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All sources NASA NTRS DOE OSTI

NASA NTRS1992

Magnetic beneficiation of lunar soils

We will present a review of recent laboratory results obtained in dry magnetic separation of one gram samples of the minus 1 mm size fraction of five lunar soils of widely differing maturities. Two highland soils were investigated as potential sources of low iron content feed stocks for space manufacture of metals, including aluminum, silicon, and calcium. Pure anorthite was separated from the diamagnetic fraction of immature highland regolith. Three high titanium mare soils were investigated as potential sources of ilmenite for production of hydrogen and for recovery of He-3. Ilmenite and pyroxene were separated from the paramagnetic fractions of the mare basalts. Agglutinates and other fused soil components containing metallic iron were separated from the strongly magnetic fractions of all soils. We will present conceptual magnetic separation flow sheets developed from the laboratory data and designed for production of anorthite from highland soils and for production of ilmenite from mare soils. Using these flow sheets, we will discuss problems and opportunities associated with the magnetic separation of lunar soils. Separation of high-grade anorthite or other diamagnetic components at moderately high recovery can be achieved in processing immature highland soils. Further, while magnet weight is always an issue in magnetic separation technology, recent developments in both low temperature and high temperature superconductivity present unusual opportunities for magnet design specific to the lunar environment.

Mckay, D. S↗

DOE OSTI2020

Design of additively manufactured methanol conversion reactor for high throughput production

Additively manufactured methanol conversion reactor was designed and fabricated for high throughput fuel production while capturing carbon dioxide. Here, the reactor designed is part of large effort in integrating electrolyzer and catalytic reactor system. Processing in fabricating the steel, titanium, and nickel alloy reactors were optimized to improve the catalyst deposition process and reaction efficiency. Microstructure of the additively manufactured reactors were characterized. General design is utilized to improve the performance of the reactor while exploring the benefit of freeform in additive manufacturing.

08 HYDROGEN↗

NASA NTRS2009

An Operational Assessment of the MODIS False Color Composite with the Great Falls, Montana National Weather Service

The close and productive collaborations between the NWS Warning and Forecast Office (WFO) in Great Falls, MT and the Short Term Prediction and Research Transition (SPORT) Center at NASA/Marshall Space Flight Center have provided a unique opportunity for science sharing and technology transfer. In particular, SPoRT has provided a false color composite product derived from MODIS data, which is part of NASA's Earth Observing System. This product is designed to delineate snow and ice covered ground, bare ground and clouds. The Great Falls WFO has been a test bed of the MODIS false color composite as a tool in operations to monitor the development and dissipation of snow cover In particular, preliminary applications have shown that the product can be used to monitor snow cover in remote locations as well as ice in rivers. This information can lead to improved assessments of flooding potential during post event conditions where rapid melting and runoff are anticipated. The potential of this product on future geostationary satellites may substantially contribute to the NWS mission by providing enhanced situational awareness. The operational use of this product has been transitioned at WFO Great Falls through a process of product implementation, discussions with the service hydrologist and forecasters, and post event analysis. A concentrated assessment period from January to March, 2008 was initiated to investigate the impact of the MODIS false color product on WFO Great Falls' operations. This presentation will emphasize the impact the MODIS false color product had in the WFO's situational awareness and how best this information can be used to influence operational decisions.

