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DOE OSTI2023

Solar Decathlon Education Partner: Cooperative Research and Development Final Report

The U.S. Department of Energy Solar Decathlon (DOE/SD) is a collegiate competition, comprising 10 contests, that challenges student teams to design and build highly efficient and innovative buildings powered by renewable energy. The winners will be those teams that best blend architectural and engineering excellence with innovation, market potential, building efficiency, and smart energy production. Solar Decathlon is comprised of two Challenges - Design Challenge (annual) and Build Challenge (biennial). The National Renewable Energy Laboratory (NREL) provides competition management for Solar Decathlon. NREL and Participant establish this CRADA to enable the success of the Solar Decathlon program in managing sponsorship funds and creating a K12 education program. Participant is to act as an Education Partner to Solar Decathlon, which includes: 1) accepting and dispersing sponsorship funds for DOE/SD; and 2) providing K12 education program to support Solar Decathlon Competition Events in April each year.

14 SOLAR ENERGY↗

NASA NTRS1971

Meeting the challenge of a 50000-hour-life-time requirement

Space mission requirements for the 70's have established a 50,000-hour-lifetime challenge for the mechanisms designer. This challenge may be met by two approaches: (1) development of new materials for wear-prone elements, and (2) design innovation of new electromechanical devices that do not include mechanical wear-prone components. Present state-of-the-art materials require restricted operation regarding load, speed, and power for gears, bearings, and brush-slipring components. These restrictions are discussed, and methods of improvement are suggested. The design-innovations approach is discussed and is illustrated by the design of an experimental magnetically suspended motor.

Vest, C. E.↗

NASA NTRSDate not supplied

Designing A Lunar Terrain Vehicle: Thermal Challenges

The Lunar Terrain Vehicle (LTV) is an unpressurized rover that will be used to transport astronauts on the South Pole of the moon under the Artemis Program. The National Aeronautics and Space Administration (NASA) will be partnering with an American industry partner to develop the LTV. This paper discusses the thermal challenges faced when designing a crewed lunar vehicle concept and shares a concept that addresses these constraints. One of the most difficult aspects of the design is surviving the cold lunar night on the South Pole which includes permanently shadowed regions (PSR) that can have an extended lunar night duration of 125 hours. Other challenges are critical component temperature limits and programmatic constraints.

Zaida Y. Hernandez↗

NASA NTRS2006

Innovative Trajectory Designs to meet Exploration Challenges

This document is a viewgraph presentation of the conference paper. Missions incorporated into NASA's Vision for Space Exploration include many different destinations and regions; are challenging to plan; and need new and innovative trajectory design methods to enable them. By combining proven methods with chaos dynamics, exploration goals that require maximum payload mass or minimum duration can be achieved. The implementation of these innovative methods, such as weak stability boundaries, has altered NASA's approach to meet exploration challenges and is described to show how exploration goals may be met in the next decade. With knowledge that various perturbations play a significant role, the mission designer must rely on both traditional design strategies as well as these innovative methods. Over the past decades, improvements have been made that would at first glance seem dramatic. This paper provides a brief narrative on how a fundamental shift has occurred and how chaos dynamics improve the design of exploration missions with complex constraints.

Folta, David C.↗

NASA NTRS1998

X-33 Attitude Control System Design for Ascent, Transition, and Entry Flight Regimes

The Vehicle Control Systems Team at Marshall Space Flight Center, Systems Dynamics Laboratory, Guidance and Control Systems Division is designing under a cooperative agreement with Lockheed Martin Skunkworks, the Ascent, Transition, and Entry flight attitude control system for the X-33 experimental vehicle. Ascent flight control begins at liftoff and ends at linear aerospike main engine cutoff (NECO) while Transition and Entry flight control begins at MECO and concludes at the terminal area energy management (TAEM) interface. TAEM occurs at approximately Mach 3.0. This task includes not only the design of the vehicle attitude control systems but also the development of requirements for attitude control system components and subsystems. The X-33 attitude control system design is challenged by a short design cycle, the design environment (Mach 0 to about Mach 15), and the X-33 incremental test philosophy. The X-33 design-to-launch cycle of less than 3 years requires a concurrent design approach while the test philosophy requires design adaptation to vehicle variations that are a function of Mach number and mission profile. The flight attitude control system must deal with the mixing of aerosurfaces, reaction control thrusters, and linear aerospike engine control effectors and handle parasitic effects such as vehicle flexibility and propellant sloshing from the uniquely shaped propellant tanks. The attitude control system design is, as usual, closely linked to many other subsystems and must deal with constraints and requirements from these subsystems.

