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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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At least 595 records · Page 33

Studies in Software Cost Model Behavior: Do We Really Understand Cost Model Performance?

While there exists extensive literature on software cost estimation techniques, industry practice continues to rely upon standard regression-based algorithms. These software effort models are typically calibrated or tuned to local conditions using local data. This paper cautions that current approaches to model calibration often produce sub-optimal models because of the large variance problem inherent in cost data and by including far more effort multipliers than the data supports. Building optimal models requires that a wider range of models be considered while correctly calibrating these models requires rejection rules that prune variables and records and use multiple criteria for evaluating model performance. The main contribution of this paper is to document a standard method that integrates formal model identification, estimation, and validation. It also documents what we call the large variance problem that is a leading cause of cost model brittleness or instability.

data mining↗

From Deposition to Encapsulation: Roll-to-roll manufacturing of organic light emitting devices for lighting (Final Report)

Organic light emitting devices (OLEDs) are promising solid state light sources due to their high efficiency, high color quality and flexible form factors. The key to enable low cost OLED lighting, is to rapidly fabricate thin film organic layers on a continuous flexible roll, called R2R processing. This project aims to investigate the feasibility of mass production of OLED lighting using the R2R process, from deposition to encapsulation. A high efficiency white OLED is fabricated on 10 cm-wide substrate rolls in a pilot R2R tool comprising of two different organic deposition: vacuum thermal evaporation (VTE) and organic vapor phase deposition (OVPD). A high quality encapsulation process to package OLEDs is demonstrated using an atomic layer deposition tool integrated to the R2R system without air exposure. The method to achieve ultrahigh deposition rates required by R2R processing is demonstrated by OVPD. Uniform organic semiconductor thin films grown by OVPD at rates as high as 50 Å/s are achieved. A comprehensive numerical model that is capable of simulating complex, multilayer WOLED structures is developed to provide an alternative to experimental iterations of OLED design and tests. A cost estimate on the R2R production of WOLEDs for lighting is developed. Assuming a WOLED luminance of 10 klm/m 2 , the cost of a WOLED light engine is anticipated to be $\$ 12.5$ /klm. With incremental reduction in material and driver costs and improved luminance, the cost of WOLED lighting can be reduced to $\$ 6.3$ /klm in the near term. These findings suggest OLED lighting can be volume manufactured by R2R vapor deposition methods with much reduced costs compared to current batch processing methods, potentially positioning WOLEDs for use in numerous premium lighting applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Magnesium production by molten salt electrolysis with liquid tin cathode and multiple effect distillation

Low-cost clean primary production of magnesium metal is important for its use in many applications, from light-weight structural components to energy technologies. This work describes new experiments and cost and emissions analysis for a magnesium metal production process. The process combines molten salt electrolysis of MgO using MgF₂-CaF₂ electrolyte and a reactive liquid tin cathode, with gravity-driven multiple effect thermal system (G-METS) distillation to separate out the magnesium product, and re-use of the tin. Electrolysis experiments with carbon anodes showed current yield above 90%, while a yttria-stabilized zirconia solid oxide membrane (SOM) anode experiment showed 84% current yield. G-METS distillation is an important component of the envisioned process. It can potentially lower costs and energy use considerably compared with conventional magnesium distillation. Techno-economic analysis including detailed mass and energy balances shows that this electrolyte composition could lower costs by utilizing CaO, which is the primary impurity in MgO, as the Hall-Héroult process uses the sodium impurity in alumina. Analysis options include: raw material types (magnesite rock vs. brine or seawater), drying and calcining using electricity vs. natural gas, and carbon vs. SOM anode type. Using SOM inert anodes results in a cost premium around 10%–15%, mostly due to higher electrical energy usage resulting from membrane resistance, and reduces GHG emissions by approximately 1 kg CO₂/kg Mg product. Capital and operating cost estimates, and cradle to gate greenhouse gas (GHG) emissions analysis under several raw material and process technology scenarios, show comparable costs and emissions to those of aluminum production.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Space shuttle

The transportation cost associated with space materials processing were studied to determine the feasibility of space manufacturing. The assumptions use to determining the cost estimates for a 12 year planning period are listed, and the orbitor is described in terms of payloads. Shuttle operational costs, ground operational costs, and nonrecurring investment and development costs were analyzed.

