPD from a Decision-Based Design Perspective

Integrated Product and Process Development (IPPD) embodies the simultaneous application of both system and quality engineering methods throughout an iterative design process. The use of IPPD results in the time-conscious, cost-saving development of engineering systems. Georgia Tech has proposed the development of an Integrated Design Engineering Simulator that will merge Integrated Product and Process Development with interdisciplinary analysis techniques and state-of-the-art computational technologies. To implement IPPD, a Decision-Based Design perspective is encapsulated in an approach that focuses on the role of the human designer in product development. The approach has two parts and is outlined in this paper. First, an architecture, called DREAMS, is being developed that facilitates design from a decision-based perspective. Second, a supporting computing infrastructure, called IMAGE, is being designed. The current status of development is given and future directions are outlined.

Hale, Mark A.↗

Distributed Solar Quality and Safety in India: Key Challenges and Potential Solutions

The quality and safety of solar systems and their installation has become a concern for investors, regulators, consumers, and Discoms in India. The push for low prices and lack of quality standards are driving project developers to install low quality products, with poor system design and execution on-site. Existing literature and stakeholder interviews point to the rampant use of low quality, sub-standard solar products in India. These products deliver less energy than expected, or have high detrition rates, or have lower product life–all of which are serious issues for developers whose return on investment depend on the amount of power generation from these solar systems for the expected life of the project. Equipment which does not conform to the minimum quality standards also creates safety risks for the distribution network. Performance and safety concerns lower investor and consumer confidence in solar products with the potential to threaten market development. This report formulates a set of recommendations to concerned authorities in India to improve the quality and safety of rooftop solar systems. Primary and secondary sources are employed to understand the current solar quality and safety scenario in India to provide the basis for future recommendations. An overview of international experiences and lessons learned on solar quality and safety issues is also conducted to understand potential solutions for India.

24 POWER TRANSMISSION AND DISTRIBUTION↗

ORION Environmental Control and Life Support Systems Suit Loop and Pressure Control Analysis

Under NASA's ORION Multi-Purpose Crew Vehicle (MPCV) Environmental Control and Life Support System (ECLSS) Project at Johnson Space Center's (JSC), the Crew and Thermal Systems Division has developed performance models of the air system using Thermal Desktop/FloCAD. The Thermal Desktop model includes an Air Revitalization System (ARS Loop), a Suit Loop, a Cabin Loop, and Pressure Control System (PCS) for supplying make-up gas (N2 and O2) to the Cabin and Suit Loop. The ARS and PCS are designed to maintain air quality at acceptable O2, CO2 and humidity levels as well as internal pressures in the vehicle Cabin and during suited operations. This effort required development of a suite of Thermal Desktop Orion ECLSS models to address the need for various simulation capabilities regarding ECLSS performance. An initial highly detailed model of the ARS Loop was developed in order to simulate rapid pressure transients (water hammer effects) within the ARS Loop caused by events such as cycling of the Pressurized Swing Adsorption (PSA) Beds and required high temporal resolution (small time steps) in the model during simulation. A second ECLSS model was developed to simulate events which occur over longer periods of time (over 30 minutes) where O2, CO2 and humidity levels, as well as internal pressures needed to be monitored in the cabin and for suited operations. Stand-alone models of the PCS and the Negative Pressure relief Valve (NPRV) were developed to study thermal effects within the PCS during emergency scenarios (Cabin Leak) and cabin pressurization during vehicle re-entry into Earth's atmosphere. Results from the Orion ECLSS models were used during Orion Delta-PDR (July, 2014) to address Key Design Requirements (KDR's) for Suit Loop operations for multiple mission scenarios.