Loss, GIna↗

DOE OSTI2020

Kinetics Modeling for Design of Continuous Enzymatic Hydrolysis

Enzymatic hydrolysis of cellulose to monomeric sugars continues to be a limiting step in cost-effectively producing sugar and fermentation-based biofuels from biomass. In particular, the high cost of enzymes coupled with the long time-scale of reaction pose challenges to economic viability. Performing enzymatic hydrolysis in a continuous mode with enzyme recycle may provide a path towards substantially reduced costs for sugar production, but design and analysis are complicated by a lack of suitable kinetics models. Computationally attainable models, such as fractal-based models, require knowledge of the reaction-history of the biomass, and are thus only suitable for describing the batch reactions from which they are derived. Fundamental models, while potentially more generalizable, are often too computationally intensive to use in process or reactor modeling. In this work, a phenomenological rate model is proposed based on a two-phase substrate representation. Good agreement is seen between batch and continuous enzymatic hydrolysis (CEH) experiment data, which validates the model and enables us to solve for reactor design parameters, such as CEH reactor size and stream flow rates, based on process variables like yield. This model is integrated with techno-economic analysis software to explore economic sensitivities. Important design optimizations and tradeoffs are identified and quantified, including the relative cost imposed by rate slowdown from sugar inhibition versus the cost to remove and concentrate sugars at a lower concentration. It also identifies, high-leverage avenues for further exploration, such as increasing the maximum feasible solids concentration, and sustaining high membrane flux and reliability.

09 BIOMASS FUELS↗

NASA NTRS2009

Improving Tools and Processes in Mechanical Design Collaboration

Cooperative product development projects in the aerospace and defense industry are held hostage to high cost and risk due to poor alignment of collaborative design tools and processes. This impasse can be broken if companies will jointly develop implementation approaches and practices in support of high value working arrangements. The current tools can be used to better advantage in many situations and there is reason for optimism that tool vendors will provide significant support.

Briggs, Clark↗

DOE OSTI2022

Demonstration of a modeling toolkit for the design of building electrical distribution systems

The deployment of building equipment (e.g., lighting, security) and miscellaneous electrical loads that fundamentally require DC power for operation is increasing. Powering these DC loads has traditionally required an AC/DC converter, but the installation of photovoltaic (PV) and battery energy storage systems that primarily produce DC power eliminates the need for AC/DC converters at each end-device. However, analyzing system energy efficiency and cost for different electrical distribution architectures can be challenging as software tools that support this are not readily available. This paper presents preliminary results from a laboratory verification of the Building Electrical Efficiency Analysis Model (BEEAM) toolkit that was developed to address this gap. Three different eight-luminaire lighting systems comprised of market-available products were designed and modeled: one that used traditional AC distribution, a second that used a hybrid AC -to- centralized DC electrical distribution architecture, and a third that used a hybrid AC -to- distributed DC architecture. Notably, AC/DC conversions are required in all three systems. BEEAM models for LED drivers as well as Power-over-Ethernet (PoE) switches were created using laboratory characterization data. The lighting systems were simulated in Modelica, and the results were compared with each other and physics-based expectations. Simulation results show that PoE system energy efficiency is highly dependent on both device specification (e.g., LED driver and PoE switch efficiency) and system architecture (e.g., PoE switch loading) choices, as expected. For the products and system architectures selected for this study, the two DC systems were found to be less efficient than the AC system over the course of typical operation. In future work, simulation results will be compared with laboratory measurements to validate the usefulness of this software for design, and lighting systems with integrated PV and battery energy storage will be simulated to quantify the energy performance improvements that result from the elimination of some AC/DC converters.

Waghale, Anay S.↗

NASA NTRS2001

Accurate Time-Dependent Traveling-Wave Tube Model Developed for Computational Bit-Error-Rate Testing