Hall, Charles E.↗

NASA NTRS2006

The Role of Flight Experiments in the Development of Cryogenic Fluid Management Technologies

This paper reviews the history of cryogenic fluid management technology development and infusion into both the Saturn and Centaur vehicles. Ground testing and analysis proved inadequate to demonstrate full scale performance. As a consequence flight demonstration with a full scale vehicle was required by both the Saturn and Centaur programs to build confidence that problems were addressed. However; the flight vehicles were highly limited on flight instrumentation and the flight demonstration locked-in the design without challenging the function of design elements. Projects reviewed include: the Aerobee Sounding Rocket Cryogenic Fluid Management (CFM) tests which served as a valuable stepping stone to flight demonstration and built confidence in the ability to handle hydrogen in low gravity; the Saturn IVB Fluid Management Qualification flight test; the Atlas Centaur demonstration flights to develop two burn capability; and finally the Titan Centaur two post mission flight tests.

Chato, David J.↗

NASA NTRSDate not supplied

Designing a Software Architecture for the Precision Assembly of Space Structures

As NASA’s space exploration and science missions expand in complexity, longevity, anddistance beyond earth’s orbit, Orbital Servicing, Assembly and Manufacturing (OSAM)technologies and concepts have become a critical area of ongoing research and innovation.Artemis’ Moon-to-Mars goals of building sustainable elements on and around the Moon andMars that allow our robots and astronauts to explore and conduct more scientific researchwill demand in situ resource utilization, construction, and maintenance to succeed. In-spaceAssembly (ISA), as a sub-component of OSAM, focuses on the on-orbit building or fabricationof mission infrastructure and payloads. One such ISA application is highlighted by the recentNASA In-Space Assembled Telescope (iSAT) study, which stated that the next generation ofspace observatories will exceed the fairing size of existing or even planned launch vehicles andISA has emerged as a viable approach for observatory assembly. Research efforts at NASALangley Research Center have led to the design of a novel TriTruss structural concept for themodular construction of large complex persistent platforms. The TriTruss design and otherdeveloping OSAM technologies enable larger and persistent space missions that would notbe possible with single-launch-sized structures. For example, 20 meter or larger telescopesor orbital platform applications. However, the increased complexity will require autonomousoperations for the construction and maintenance of long-term infrastructure to achieve missionsuccess. NASA’s Precision Assembly of Space Structures (PASS) project is focused on thestructural and autonomy capabilities required to construct an iSAT in deep space. PASSresearch efforts will develop and validate critical technologies needed for effective efficienton-orbit assembly that can be confidently adopted for future systems. PASS will utilize theTriTruss modules to demonstrate the autonomous modular assembly of a 20m-class iSAT mirrorbackbone structure including simulated mirrors and wiring harness. In this paper, we addressthe software and hardware design considerations, technologies, and challenges of designing arobust robotics framework for assembling modular space structures in support of In SpaceAssembly missions in general as well as for PASS specifically.

Benjamin N Kelley↗

NASA NTRS1973

Influence of noise constraints on supersonic transport engine design

The challenge to meet or better FAR 36 noise level requirements is particularly difficult in the SST due to the relatively high jet velocities required to give an acceptable supersonic powerplant. This requires careful tailoring of the powerplant cycle to give good flight performance with a jet velocity low enough to meet the noise requirements with a practical jet noise suppressor. The effect on engine cycle selection of meeting various noise levels will be reviewed. The range of engine cycles will cover turbojet and turbofan cycles, as well as variable cycle engines. The selection of the cycle parameters such as turbine temperature, bypass ratio, and fan pressure ratio as required to meet various noise levels will be reviewed. The effect on the engine design of jet noise suppression and engine acoustic treatment will also be reviewed. The impact of designing the engines at the different noise levels will be evaluated on an overall supersonic transport systems basis.