Eckhardt, Brad↗

A machine learning approach to water quality forecasts and sensor network expansion: Case study in the Wabash River Basin, United States

Abstract Midwestern cities require forecasts of surface nitrate loads to bring additional treatment processes online or activate alternative water supplies. Concurrently, networks of nitrate monitoring stations are being deployed in river basins, co‐locating water quality observations with established stream gauges. However, tools to evaluate the future value of expanded networks to improve water quality forecasts remains challenging. Here, we construct a synthetic data set of stream discharge and nitrate for the Wabash River Basin—one of the United States’ most nutrient polluted basins—using the established Agro‐IBIS and THMB models. Synthetic data enables rapid, unbiased and low‐cost assessment of potential sensor placements to support management objectives, such as near‐term forecasting. Using the synthetic data, we established baseline 1‐day forecasts for surface water nitrate at 12 cities in the basin using support vector machine regression (SVMR; RMSE 0.48–3.3 ppm). Next, we used the SVMRs to evaluate the improvement in forecast performance associated with deployment of additional nitrate sensors. We identified the optimal sensor placement to improve forecasts at each city, and the relative value of sensors at each candidate location. Finally, we assessed the co‐benefit realized by other cities when a sensor is deployed to optimize a forecast at one city, finding significant positive externalities in all cases. Ultimately, our study explores the potential for machine learning to make near‐term predictions and critically evaluate the improvement realized by expanding a monitoring network. While we use nitrate pollution in the Wabash River Basin as a case study, this approach could be readily applied to any problem where the future value of sensors and network design are being evaluated.

54 ENVIRONMENTAL SCIENCES↗

The MAP Autonomous Mission Control System

The Microwave Anisotropy Probe (MAP) mission is the second mission in NASA's Office of Space Science low-cost, Medium-class Explorers (MIDEX) program. The Explorers Program is designed to accomplish frequent, low cost, high quality space science investigations utilizing innovative, streamlined, efficient management, design and operations approaches. The MAP spacecraft will produce an accurate full-sky map of the cosmic microwave background temperature fluctuations with high sensitivity and angular resolution. The MAP spacecraft is planned for launch in early 2001, and will be staffed by only single-shift operations. During the rest of the time the spacecraft must be operated autonomously, with personnel available only on an on-call basis. Four (4) innovations will work cooperatively to enable a significant reduction in operations costs for the MAP spacecraft. First, the use of a common ground system for Spacecraft Integration and Test (I&T) as well as Operations. Second, the use of Finite State Modeling for intelligent autonomy. Third, the integration of a graphical planning engine to drive the autonomous systems without an intermediate manual step. And fourth, the ability for distributed operations via Web and pager access.

Breed, Juile↗

Self-Isolated Raman Lasing with a Chiral Dielectric Metasurface

The light sources that power photonic networks are small and scalable, but they also require the incorporation of optical isolators that allow light to pass in one direction only, protecting the light source from damaging backreflections. Unfortunately, the size and complex integration of optical isolators makes small-scale and densely integrated photonic networks infeasible. Here, we overcome this limitation by designing a single device that operates both as a coherent light source and as its own optical isolator. Our design relies on high-quality-factor dielectric metasurfaces that exhibit intrinsic chirality. By carefully manipulating the geometry of the constituent silicon metaatoms, we design three-dimensionally chiral modes that act as optical spin-dependent filters. Using spin-polarized Raman scattering together with our chiral metacavity, we demonstrate Raman lasing in the forward direction, while the lasing action is suppressed by over an order of magnitude for reflected light. Our high-$\textit{Q}$ chiral metasurface design presents a new approach toward compactly isolating integrated light sources by directly tailoring the emission properties of the light source itself.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

End–to–End Metasurface Design for Temperature Imaging via Broadband Planck‐Radiation Regression

A theoretical framework is presented for temperature imaging from long-wavelength infrared (LWIR) thermal radiation (e.g., 8–12 µm) through the end-to-end design of a metasurface-optics frontend and a computational-reconstruction backend. A new nonlinear reconstruction algorithm, “Planck regression”, is introduced to reconstruct the temperature map from a gray scale sensor image, even in the presence of severe chromatic aberration, by exploiting black body and optical physics particular to thermal imaging. This algorithm is combined with an end-to-end approach that optimizes manufacturable, single-layer metasurfaces to yield the most accurate reconstruction. The designs demonstrate high-quality, noise-robust reconstructions of arbitrary temperature maps (including completely random images) in simulations of an ultra-compact thermal-imaging device. Here, it is also shown that Planck regression is much more generalizable to arbitrary images than a straightforward neural-network reconstruction, which requires a large training set of domain-specific images.