The phenomenal growth of the satellite communications industry has created a large demand for traveling-wave tubes (TWT's) operating with unprecedented specifications requiring the design and production of many novel devices in record time. To achieve this, the TWT industry heavily relies on computational modeling. However, the TWT industry's computational modeling capabilities need to be improved because there are often discrepancies between measured TWT data and that predicted by conventional two-dimensional helical TWT interaction codes. This limits the analysis and design of novel devices or TWT's with parameters differing from what is conventionally manufactured. In addition, the inaccuracy of current computational tools limits achievable TWT performance because optimized designs require highly accurate models. To address these concerns, a fully three-dimensional, time-dependent, helical TWT interaction model was developed using the electromagnetic particle-in-cell code MAFIA (Solution of MAxwell's equations by the Finite-Integration-Algorithm). The model includes a short section of helical slow-wave circuit with excitation fed by radiofrequency input/output couplers, and an electron beam contained by periodic permanent magnet focusing. A cutaway view of several turns of the three-dimensional helical slow-wave circuit with input/output couplers is shown. This has been shown to be more accurate than conventionally used two-dimensional models. The growth of the communications industry has also imposed a demand for increased data rates for the transmission of large volumes of data. To achieve increased data rates, complex modulation and multiple access techniques are employed requiring minimum distortion of the signal as it is passed through the TWT. Thus, intersymbol interference (ISI) becomes a major consideration, as well as suspected causes such as reflections within the TWT. To experimentally investigate effects of the physical TWT on ISI would be prohibitively expensive, as it would require manufacturing numerous amplifiers, in addition to acquiring the required digital hardware. As an alternative, the time-domain TWT interaction model developed here provides the capability to establish a computational test bench where ISI or bit error rate can be simulated as a function of TWT operating parameters and component geometries. Intermodulation products, harmonic generation, and backward waves can also be monitored with the model for similar correlations. The advancements in computational capabilities and corresponding potential improvements in TWT performance may prove to be the enabling technologies for realizing unprecedented data rates for near real time transmission of the increasingly larger volumes of data demanded by planned commercial and Government satellite communications applications. This work is in support of the Cross Enterprise Technology Development Program in Headquarters' Advanced Technology & Mission Studies Division and the Air Force Office of Scientific Research Small Business Technology Transfer programs.

Kory, Carol L.↗

NASA NTRS2008

Aircraft System Analysis of Technology Benefits to Civil Transport Rotorcraft

An aircraft systems analysis was conducted to evaluate the net benefits of advanced technologies on two conceptual civil transport rotorcraft, to quantify the potential of future civil rotorcraft to become operationally viable and economically competitive, with the ultimate goal of alleviating congestion in our airways, runways and terminals. These questions are three of many that must be resolved for the successful introduction of civil transport rotorcraft: 1) Can civil transport rotorcraft actually relieve current airport congestion and improve overall air traffic and passenger throughput at busy hub airports? What is that operational scenario? 2) Can advanced technology make future civil rotorcraft economically competitive in scheduled passenger transport? What are those enabling technologies? 3) What level of investment is necessary to mature the key enabling technologies? This study addresses the first two questions, and several others, by applying a systems analysis approach to a broad spectrum of potential advanced technologies at a conceptual level of design. The method was to identify those advanced technologies that showed the most promise and to quantify their benefits to the design, development, production, and operation of future civil rotorcraft. Adjustments are made to sizing data by subject matter experts to reflect the introduction of new technologies that offer improved performance, reduced weight, reduced maintenance, or reduced cost. This study used projected benefits from new, advanced technologies, generally based on research results, analysis, or small-scale test data. The technologies are identified, categorized and quantified in the report. The net benefit of selected advanced technologies is quantified for two civil transport rotorcraft concepts, a Single Main Rotor Compound (SMRC) helicopter designed for 250 ktas cruise airspeed and a Civil Tilt Rotor (CTR) designed for 350 ktas cruise airspeed. A baseline design of each concept was sized for a representative civil passenger transport mission, using current technology. Individual advanced technologies are quantified and applied to resize the aircraft, thereby quantifying the net benefit of that technology to the rotorcraft. Estimates of development cost, production cost and operating and support costs are made with a commercial cost estimating program, calibrated to Boeing products with adjustments for future civil production processes. A cost metric of cash direct operating cost per available seat-mile (DOC ASM) is used to compare the cost benefit of the technologies. The same metric is used to compare results with turboprop operating costs. Reduced engine SFC was the most advantageous advanced technology for both rotorcraft concepts. Structural weight reduction was the second most beneficial technology, followed by advanced drive systems and then by technology for rotorcraft performance. Most of the technologies evaluated in this report should apply similarly to conventional helicopters. The implicit assumption is that resources will become available to mature the technologies for fullscale production aircraft. That assumption is certainly the weak link in any forecast of future possibilities. The analysis serves the purpose of identifying which technologies offer the most potential benefit, and thus the ones that should receive the highest priority for continued development. This study directly addressed the following NASA Subsonic Rotary Wing (SRW) subtopics: SR W.4.8.I.J Establish capability for rotorcraft system analysis and SRW. 4.8.I.4 Conduct limited technology benefit assessment on baseline rotorcraft configurations.