Source record↗

Conceptual design study of potential early commercial MHD powerplant. Report of task 2 results

The conceptual design of one of the potential early commercial MHD power plants was studied. The plant employs oxygen enrichment of the combustion air and preheating of this oxygen enriched air to an intermediate temperature of 1200 F attainable with a tubular type recuperative heat exchanger. Conceptual designs of plant componets and equipment with performance, operational characteristics, and costs are reported. Plant economics and overall performance including full and part load operation are reviewed. The projected performance and estimated cost of this early MHD plant are compared to conventional power plants, although it does not offer the same high efficiency and low costs as the mature MHD power plant. Environmental aspects and the methods incorporated in plant design for emission control of sulfur and nitrogen are reviewed.

Hals, F. A.↗

Effects of radiobiological uncertainty on shield design for a 60-day lunar mission

Some consequences of uncertainties in radiobiological risk due to galactic cosmic ray exposure are analyzed to determine their effect on engineering designs for a first lunar outpost - a 60-day mission. Quantitative estimates of shield mass requirements as a function of a radiobiological uncertainty factor are given for a simplified vehicle structure. The additional shield mass required for compensation is calculated as a function of the uncertainty in galactic cosmic ray exposure, and this mass is found to be as large as a factor of 3 for a lunar transfer vehicle. The additional cost resulting from this mass is also calculated. These cost estimates are then used to exemplify the cost-effectiveness of research.

Wilson, John W.↗

Electric transmission value and its drivers in United States power markets

Electric transmission infrastructure plays a vital role during extreme weather and supply disruptions and can enable low-cost electricity systems. This paper contributes to a more complete understanding of the value and cost-effectiveness of transmission, as well as barriers to its development. By studying wholesale energy market prices in the United States between 2012 and 2022, we find that additional transfer capacity between regions would have been especially valuable, with a median value of $116 million per GW per year. This capacity would often have provided balanced benefits to each region. The market value of transmission was highly influenced by a small fraction of time: 5% of hours typically captured at least 45% of the total value. These peak periods were primarily driven by unforeseen changes in conditions within one day of operations. Annualized transmission infrastructure cost estimates were lower than the average market value for most locations, including all links crossing regional seams, where the value-to-cost ratio was often greater than 4. This suggests that there are barriers to developing valuable grid infrastructure. These results complement forward-looking modeling studies and support efforts to improve modeling practices.

Energy economics↗

Hybrid Energy-Powered Electrochemical Direct Ocean Capture Model

Offshore synthetic fuel production and marine carbon dioxide removal can be enabled by direct ocean capture, which extracts carbon dioxide from the ocean that then can be used as a feedstock for fuel production or sequestered underground. To maximize carbon capture, plants require a variety of low-carbon energy sources to operate, such as variable renewable energy. However, the impacts of variable power on direct ocean capture have not yet been thoroughly investigated. To facilitate future deployments, a generalizable model for electrodialysis-based direct ocean capture plants is created to evaluate plant performance and electricity costs under intermittent power availability. This open-source Python-based model captures key aspects of the electrochemistry, ocean chemistry, post-processing, and operation scenarios under various conditions. To incorporate realistic energy supply dynamics and cost estimates, the model is coupled with the National Renewable Energy Laboratory’s H2Integrate tool, which simulates hybrid energy system performance profiles and costs. This integrated framework is designed to provide system-level insights while maintaining computational efficiency and flexibility for scenario exploration. Initial evaluations show similar results to those predicted by the industry, and demonstrate how a given plant could function with variable power in different deployment locations, such as with wind energy off the coast of Texas and with wind and wave energy off the coast of Oregon. The results suggest that electrochemical systems with greater tolerances for power variability and low minimum power requirements may offer operational advantages in variable-energy contexts. However, further research is needed to quantify these benefits and evaluate their implications across different deployment scenarios.

16 TIDAL AND WAVE POWER↗

Solar power satellite rectenna design study: Directional receiving elements and parallel-series combining analysis

Rectenna conversion efficiencies (RF to dc) approximating 85 percent were demonstrated on a small scale, clearly indicating the feasibility and potential of efficiency of microwave power to dc. The overall cost estimates of the solar power satellite indicate that the baseline rectenna subsystem will be between 25 to 40 percent of the system cost. The directional receiving elements and element extensions were studied, along with power combining evaluation and evaluation extensions.