36 MATERIALS SCIENCE↗

Can machine learning accelerate process understanding and decision‐relevant predictions of river water quality?

Abstract The global decline of water quality in rivers and streams has resulted in a pressing need to design new watershed management strategies. Water quality can be affected by multiple stressors including population growth, land use change, global warming, and extreme events, with repercussions on human and ecosystem health. A scientific understanding of factors affecting riverine water quality and predictions at local to regional scales, and at sub‐daily to decadal timescales are needed for optimal management of watersheds and river basins. Here, we discuss how machine learning (ML) can enable development of more accurate, computationally tractable, and scalable models for analysis and predictions of river water quality. We review relevant state‐of‐the art applications of ML for water quality models and discuss opportunities to improve the use of ML with emerging computational and mathematical methods for model selection, hyperparameter optimization, incorporating process knowledge into ML models, improving explainablity, uncertainty quantification, and model‐data integration. We then present considerations for using ML to address water quality problems given their scale and complexity, available data and computational resources, and stakeholder needs. When combined with decades of process understanding, interdisciplinary advances in knowledge‐guided ML, information theory, data integration, and analytics can help address fundamental science questions and enable decision‐relevant predictions of riverine water quality.

54 ENVIRONMENTAL SCIENCES↗

The state of the art for neutron irradiation experiments from the perspective of the High Flux Isotope Reactor (HFIR)

Irradiation experiment campaigns are critical to advancing nuclear energy technologies by providing data on material performance under relevant radiation conditions. Successful irradiation experiments require integrated design efforts that balance technical goals with facility constraints. Here, this paper presents an expert-informed overview of irradiation experiment design at the High Flux Isotope Reactor. It addresses the nuclear materials research and irradiation experiment communities to guide them toward developing technically sound, facility-compatible campaigns. The High Flux Isotope Reactor is a multipurpose reactor supporting isotope production, neutron scattering, and materials testing. Its high, steady-state neutron flux is ideal for irradiation experiments, but successful execution demands coordinated thermal, structural, and reactor physics analyses. The paper outlines the complete development workflow from concept definition and design optimization to safety qualification and post-irradiation examination. Standardized capsule platforms are also discussed in terms of flexibility, specimen capacity, and thermal performance. Common failure modes such as unanticipated geometric variations, can impact temperature-dose profiles and compromise data reliability. Therefore, detailed thermal modeling and accurate as-built characterization are essential for meaningful post-irradiation data interpretation. Key recommendations include early engagement all stakeholders, clearly defined design expectations, and alignment of specimen geometries with post-irradiation examination capabilities. This approach reduces design iterations, enhances data quality, and supports more efficient use of irradiation resources. Strategic and well-planned irradiation testing not only improves individual campaign success but also accelerates the deployment of advanced nuclear technologies. By closing critical data gaps and reducing development risks, the nuclear materials community can more effectively contribute to the future of clean, resilient energy systems.

Experiments↗

Microstructure and Composition of Passivating Interfaces in Silicon Heterojunction Solar Modules Weathered in Different Climates

Sanyo/Panasonic patented silicon heterojunction with intrinsic thin layer (HIT) solar cells in the 1990's, which demonstrated world record photovoltaic (PV) efficiency around 2014 and inspired the newer generations of silicon heterojunction technology (SHJ) as well as the current world record back-contact PV cell designs. The high-quality passivation strategy, utilizing ultra-thin layers of hydrogenated amorphous silicon (a-Si:H), leads to high voltages and long carrier lifetimes, but these qualities may degrade over time as the modules operate outdoors. Here, we investigate local microstructure and composition at the interface layers of cells from HIT modules weathered in a hot, humid climate (Florida, USA) and temperate climate (Colorado, USA) for 10 years. We employ a comprehensive set of high-resolution electron microscopy imaging and spectroscopy to directly resolve structure and composition in these cells down to the nanoscale. We show features such as alignment of the In2O3 transparent conducting oxide and a-Si:H layers on the textured c-Si facets, interfacial oxidation at the a-Si:H/c-Si and In2O3/a-Si:H interfaces, and twinned c-Si resulting from epitaxial growth into the a-Si:H layer. Our results raise potential degradation mechanisms in these outdoor-weathered modules, but the root cause of electrical loss remains uncertain due to the very small changes in aged samples. This study shows that many atomic scale features at the In2O3/a-Si:H/c-Si interfaces are surprisingly robust, and the electrical losses with aging may either be attributed to other pathways or be very sensitive to the subtle chemical and microstructural features observed here.