Wilkerson, Joseph B.↗

NASA NTRS1994

Facility design consideration for continuous mix production of class 1.3 propellant

In November of 1989, NASA awarded the Advanced Solid Rocket Motor (ASRM) contract to Lockheed Missiles and Space Company (LMSC) for production of advanced solid rocket motors using the continuous mix process. Aerojet ASRM division (AAD) was selected as the facility operator and RUST International Corporation provided the engineering, procurement, and construction management services. The continuous mix process mandates that the mix and cast facilities be 'close-coupled' along with the premix facilities, creating unique and challenging requirements for the facility designer. The classical approach to handling energetic materials-division into manageable quantities, segregation, and isolation-was not available due to these process requirements and quantities involved. This paper provides a description of the physical facilities, the continuous mix process, and discusses the monitoring and detection techniques used to mitigate hazards and prevent an incident.

Williamson, K. L.↗

NASA NTRS2000

Fully Three-Dimensional Helical RF Field Effects on TWT Interaction

The phenomenal growth of the satellite communications industry has created a large demand for traveling wave-tubes (TWTs) operating with unprecedented specifications requiring design and production of many novel devices in record time. To achieve this, the TWT industry heavily relies upon computational modeling. However, there is a need for improvement in the TWT industry's computational modeling capabilities as there are often discrepancies between measured TWT data and that predicted by conventional two-dimensional helical TWT interaction codes. This severely limits the analysis and design of novel devices or TWTs with parameters differing from what is conventionally manufactured. In addition, the inaccuracy of current computational tools limits achievable TWT performance because optimized designs require highly accurate models. In particular, collector efficiency, which significantly affects overall TWT efficiency, is difficult to optimize unless extremely accurate spent beam data is predicted by the interaction code.

Kory, Carol L.↗

DOE OSTI2021

Probing specificities of alcohol acyltransferases for designer ester biosynthesis with a high–throughput microbial screening platform

Alcohol acyltransferases (AATs) enables microbial biosynthesis of a large space of esters by condensing an alcohol and an acyl-CoA. However, substrate promiscuity of AATs prevents microbial biosynthesis of designer esters with high selectivity. Here, we developed a high-throughput microbial screening platform that facilitates rapid identification of AATs for designer ester biosynthesis. First, we established a microplate-based culturing technique with in situ fermentation and extraction of esters. We validated its capability in rapid profiling of the alcohol substrate specificity of 20 chloramphenicol acetyltransferase variants derived from Staphylococcus aureus (CAT Sa ) for microbial biosynthesis of acetate esters with various exogeneous alcohol supply. By coupling the microplate-based culturing technique with a previously established colorimetric assay, we developed a high-throughput microbial screening platform for AATs. We demonstrated that this platform could not only probe the alcohol substrate specificity of both native and engineered AATs but also identify the beneficial mutations in engineered AATs for enhanced ester synthesis. Here, we anticipate the high-throughput microbial screening platform provides a useful tool to identify novel wildtype and engineered AATs that have important roles in nature and industrial biocatalysis for designer bioester production.