Gutmann, R. J.↗

Video distribution system cost model

A cost model that can be used to systematically identify the costs of procuring and operating satellite linked communications systems is described. The user defines a network configuration by specifying the location of each participating site, the interconnection requirements, and the transmission paths available for the uplink (studio to satellite), downlink (satellite to audience), and voice talkback (between audience and studio) segments of the network. The model uses this information to calculate the least expensive signal distribution path for each participating site. Cost estimates are broken downy by capital, installation, lease, operations and maintenance. The design of the model permits flexibility in specifying network and cost structure.

Gershkoff, I.↗

A conceptual design study for a two-dimensional, electronically scanned thinned array radiometer

A conceptual design for the Two-Dimensional, Electronically Steered Thinned Array Radiometer (ESTAR) is described. This instrument is a synthetic aperture microwave radiometer that operates in the L-band frequency range for the measurement of soil moisture and ocean salinity. Two auxiliary instruments, an 8-12 micron, scanning infrared radiometer and a 0.4-1.0 micron, charge coupled device (CCD) video camera, are included to provided data for sea surface temperature measurements and spatial registration of targets respectively. The science requirements were defined by Goddard Space Flight Center. Instrument and the spacecraft configurations are described for missions using the Pegasus and Taurus launch vehicles. The analyses and design trades described include: estimations of size, mass and power, instrument viewing coverage, mechanical design trades, structural and thermal analyses, data and communications performance assessments, and cost estimation.

Mutton, Philip↗

Machine Learning Based Path Planning for Improved Rover Navigation

Enhanced AutoNav (ENav), the baseline surface navigation software for NASA’s Perseverance rover, sorts a list of candidate paths for the rover to traverse, then uses the Approximate Clearance Evaluation (ACE) algorithm to evaluate whether the most highly ranked paths are safe. ACE is crucial for maintaining the safety of the rover, but is computationally expensive. If the most promising candidates in the list of paths are all found to be infeasible, ENav must continue to search the list and run time-consuming ACE evaluations until a feasible path is found. In this paper, we present two heuristics that, given a terrain heightmap around the rover, produce cost estimates that more effectively rank the candidate paths before ACE evaluation. The first heuristic uses Sobel operators and convolution to incorporate the cost of traversing high-gradient terrain. The second heuristic uses a machine learning (ML) model to predict areas that will be deemed untraversable by ACE. We used physics simulations to collect training data for the ML model and to run Monte Carlo trials to quantify navigation performance across a variety of terrains with various slopes and rock distributions. Compared to ENav's baseline performance, integrating the heuristics can lead to a significant reduction in ACE evaluations and average computation time per planning cycle, increase path efficiency, and maintain or improve the rate of successful traverses. This strategy of targeting specific bottlenecks with ML while maintaining the original ACE safety checks provides an example of how ML can be infused into planetary science missions and other safety-critical software.

Yue, Yisong↗

Probabilistic Mass Growth Uncertainties

Mass has been widely used as a variable input parameter for Cost Estimating Relationships (CER) for space systems. As these space systems progress from early concept studies and drawing boards to the launch pad, their masses tend to grow substantially, hence adversely affecting a primary input to most modeling CERs. Modeling and predicting mass uncertainty, based on historical and analogous data, is therefore critical and is an integral part of modeling cost risk. This paper presents the results of a NASA on-going effort to publish mass growth datasheet for adjusting single-point Technical Baseline Estimates (TBE) of masses of space instruments as well as spacecraft, for both earth orbiting and deep space missions at various stages of a project's lifecycle. This paper will also discusses the long term strategy of NASA Headquarters in publishing similar results, using a variety of cost driving metrics, on an annual basis. This paper provides quantitative results that show decreasing mass growth uncertainties as mass estimate maturity increases. This paper's analysis is based on historical data obtained from the NASA Cost Analysis Data Requirements (CADRe) database.

Plumer, Eric↗

Development of Advanced Life Cycle Costing Methods for Technology Benefit/Cost/Risk Assessment

