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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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DOE OSTI2022

Environmental Benefits of Closing the Solar Manufacturing and Recycling Loop: Preparation of Solar Manufacturing Inventories

The cumulative global solar panel waste stream is projected to reach between 60 and 78 million tonnes by 2050. Steps towards developing, demonstrating, and implementing processes that recover glass, metals, and semiconductor materials from end-of-life solar panels have already been taken. However, these processes result in the downcycling of most secondary solar materials. Critically, the costs and benefits of capturing these secondary materials for use in new solar panels are unknown. To evaluate the environmental benefit associated with solar material recycling and reuse in next generation panels, prior inventories must be updated and prepared for integration with recycling processes to examine the benefit of closing the material loop between solar panel end-of-life and new panel manufacturing. This current work describes steps taken to upgrade existing inventories that detail the manufacturing of cadmium-telluride (CdTe) panels from the Ecoinvent -v2.2 life cycle inventory database to Ecoinvent -v3. During this update, material inventories were modified to capture different realistic material supply chains within the constraints of Ecoinvent -v3. Materials discussed in detail in this work include primary flat glass, aluminum, steel, copper, and CdTe. This work demonstrated that environmental indicators such as embodied carbon, acidification, and terrestrial eutrophication associated with solar panel production can be reduced by 25% to over 40% through improved primary material sourcing.

CdTe solar panels↗

DOE OSTI2025

Developing Fluorescence-Based Sensors to Support Rare Earth Element Separation

Rare earth elements (REEs) are essential to most renewable energy technologies. Unfortunately, as we transition to sustainable energy production, the demand for REEs is rapidly growing well beyond current rates of production. As a result, novel means of efficient, scalable, and easily adaptable methods for processing primary and recycle feedstocks are needed. Development and integration of sensors for highly selective in-line monitoring can support more efficient design and testing of such novel separation processes, as well as more cost-effective deployment of those separation flowsheets. Work here will explore the application of fluorescence spectroscopy, a highly sensitive and selective technique, to quantify multiple lanthanides in complex mixtures including known interferents or quenching agents. Results include identification of the optimal excitation wavelength and the limit of detection of various rare earth elements as well as the performance of data-science-based quantification approaches in streams where “unknowns” are present. Overall, the data science tools in conjunction with optical sensor data were able to quantify analytes in the presence of other lanthanides which can be anticipated in the actual industrial stream. Here we include characterization of lanthanides in a microfluidic device similar to those used in new process development. This study demonstrates the capability of utilizing fluorescence spectroscopy to quantify analytes in a complicated solution matrix, suggesting this is a successful approach for in-line monitoring to optimize the separation efficiency in an industrial stream.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1978

Development of fire-resistant, low smoke generating, thermally stable end items for aircraft and spacecraft

A new approach to the problem of flammability by the use of materials obtained from foamy polyimide resins is developed. The ability of these materials to provide fire protection is demonstrated. The development of processes for producing resilient cell foam for use in aircraft seating, thermal acoustical insulation, floor and wall panels, coated glass fabrics, and molded hardware.

Gagliani, J.↗

NASA NTRS1994

Using formal specification in the Guidance and Control Software (GCS) experiment. Formal design and verification technology for life critical systems

The goal of this task was to investigate how formal methods could be incorporated into a software engineering process for flight-control systems under DO-178B and to demonstrate that process by developing a formal specification for NASA's Guidance and Controls Software (GCS) Experiment. GCS is software to control the descent of a spacecraft onto a planet's surface. The GCS example is simplified from a real example spacecraft, but exhibits the characteristics of realistic spacecraft control software. The formal specification is written in Larch.