Hines, R. W.↗

NASA NTRS1981

The E3 combustors: Status and challenges

The design, fabrication, and initial testing of energy efficient engine combustors, developed for the next generation of turbofan engines for commercial aircraft, are described. The combustor designs utilize an annular configuration with two zone combustion for low emissions, advanced liners for improved durability, and short, curved-wall, dump prediffusers for compactness. Advanced cooling techniques and segmented construction characterize the advanced liners. Linear segments are made from castable, turbine-type materials.

Sokolowski, D. E.↗

NASA NTRS2014

Asteroid Crewed Segment Mission Lean Development

The next generation of human spaceflight missions presents numerous challenges to designers that must be addressed to produce a feasible concept. The specific challenges of designing an exploration mission utilizing the Space Launch System and the Orion spacecraft to carry astronauts beyond earth orbit to explore an asteroid stored in a distant retrograde orbit around the moon will be addressed. Mission designers must carefully balance competing constraints including cost, schedule, risk, and numerous spacecraft performance metrics including launch mass, nominal landed mass, abort landed mass, mission duration, consumable limits and many others. The Asteroid Redirect Crewed Mission will be described along with results from the concurrent mission design trades that led to its formulation. While the trades presented are specific to this mission, the integrated process is applicable to any potential future mission. The following trades were critical in the mission formulation and will be described in detail: 1) crew size, 2) mission duration, 3) trajectory design, 4) docking vs grapple, 5) extravehicular activity tasks, 6) launch mass and integrated vehicle performance, 7) contingency performance, 8) crew consumables including food, clothing, oxygen, nitrogen and water, and 9) mission risk. The additional Orion functionality required to perform the Asteroid Redirect Crewed Mission and how it is incorporated while minimizing cost, schedule and mass impacts will be identified. Existing investments in the NASA technology portfolio were leveraged to provide the added functionality that will be beneficial to future exploration missions. Mission kits are utilized to augment Orion with the necessary functionality without introducing costly new requirements to the mature Orion spacecraft design effort. The Asteroid Redirect Crewed Mission provides an exciting early mission for the Orion and SLS while providing a stepping stone to even more ambitious missions in the future.

Gard, Joe↗

DOE OSTI2020

Transformational Challenge Reactor preconceptual core design studies

In the nuclear industry, a manufacturing-informed design approach has the potential to yield the most benefit from advanced manufacturing. By leveraging advanced materials, data science, and rapid testing and deployment, manufacturing-informed design can drive down costs and development times, ultimately improving future commercial viability. This approach is being demonstrated in the US Department of Energy Office of Nuclear Energy (DOE-NE) Transformational Challenge Reactor (TCR) program. Preconceptual design activities for TCR have been focused on analyzing and maturing four reactor core design concepts: two fast-spectrum and two thermal-spectrum systems. Furthermore, the designs were iteratively modified and analyzed, and subcomponents were manufactured in parallel over weeks instead of months or years. To meet key program initiatives (e.g., timeline and material use), several constraints—including fissile material availability, component availability, materials compatibility, and additive manufacturing capabilities—were factored into the design effort, yielding small cores less than one cubic meter in volume with near-term viability. Additionally, the TCR program has made significant progress on development of advanced moderator materials such as yttrium hydride, advancing the feasibility of gas-cooled thermal spectrum systems using less than 250 kg of high-assay low enriched uranium (HALEU) and occupying less than 1 m3. Each of the two resulting thermal designs uses a different fuel form: traditional UO2 ceramic fuel and tristructural isotropic (advanced TRISO) fuel particles embedded inside a SiC matrix. Core neutronics and thermal performance for these systems were assessed and summarized. Evaluation of the performance metrics for these two moderated designs has yielded the downselected TCR design: a TRISO-fueled and yttrium hydride moderated gas-cooled reactor.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Conceptual Design of the Transformational Challenge Reactor