14 SOLAR ENERGY↗

Surface-Enhanced Raman Detection of the CO 2 Moisture Swing

The development of scalable, energy-efficient carbon dioxide (CO 2 ) capture technologies is critical for achieving net-zero emissions. Moisture swing (MS) sorbents offer a promising alternative to traditional thermal regeneration methods by enabling reversible CO 2 binding through humidity-driven ion hydrolysis. In this study, we investigate the anion speciation dynamics in two classes of MS materials─an anion-exchange resin with a bicarbonate anion and activated carbon impregnated with potassium bicarbonate salt─using both sorption measurements and in situ surface-enhanced Raman spectroscopy (SERS). Ni-coated Ag nanowires were employed as SERS substrates to enhance signal intensity and enable the real-time detection of carbonate (CO 3 2– ), bicarbonate (HCO 3 – ), and hydroxide (OH – ) species under controlled humidity conditions in both air and nitrogen atmospheres. The results reveal humidity-dependent interconversion between anionic species with significant spectral shifts confirming the reversible hydrolysis reactions that drive the MS mechanism. Under humid conditions, we observed the depletion of bicarbonate signals and a concurrent increase in carbonate species, consistent with moisture-induced desorption of CO 2 . With the activated carbon samples, we further observed the formation of hydroxide. These findings not only validate the mechanistic models of humidity-driven anion exchange in MS sorbents but also demonstrate the practical potential of SERS as an operando diagnostic tool for monitoring CO 2 capture media. The ability to resolve and semiquantitatively evaluate the reversible transformation of carbonate, bicarbonate, and hydroxide ions under realistic environmental conditions provides valuable insight for the rational design, performance optimization, and quality control of next-generation sorbent materials for direct air capture applications.

CO2 capture↗

Sinuosity‐Driven Hyporheic Exchange: Hydrodynamics and Biogeochemical Potentials

Abstract Hydrologic exchange processes are critical for ecosystem services along river corridors. Meandering contributes to this exchange by driving channel water, solutes, and energy through the surrounding alluvium, a process called sinuosity‐driven hyporheic exchange. This exchange is embedded within and modulated by the regional groundwater flow (RGF), which compresses the hyporheic zone and potentially diminishes its overall impact. Quantifying the role of sinuosity‐driven hyporheic exchange at the reach‐to‐watershed scale requires a mechanistic understanding of the interplay between drivers (meander planform) and modulators (RGF) and its implications for biogeochemical transformations. Here, we use a 2D, vertically integrated numerical model for flow, transport, and reaction to analyze sinuosity‐driven hyporheic exchange systematically. Using this model, we propose a dimensionless framework to explore the role of meander planform and RGF in hydrodynamics and how they constrain nitrogen cycling. Our results highlight the importance of meander topology for water flow and age. We demonstrate how the meander neck induces a shielding effect that protects the hyporheic zone against RGF, imposing a physical constraint on biogeochemical transformations. Furthermore, we explore the conditions when a meander acts as a net nitrogen source or sink. This transition in the net biogeochemical potential is described by a handful of dimensionless physical and biogeochemical parameters that can be measured or constrained from literature and remote sensing. This work provides a new physically based model that quantifies sinuosity‐driven hyporheic exchange and biogeochemical reactions, a critical step toward their representation in water quality models and the design and assessment of river restoration strategies.

54 ENVIRONMENTAL SCIENCES↗