Weber, Doug↗

NASA NTRS1994

An integrated optical CO2 sensor. Phase 0: Design and fabrication of critical elements

Significant progress has been made toward all of the goals for the first phase of the project short of actual fabrication of a light path. Two alternative approaches to fabricating gold mirrors using the basic LIGA process were developed, one using electroplated solid gold mirrors and the second using gold plated over a nickel base. A new method of fabrication, the transfer mask process, was developed and demonstrated. Analysis of the projected surface roughness and beam divergence effects was completed. With gold surface with low surface roughness scattering losses are expected to be insignificant. Beam divergence due to diffraction will require a modification of the original design, but should be eliminated by fabricating mirrors 1000 mu m in height by 1000 mu m in width and using a source with an initial beam radius greater than 300 mu m. This may eliminate any need for focusing optics. Since the modified design does not affect the mask layout, ordering of the mask and fabrication of the test structures can begin immediately at the start of Phase 1.

Murphy, Michael C.↗

NASA NTRS2000

T1 VSAT Fade Compensation Statistical Results

New satellite communication systems are steadily seeking to use higher frequency bands to accommodate the requirements for additional capacity. At these higher frequencies, propagation impairments that did not significantly affect the signal at lower frequencies begin to have considerable impact. In Ka-band. the next logical commercial frequency band to be used for satellite communication, attenuation of the signal due to rain is a primary concern. An experimental satellite built by NASA, the Advanced Communication Technology Satellite (ACTS). launched in September 1993, is the first U.S. communication satellite operating in the Ka-band. In addition to higher carrier frequencies, a number of other new technologies, including on-board baseband processing. multiple beam antennas, and rain fade detection and compensation techniques, were designed into the ACTS. Verification experiments have been conducted since the launch to characterize the new technologies. The focus of this paper is to characterize the method used by the ACTS TI Very Small Aperture Terminal (TI VSAT) ground stations in detecting the presence of fade in the communication signal and to adaptively compensate for it by the addition of burst rate reduction and forward error correction. Measured data obtained from the ACTS program was used to validate the compensation technique. A software process was developed and demonstrated to statistically characterize the increased availability achieved by the compensation techniques in terms of the bit error rate time enhancement factor. Several improvements to the ACTS technique are discussed and possible implementations for future Ka band system are offered.

Johnson, Sandra K.↗

NASA NTRS2001

Large Composite Structures Processing Technologies for Reusable Launch Vehicles

Significant efforts have been devoted to establishing the technology foundation to enable the progression to large scale composite structures fabrication. We are not capable today of fabricating many of the composite structures envisioned for the second generation reusable launch vehicle (RLV). Conventional 'aerospace' manufacturing and processing methodologies (fiber placement, autoclave, tooling) will require substantial investment and lead time to scale-up. Out-of-autoclave process techniques will require aggressive efforts to mature the selected technologies and to scale up. Focused composite processing technology development and demonstration programs utilizing the building block approach are required to enable envisioned second generation RLV large composite structures applications. Government/industry partnerships have demonstrated success in this area and represent best combination of skills and capabilities to achieve this goal.

Clinton, R. G., Jr.↗

NASA NTRSDate not supplied

System-Theoretic Analysis of Unsafe Collaborative Control in Teaming Systems

The interactions that occur in human-teaming are inspiring novel aerospace designs aimed at improving how humans and machines, or multiple machines, work together. Unfortunately, current Systems Engineering processes are ill-equipped to handle these complex relationships and are unable to design and assure the safety for these systems. To close part of this gap, this paper introduces a novel system-theoretic analytical process to identify unsafe collaborative control actions. It is part of a broader set of techniques that extend the state-of-the-art in hazard analysis, System Theoretic Process Analysis (STPA), to systematically address collaboration. The method rigorously expresses the different ways multiple commands may be unsafe together. Using Systems Theory, it employs abstraction to manage the combinatorial complexity in enumerating control contributions from multiple collaborating components. An algorithm integrates these concepts into an end-to-end process and is supported by automation to enumerate, refine, prune, and prioritize unsafe combinations of control actions. The output of the method feeds the specification of system requirements to implement safety-guided design starting early in concept development. The process is demonstrated on a manned-unmanned aircraft teaming case study and finds new causal factors that were not previously found in a past hazard analysis of the same system.