The Transformational Challenge Reactor is a 3-MW(thermal) helium-cooled experimental nuclear reactor designed using an additive manufacturing–informed agile design process. This design process leverages rapid prototyping and advanced materials from emerging additive manufacturing technologies, key characteristics that enable rapid design maturation. The resulting core design incorporates a blend of advanced reactor technologies into an intermediate-spectrum microreactor, including conventionally manufactured tristructural isotropic (TRISO) fuel particles in an advanced manufactured SiC fuel element and a solid yttrium hydride moderator encapsulated in steel. Matured during the design effort, these technologies are incorporated with additively manufactured steel support and fluidic structures to form a 75-cm-outer-diameter cylindrical active core region. Below and above the active core region are axial SiC reflectors, which are housed inside the reactor pressure vessel. The reactor is controlled with an annular shroud actuated external to the pressure vessel in the gap between the pressure vessel and a steel radial reflector. A safety rod is at the center of the core to shut down the reactor when necessary. Helium pressurized at 5 MPa is forced into the pressure vessel below the core and around the core to the top plenum before it is forced down through the axial reflectors and the active core region. The primary pressurized helium loop is operated up to 500°C and includes the pressure vessel, the circulator, and the hot side of a helium-to-air heat exchanger. The secondary loop rejects all heat from the primary loop to ambient air through a heat exchanger. A vented temporary confinement building contains the entire primary loop, with penetrations for a stack, cooling, and the secondary ambient air loop. Finally, this is the first advanced nuclear microreactor designed using additive manufacturing technologies, demonstrating their applicability in an accelerated advanced design process.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS2017

Human Mars Mission Design - The Ultimate Systems Challenge

A human mission to Mars will occur at some time in the coming decades. When it does, it will be the end result of a complex network of interconnected design choices, systems analyses, technical optimizations, and non-technical compromises. This mission will extend the technologies, engineering design, and systems analyses to new limits, and may very well be the most complex undertaking in human history. It can be illustrated as a large menu, or as a large decision tree. Whatever the visualization tool, there are numerous design decisions required to assemble a human Mars mission, and many of these interconnect with one another. This paper examines these many decisions and further details a number of choices that are highly interwoven throughout the mission design. The large quantity of variables and their interconnectedness results in a highly complex systems challenge, and the paper illustrates how a change in one variable results in ripples (sometimes unintended) throughout many other facets of the design. The paper concludes with a discussion of some mission design variables that can be addressed first, and those that have already been addressed as a result of ongoing National Aeronautics and Space Administration (NASA) developments, or as a result of decisions outside the technical arena. It advocates the need for a 'reference design' that can be used as a point of comparison, and to illustrate the system-wide impacts as design variables change.

Connolly, John F.↗

DOE OSTI2022

Lattice QCD and the Computational Frontier

The search for new physics requires a joint experimental and theoretical effort. Lattice QCD is already an essential tool for obtaining precise model-free theoretical predictions of the hadronic processes underlying many key experimental searches, such as those involving heavy flavor physics, the anomalous magnetic moment of the muon, nucleon-neutrino scattering, and rare, second-order electroweak processes. As experimental measurements become more precise over the next decade, lattice QCD will play an increasing role in providing the needed matching theoretical precision. Achieving the needed precision requires simulations with lattices with substantially increased resolution. As we push to finer lattice spacing we encounter an array of new challenges. They include algorithmic and software-engineering challenges, challenges in computer technology and design, and challenges in maintaining the necessary human resources. In this white paper we describe those challenges and discuss ways they are being dealt with. Overcoming them is key to supporting the community effort required to deliver the needed theoretical support for experiments in the coming decade.

Boyle, Peter↗

NASA NTRS2010

Practical Loop-Shaping Design of Feedback Control Systems

An improved methodology for designing feedback control systems has been developed based on systematically shaping the loop gain of the system to meet performance requirements such as stability margins, disturbance attenuation, and transient response, while taking into account the actuation system limitations such as actuation rates and range. Loop-shaping for controls design is not new, but past techniques do not directly address how to systematically design the controller to maximize its performance. As a result, classical feedback control systems are designed predominantly using ad hoc control design approaches such as proportional integral derivative (PID), normally satisfied when a workable solution is achieved, without a good understanding of how to maximize the effectiveness of the control design in terms of competing performance requirements, in relation to the limitations of the plant design. The conception of this improved methodology was motivated by challenges in designing control systems of the types needed for supersonic propulsion. But the methodology is generally applicable to any classical control-system design where the transfer function of the plant is known or can be evaluated. In the case of a supersonic aerospace vehicle, a major challenge is to design the system to attenuate anticipated external and internal disturbances, using such actuators as fuel injectors and valves, bypass doors, and ramps, all of which are subject to limitations in actuator response, rates, and ranges. Also, for supersonic vehicles, with long slim type of structures, coupling between the engine and the structural dynamics can produce undesirable effects that could adversely affect vehicle stability and ride quality. In order to design distributed controls that can suppress these potential adverse effects, within the full capabilities of the actuation system, it is important to employ a systematic control design methodology such as this that can maximize the effectiveness of the control design in a methodical and quantifiable way. The emphasis is in generating simple but rather powerful design techniques that will allow even designers with a layman s knowledge in controls to develop effective feedback control designs. Unlike conventional ad hoc methodologies of feedback control design, in this approach actuator rates are incorporated into the design right from the start: The relation between actuator speeds and the desired control bandwidth of the system is established explicitly. The technique developed is demonstrated via design examples in a step-by-step tutorial way. Given the actuation system rates and range limits together with design specifications in terms of stability margins, disturbance rejection, and transient response, the procedure involves designing the feedback loop gain to meet the requirements and maximizing the control system effectiveness, without exceeding the actuation system limits and saturating the controller. Then knowing the plant transfer function, the procedure involves designing the controller so that the controller transfer function together with the plant transfer function equate to the designed loop gain. The technique also shows what the limitations of the controller design are and how to trade competing design requirements such as stability margins and disturbance rejection. Finally, the technique is contrasted against other more familiar control design techniques, like PID control, to show its advantages.