2-phenhylethyl acetate↗

NASA NTRS1991

Space system production cost benefits from contemporary philosophies in management and manufacturing

The cost of manufacturing space system hardware has always been expensive. The Engineering Cost Group of the Program Planning office at Marshall is attempting to account for cost savings that result from new technologies in manufacturing and management. The objective is to identify and define contemporary philosophies in manufacturing and management. The seven broad categories that make up the areas where technological advances can assist in reducing space system costs are illustrated. Included within these broad categories is a list of the processes or techniques that specifically provide the cost savings within todays design, test, production and operations environments. The processes and techniques listed achieve savings in the following manner: increased productivity; reduced down time; reduced scrap; reduced rework; reduced man hours; and reduced material costs. In addition, it should be noted that cost savings from production and processing improvements effect 20 to 40 pct. of production costs whereas savings from management improvements effects 60 to 80 of production cost. This is important because most efforts in reducing costs are spent trying to reduce cost in the production.

Rosmait, Russell L.↗

NASA NTRS1983

Overview of the Integrated Programs for Aerospace Vehicle Design (IPAD) project

To respond to national needs for improved productivity in engineering design and manufacturing, a NASA supported joint industry/government project is underway denoted Integrated Programs for Aerospace Vehicle Design (IPAD). The objective is to improve engineering productivity through better use of computer technology. It focuses on development of data base management technology and associated software for integrated company wide management of engineering and manufacturing information. Results to date on the IPAD project include an in depth documentation of a representative design process for a large engineering project, the definition and design of computer aided design software needed to support that process, and the release of prototype software to manage engineering information. This paper provides an overview of the IPAD project and summarizes progress to date and future plans.

Venneri, S. L.↗

NASA NTRSDate not supplied

Additive Manufacturing: Disrupting Global Supply Chains and Enabling Sustainable Development

The integration of new materials and innovative manufacturing technologies into product supply chains are critically needed to address human and societal needs and to promote sustainable development and economic competitiveness. Recently, there has been tremendous growth in the additive manufacturing (AM) landscape with the introduction of high- end machines suitable for industrial applications. In addition, availability of desktop 3-D printers as well as open source printers and platforms have also facilitated the large scale growth of distributed manufacturing. The paradigm shift in thinking, where one can turn their design into product on demand, is leading to new business models and challenging traditional models of product development and distribution. In this presentation, an overview of different AM technologies will be provided along with technical challenges and opportunities. Various examples of materials (polymers, ceramics, metals, hybrids, and multi material systems) and structures achieved from utilizing a wide variety of additive manufacturing approaches will be provided. Technical challenges and opportunities for the utilization of additive manufacturing as a powerful enabler for sustainable development and disruptive technological threat to global supply chains for different materials and systems will be presented.

Additive Manufacturing↗

DOE OSTI2023

Defining a compact dry cooler design to reduce LCOE contribution in a CSP facility

Concentrating solar power (CSP), when coupled with a supercritical carbon dioxide (sCO 2 ) power cycle and sensible heat storage, presents a renewable and clean alternative for utility-scale power generation. However, in order to be competitive in the current and future markets, CSP facilities must limit their levelized cost of electricity (LCOE) by minimizing capital costs and reducing operating costs over the lifetime of the plant. Targeting this goal, this study investigates the LCOE impact of the power cycle pre-cooler. This study considers a compact dry cooler with micro-channel technology on the CO 2 side and formed fin geometry on the air side, using directly-coupled centrifugal fans and a transition duct to improve air distribution across the fins as well as protect the fins from contaminants which may cause blockage, soiling, fouling, and damage. In an effort to better understand the dry cooler impact on LCOE, a sensitivity study was conducted using various combinations of end-to-end approach temperatures, air-side pressure drop values, CO 2 -side pressure drop values, fan types, cooler turndown control schemes, cooler module sizes, and design-point ambient temperatures. Furthemore, off-design cycle performance data was calculated for each dry cooler design using NPSS simulation software; cycle performance data were then input to System Advisor Model (SAM) along with the associated capital costs for LCOE prediction of a 100 MW system over a 30 year plant lifetime. Results of this study show the LCOE is most sensitive to air-side performance, followed by heat transfer effectiveness and capital cost. It was found that a power cycle with a mid- to high-performance dry cooler will produce the most competitive power-production costs. Designing at the extreme ends for approach temperature (or effectiveness), design-point ambient temperature, and compactness (footprint) produce higher LCOE values; mid-range values for these parameters balance performance, operating costs, and associated capital cost to optimize LCOE.