System Safety↗

NASA NTRS1992

Framework Programmable Platform for the Advanced Software Development Workstation (FPP/ASDW). Demonstration framework document. Volume 2: Framework process description

In the second volume of the Demonstration Framework Document, the graphical representation of the demonstration framework is given. This second document was created to facilitate the reading and comprehension of the demonstration framework. It is designed to be viewed in parallel with Section 4.2 of the first volume to help give a picture of the relationships between the UOB's (Unit of Behavior) of the model. The model is quite large and the design team felt that this form of presentation would make it easier for the reader to get a feel for the processes described in this document. The IDEF3 (Process Description Capture Method) diagrams of the processes of an Information System Development are presented. Volume 1 describes the processes and the agents involved with each process, while this volume graphically shows the precedence relationships among the processes.

Mayer, Richard J.↗

DOE OSTI2023

Manufacturing Demonstration Facility: Development and Evaluation of Hybrid Manufacturing Toolpaths

The integration of additive manufacturing (AM) capabilities on Computer Numerical Control (CNC) systems allows for the expansion of additive manufacturing to a wide range of part and tool repair operations. This multi-tasking integration, termed hybrid manufacturing, has been researched by others in the past, and Autodesk has been critical in developing process planning and toolpath algorithms for hybrid systems. Objectives and Tasks: Hybrid manufacturing systems enable both additive and subtractive capabilities in a single manufacturing workcell. These systems have the potential to impact a variety of industries, including the tool and die industry due to their repair, refurbishment, and complex geometry manufacturing capabilities. While there has been significant development of toolpath planning for both subtractive and additive processes independently, there has been little, if any, development of hybrid toolpath planning to integrate both processes during the manufacturing design and toolpath generation stage of a product’s lifecycle. Furthermore, additive toolpath planning has been limited to planar manufacturing, but this limitation could be overcome as hybrid CNC machines have multi-axis control. The objectives of this research include: - Development and demonstration of independent three-, four-, and five-axis toolpath generation algorithms for both additive and subtractive processes, and - Development, demonstration, and integration of three-, four-, and five-axis hybrid process planning and toolpath generation algorithms for hybrid additive and subtractive processes. The team will leverage the widely used Autodesk Fusion 360 product design and manufacturing (CAD/CAM) platform to achieve these objectives. Autodesk will provide the expertise in CAD tools, as well as access to their new CAD/CAM manufacturing tools (3-, 4-, and 5-axis milling, additive toolpath generation). ORNL will provide expertise in additive manufacturing toolpath generation, process planning, and manufacturing validation. By the end of the program, the team will have developed and validated multi-axis milling, additive manufacturing, and hybrid manufacturing on an industrial hybrid CNC system (Mazak 500-VC).

42 ENGINEERING↗

NASA NTRS1997

Insoluble Coatings for Stirling Engine Heat Pipe Condenser Surfaces

The principal objective of this Phase 2 SBIR program was to develop and demonstrate a practically insoluble coating for nickel-based superalloys for Stirling engine heat pipe applications. Specific technical objectives of the program were: (1) Determine the solubility corrosion rates for Nickel 200, Inconel 718, and Udimet 72OLI in a simulated Stirling engine heat pipe environment, (2) Develop coating processes and techniques for capillary groove and screen wick structures, (3) Evaluate the durability and solubility corrosion rates for capillary groove and screen wick structures coated with an insoluble coating in cylindrical heat pipes operating under Stirling engine conditions, and (4) Design and fabricate a coated full-scale, partial segment of the current Stirling engine heat pipe for the Stirling Space Power Convertor program. The work effort successfully demonstrated a two-step nickel aluminide coating process for groove wick structures and interior wall surfaces in contact with liquid metals; demonstrated a one-step nickel aluminide coating process for nickel screen wick structures; and developed and demonstrated a two-step aluminum-to-nickel aluminide coating process for nickel screen wick structures. In addition, the full-scale, partial segment was fabricated and the interior surfaces and wick structures were coated. The heat pipe was charged with sodium, processed, and scheduled to be life tested for up to ten years as a Phase 3 effort.