Kopasakis, George↗

DOE OSTI2024

Simultaneous enhancement of multiple functional properties using evolution-informed protein design

Abstract A major challenge in protein design is to augment existing functional proteins with multiple property enhancements. Altering several properties likely necessitates numerous primary sequence changes, and novel methods are needed to accurately predict combinations of mutations that maintain or enhance function. Models of sequence co-variation (e.g., EVcouplings), which leverage extensive information about various protein properties and activities from homologous protein sequences, have proven effective for many applications including structure determination and mutation effect prediction. We apply EVcouplings to computationally design variants of the model protein TEM-1 β -lactamase. Nearly all the 14 experimentally characterized designs were functional, including one with 84 mutations from the nearest natural homolog. The designs also had large increases in thermostability, increased activity on multiple substrates, and nearly identical structure to the wild type enzyme. This study highlights the efficacy of evolutionary models in guiding large sequence alterations to generate functional diversity for protein design applications.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2025

National Energy Education Development Project (NEED Project) (CRADA Final Report)

The U.S. Department of Energy Building Technologies Office (BTO) funds student competitions that introduce students to careers in the building sciences and increase public awareness around high-performance buildings to support the goal of developing, demonstrating, and accelerating the adoption of cost-effective technologies, techniques, tools, and services that enable high-performing, energy-efficient and demand-flexible residential and commercial buildings in both the new and existing buildings markets. The U.S. Department of Energy Solar Decathlon® (DOE/SD) is a flagship, high-visibility international competition started in 2002 that advances the goals of BTO by introducing students to building science careers; educating students and the public about the latest technologies and materials in high-performance buildings; encouraging student-led projects and research centered around building science; and demonstrating to the public the comfort and savings of homes that combine energy-efficient construction, home systems, appliances and innovative design with onsite renewable energy production. SD is a collegiate competition, comprising 10 contests, that challenges student teams to design and build highly efficient and innovative buildings powered by renewable energy. The winners will be those teams that best blend architectural and engineering excellence with innovation, market potential, building efficiency, and smart energy production. Solar Decathlon is comprised of two Challenges – Design Challenge (annual) and Build Challenge (biennial). The National Renewable Energy Laboratory (NREL) provides competition management for Solar Decathlon. NREL and Participant establish this CRADA to enable the success of the overall Solar Decathlon program by managing sponsorship funds and creating a K12 education program. Participant is to act as an Education Partner to Solar Decathlon, which includes: 1) accepting and dispersing sponsorship funds for DOE/SD; and 2) providing K12 education program to support Solar Decathlon Competition Events in April each year.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1985

Design evolution of the orbiter reaction control subsystem

The challenges of space shuttle orbiter reaction control subsystem development began with selection of the propellant for the subsystem. Various concepts were evaluated before the current Earth storable, bipropellant combination was selected. Once that task was accomplished, additional challenges of designing the system to satisfy the wide range of requirements dictated by operating environments, reusability, and long life were met. Verification of system adequacy was achieved by means of a combination of analysis and test. The studies, the design efforts, and the test and analysis techniques employed in meeting the challenges are described.

Taeber, R. J.↗