The overall objective of this three-year grant is to provide NASA Langley's System Analysis Branch with improved affordability tools and methods based on probabilistic cost assessment techniques. In order to accomplish this objective, the Aerospace Systems Design Laboratory (ASDL) needs to pursue more detailed affordability, technology impact, and risk prediction methods and to demonstrate them on variety of advanced commercial transports. The affordability assessment, which is a cornerstone of ASDL methods, relies on the Aircraft Life Cycle Cost Analysis (ALCCA) program originally developed by NASA Ames Research Center and enhanced by ASDL. This grant proposed to improve ALCCA in support of the project objective by updating the research, design, test, and evaluation cost module, as well as the engine development cost module. Investigations into enhancements to ALCCA include improved engine development cost, process based costing, supportability cost, and system reliability with airline loss of revenue for system downtime. A probabilistic, stand-alone version of ALCCA/FLOPS will also be developed under this grant in order to capture the uncertainty involved in technology assessments. FLOPS (FLight Optimization System program) is an aircraft synthesis and sizing code developed by NASA Langley Research Center. This probabilistic version of the coupled program will be used within a Technology Impact Forecasting (TIF) method to determine what types of technologies would have to be infused in a system in order to meet customer requirements. A probabilistic analysis of the CER's (cost estimating relationships) within ALCCA will also be carried out under this contract in order to gain some insight as to the most influential costs and the impact that code fidelity could have on future RDS (Robust Design Simulation) studies.

Yackovetsky, Robert↗

LIBRA: An inexpensive geodetic network densification system

A description is given of the Libra (Locations Interposed by Ranging Aircraft) system, by which geodesy and earth strain measurements can be performed rapidly and inexpensively to several hundred auxiliary points with respect to a few fundamental control points established by any other technique, such as radio interferometry or satellite ranging. This low-cost means of extending the accuracy of space age geodesy to local surveys provides speed and spatial resolution useful, for example, for earthquake hazards estimation. Libra may be combined with an existing system, Aries (Astronomical Radio Interferometric Earth Surveying) to provide a balanced system adequate to meet the geophysical needs, and applicable to conventional surveying. The basic hardware design was outlined and specifications were defined. Then need for network densification was described. The following activities required to implement the proposed Libra system are also described: hardware development, data reduction, tropospheric calibrations, schedule of development and estimated costs.

Fliegel, H. F.↗

AEMS implementation cost study for Boeing 727

Costs for airline operational implementation of a NASA-developed approach energy management system (AEMS) concept, as applied to the 727 airplane, were determined. Estimated costs are provided for airplane retrofit and for installation of the required DME ground stations. Operational costs and fuel cost savings are presented in a cost-of-ownership study. The potential return on the equipment investment is evaluated using a net present value method. Scheduled 727 traffic and existing VASI, ILS, and collocated DME ground station facilities are summarized for domestic airports used by 727 operators.

Allison, R. L.↗

Application of Gr/PMR-15 to commercial aircraft

Following from early experience with polyimides on the SST program and Shuttle aft flap studies the Boeing Company is now working on collaborative programs with its principal nacelle suppliers to pursue the development of Gr/PMR-15 nacelle components. Two programs are currently in effect. The first program is directed specifically towards the flight test and service evaluation at the earliest possible date of a 747 nacelle core cowl structure. The second program seeks to firmly establish the producibility and cost of a 757 thrust reverser C duct in a production environment. The near term objectives of these programs include: (1) the comparison of estimated cost and weight of Gr/PMR-15 versus metal structure, (2) the engine test of representative composite structure, (3) the preliminary design and analysis of the C duct structure, and (4) the preparation of cost data and time schedules for the development and producibility program. In addition to powerplant structure, the propulsion ducting system has shown to be a strong candidate for Gr/PMR-15 application. Currently, the Boeing 747 Organization is evaluating the use of PMR-15 matrix composites to replace nearly 800 lbs of titanium ducting per airplane.

Postlewaite, J.↗

Mars Pathfinder mission operations concepts

The Mars Pathfinder Project plans a December 1996 launch of a single spacecraft. After jettisoning a cruise stage, an entry body containing a lander and microrover will directly enter the Mars atmosphere and parachute to a hard landing near the sub-solar latitude of 15 degrees North in July 1997. Primary surface operations last for 30 days. Cost estimates for Pathfinder ground systems development and operations are not only lower in absolute dollars, but also are a lower percentage of total project costs than in past planetary missions. Operations teams will be smaller and fewer than typical flight projects. Operations scenarios have been developed early in the project and are being used to guide operations implementation and flight system design. Recovery of key engineering data from entry, descent, and landing is a top mission priority. These data will be recorded for playback after landing. Real-time tracking of a modified carrier signal through this phase can provide important insight into the spacecraft performance during entry, descent, and landing in the event recorded data is never recovered. Surface scenarios are dominated by microrover activity and lander imaging during 7 hours of the Mars day from 0700 to 1400 local solar time. Efficient uplink and downlink processes have been designed to command the lander and microrover each Mars day.

Sturms, Francis M., Jr.↗