Dussinger, Peter M.↗

NASA NTRS2016

Advanced Exploration Systems Atmosphere Resource Recovery and Environmental Monitoring

In September 2011, the Atmosphere Resource Recovery and Environmental Monitoring (ARREM) project was commissioned by NASA's Advanced Exploration Systems program to advance Atmosphere Revitalization Subsystem (ARS) and Environmental Monitoring Subsystem (EMS) technologies for enabling future crewed space exploration missions beyond low Earth orbit. The ARREM project's period of performance covered U.S. Government fiscal years 2012-2014. The ARREM project critically assessed the International Space Station (ISS) ARS and EMS architectures and process technologies as the foundation for an architecture suitable for deep space exploration vehicles. The project's technical content included technical tasks focused on improving the reliability and life cycle cost of ARS and EMS technologies as well as reducing future flight project developmental risk and design, development, test, and evaluation costs. Targeted technology development and maturation tasks, including key technical trade assessments, were accomplished and integrated ARS architectures were demonstrated. The ARREM project developed, demonstrated, and tested leading process technology candidates and subsystem architectures that met or exceeded key figures of merit, addressed capability gaps, and significantly improved the efficiency, safety, and reliability over the state-of-the-art ISS figures of merit. Promising EMS instruments were developed and functionally demonstrated in a simulated cabin environment. The project's technical approach and results are described and recommendations for continued development are provided.

Perry, J.↗

NASA NTRSDate not supplied

The Trash Compaction Processing System (TCPS) Technology Demonstration and Risk Reduction Updates FY23-FY24

The Next STEP Phase BTrash Compaction Processing System (TCPS) is being developed for a technology demonstration on the International Space Station(ISS) to process common spacecraft consumables trash such as food packaging and clothing to reduce trash storage volume, recover water, safen(e.g. reduce biological activity), and shape the trash for storage, jettison, reuse (e.g.,radiation shielding) and/or recycling. Sierra Space is developing the flight demonstration hardware and National Aeronautics and Space Administration(NASA) continues to conduct risk reduction activities to exploreoperational scenarios, setting the stage for successful on-orbit tests. After the flight demonstration on ISS, the TCPS becomes available to be infused into NASA short-and long-term missions.This paper will discuss the rationale for the updated requirement definitions outlined in the 2023 International Conference on Environmental System TCPS paper and the ongoing risk reduction activities. In addition, drawing from lessons learned in the development of the TCPS, a discussion of other compression technologies will be introduced for various mission types.

Trash Compaction Processing System↗

NASA NTRSDate not supplied

The Trash Compaction Processing System (TCPS) Technology Demonstration and Risk Reduction Updates FY23-FY24 Presentation

Trash Compaction Processing System↗

DOE OSTI2025

Crossing the Finish Line: Integration of Data-Driven Process Control for Maximization of Energy and Resource Efficiency in Advanced Water Resource Recovery Facilities

Improvements in process monitoring and control at water resource recovery facilities (WRRFs) could result in reductions in electricity consumption, chemical inputs, and greenhouse gas emissions, as well as improved energy recovery. Many current WRRF data collection, monitoring, and control approaches use 20th century process monitoring and control systems, which require large design safety factors to ensure reliability in the absence of more advanced, precise controls. Implementation of more modern data-driven control tools could lead to more efficient operations that provide intrinsic reliability with better overall process performance at full-scale. This project (1) developed and demonstrated data-driven process controls at full-scale facilities for five promising WRRF process technologies that provide whole-plant approaches and offer substantial energy and resource recovery benefits, and (2) created a Machine Learning (ML) Toolkit and an implementation guide of new process control approaches that walks users through each step of the ML workflow and illustrates the steps through case study examples.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS2011