14 SOLAR ENERGY↗

NASA NTRS2009

A Real-Time Microwave Camera at K-Band (24 GHz)

Nondestructive testing (NDT) community has been moving towards effective and robust inspection systems that can provide real-time information about materials, geometrical, structural and mechanical characteristics of composite materials/structures. Moreover, in many applications it is desired to have an image of the structure, after which the information contained in the image is correlated to the above characteristics. Microwave signals penetrate inside of dielectric composite structures and their interaction with the interior of the structure renders critical information for NDT purposes. Subsequently, this information (i.e., magnitude and phase or reflected signal) may be used to produce an image of the interior of the structure revealing potential flaws or anomalies. Image processing and reconstruction techniques may also be incorporated to produce high-resolution images (i.e., synthetic-aperture, back-propagation, etc.). There are several different approaches for designing areal-time microwave camera system. One approach is based on modulated scatterer technique (MST), which is used to tag scattered electric field in a discrete two-dimensional (2D) spatial domain (e.g. a retina) resulting in the 2D magnitude and phase distribution of the scattered electric field which is required for producing an image of a material or structure under inspection. The ability to rapidly modulate resonant slot antennas in such a retina along with using receivers with fast responses provide for real-time image production capability. Design issue and criteria become more challenging at higher frequencies and for a relatively large retina size. This paper presents the basic design and challenges for a microwave camera with a retina size of 6" by 6" operating at a frequency of 24 GHz.

Ghasr, M. T.↗

DOE OSTI2020

Design Advancement of an Indoor Soil Deposition Chamber: A Road to Standardization

An indoor soil deposition chamber has been designed and constructed at the Arizona State University Photovoltaic Reliability Lab (ASU-PRL) to simulate photovoltaic (PV) module soiling in the field. This paper discusses the next set of revisions to the design, which are organized into three categories: design improvements, cost reduction, and new features. The design process was carried out with the intention of working toward the development of a national or international soiling standard. The improvements made to the chamber are described in detail to provide a guide for other laboratories or research facilities who wish to study photovoltaic (PV) soiling.

14 SOLAR ENERGY↗

DOE OSTI2024

Design And Control of Thermal Storage for Ventilative Cooling in Multifamily Buildings (Final Report)

The concept of natural ventilation is to provide a heat sink for cooling the building during the occupancy periods at night and improve indoor thermal comfort during the daytime without or with minimal need for mechanical cooling. Commonly, natural ventilation through the window or mechanical circulation of the air through the ventilation ducts are two key methods used to achieve night ventilation. Due to the increasing electric need for space heating and cooling, renewable energies combined with energy storage systems are receiving attention worldwide nowadays. When designed and controlled properly, this strategy can reduce energy use for cooling, reduce the size of mechanical cooling equipment, reduce peak electrical demand for cooling, and better enable demand flexibility for mechanical cooling equipment. In some cases, ventilative cooling can eliminate the need for mechanical cooling altogether. For these reasons, California’s Building Energy Efficiency Standards have recently added prescriptive requirements that all new single-family residences (in most California climates) must include ventilative cooling systems (aka: “whole house fans”). However, the current standards do not address multifamily buildings because market-available ventilative cooling products are designed for single-family residences and are physically incompatible with many multifamily building archetypes. The results from the study show that the combination of thermal energy storage on building walls along with nighttime ventilation cooling assisted with nighttime ventilation can save total building energy usage by up to 9% and peak load by 16% in moderate climate zones. The controlled nighttime ventilation cooling (activate ventilation only when outdoor conditions are favorable) can also provide total electricity savings of up to 5% and 7% in hot and cold climates, respectively. In the case of moderate climates, kitchen exhaust-assisted nighttime ventilation cooling can eliminate the need for cooling during overnight hours. This can also significantly assist in reducing carbon emissions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