The MSFC Collaborative Engineering Process for Preliminary Design and Concept Definition Studies

This paper describes a collaborative engineering process developed by the Marshall Space Flight Center's Advanced Concepts Office for performing rapid preliminary design and mission concept definition studies for potential future NASA missions. The process has been developed and demonstrated for a broad range of mission studies including human space exploration missions, space transportation system studies and in-space science missions. The paper will describe the design team structure and specialized analytical tools that have been developed to enable a unique rapid design process. The collaborative engineering process consists of integrated analysis approach for mission definition, vehicle definition and system engineering. The relevance of the collaborative process elements to the standard NASA NPR 7120.1 system engineering process will be demonstrated. The study definition process flow for each study discipline will be will be outlined beginning with the study planning process, followed by definition of ground rules and assumptions, definition of study trades, mission analysis and subsystem analyses leading to a standardized set of mission concept study products. The flexibility of the collaborative engineering design process to accommodate a wide range of study objectives from technology definition and requirements definition to preliminary design studies will be addressed. The paper will also describe the applicability of the collaborative engineering process to include an integrated systems analysis approach for evaluating the functional requirements of evolving system technologies and capabilities needed to meet the needs of future NASA programs.

Mulqueen, Jack↗

NASA NTRS2020

Representation of Modes of Variability in 6 U.S. Climate Models

We compare the performance of several modes of variability across six US climate modeling groups, with a focus on identifying robust improvements in recent models (including those participating in the Coupled Model Intercomparison Project (CMIP) Phase 6) compared to previous versions. In particular, we examine the representation of the Madden-Julian Oscillation (MJO), the El Ni˜no/Southern Oscillation (ENSO), the Pacific Decadal Oscillation (PDO), the Quasi-Biennial Oscillation (QBO) in the tropical stratosphere and the dominant modes of extra-tropical variability, including the Southern Annular Mode (SAM), the Northern Annular Mode (NAM) (and the closely related North Atlantic Oscillation (NAO)), and the Pacific-North American Pattern (PNA). Where feasible, we explore the processes driving these improvements through the use of “intermediary” experiments that utilize model versions between CMIP3/5 and CMIP6 as well as targeted sensitivity experiments in which individual modeling parameters are altered. We find clear and systematic improvements in the MJO and QBO and in the teleconnection patterns associated with the PDO and ENSO. Some gains arise from better process representation, while others (e.g. the QBO) from higher resolution that allows for a greater range of interactions. Our results demonstrate that the incremental development processes in multiple climate model groups lead to more realistic simulations over time.

Modes of variability↗

DOE OSTI2022

Using Incremental Changes to Convert Lignocellulosic Feedstocks to Cellulosic Ethanol

One billion tons of biomass feedstocks have been identified for the production of renewable biofuels and biochemicals. This is one of the key carbon feedstocks to supply energy to the transportation sector for light duty, heavy duty and aviation fuels. Utilization of lignocellulosic feedstocks supports an improved energy security by reducing demand of petroleum imports, agricultural development, job creation, and reducing greenhouse gas emissions. To date, however, operational challenges have stymied the industrial production of large volumes of lignocellulosic-based fuels and chemicals. As a result, significant research investment has been led by the United States Department of Energy to understand and improve operational reliability at pioneer cellulosic biorefineries. In this perspective article lignocellulosic conversion technologies are described that have been adopted from the starch ethanol process. The developed process culminated in successful demonstration of 1,000-h integrated runs using several feedstocks, including switchgrass, energy sorghum, and two types of corn kernel fiber. This report highlights process development that solved several of the issues that plagued—and continue to plague—many in the cellulosic sugars space such as biomass feeding into equipment, high ash content, diversified co-product value, and others.

09 BIOMASS FUELS↗