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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 613 records · Page 34
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

High Strength Steel-Aluminum Components by Vaporizing Foil Actuator Welding

This project aimed to address the challenge of effectively welding dissimilar materials—high-strength steel and high-strength aluminum for creating lightweight, multi-material automotive components. For automotive companies, reducing weight of a vehicle is critical task regulated by the government to solve the issue of greenhouse gas emissions. Production of lightweight cars and trucks can be achieved by substitution of current all-steel structures with multi-material lightweight structures that include high strength-to-weight-ration materials such as high-strength steels, aluminum alloys, magnesium alloys, titanium alloys, coupled with lightweight designs. This requires dissimilar metal welding, which is challenging for state of the art joining processes such as resistance spot welding. The cycle of melting-cooling-freezing during traditional welding that can easily ruin the designed outstanding properties of the advanced base metals, such as aluminum alloys, making the welded area much weaker than the base metals. To weld two different metals with great difference in melting points, such as aluminum and steel, it’s even more difficult or impossible because of the formation of brittle intermetallic compounds at the welded interface. In this project, a novel welding method, developed at OSU, was selected for validation and development. This novel technology enables welding by impact without melting and proves to be robust to join various dissimilar lightweight metals. Termed as vaporizing foil actuator welding or VFAW, the technology uses a thin aluminum foil that is rapidly vaporized by a high current pulse to produce an explosive-like pressure pulse to drive one metallic piece into another at the high speed required for impact welding. This project entailed development of the early-stage welding technology in terms of (a) the consumables, the welding apparatus and the power sources, (b) coupon scale screening of many material combinations including corrosion studies, (c) computational modeling and design of the welded interface as well as of the multi-material prototype component, and (d) mechanical testing for strength and durability at coupon scale and to a certain extent the prototype scale. The all-steel engine cradle of 2016 Chevrolet Cruze was chosen as the baseline prototype component. The target set for the project was to demonstrate a 20% weight reduction at a cost premium of less than $\$ $5/lb saved without compromising on baseline mechanical properties. At project completion, a 12% lighter prototype component was demonstrated with an estimated cost premium of $\$ $9.8/lb saved. Besides prototype level demonstration of the technology, this project also enabled elevation of the technology’s readiness level to where a hydraulically actuated welding head was developed and made ready for deployment at a research and development facility for Tier 1 automotive supplier.

36 MATERIALS SCIENCE↗
NASA NTRS1980

Shipboard fisheries management terminals

The needs of the National Marine Fisheries Service (NMGS), National Weather Service, and the U.S. Coast Guard for locational, biological, and environmental data were assessed. The fisheries conservation zones and the yellowfin tuna jurisdiction of the NMFS operates observer programs on foreign and domestic fishing vessels. Data input terminal and data transfer and processing technology are reviewed to establish available capability. A matrix of implementation options is generated to identify the benefits of each option, and preliminary cost estimates are made. Recommendations are made for incremental application of available off the shelf hardware to obtain improved performance and benefits within a well bounded cost. Terminal recommendations are made for three interdependent shipboard units emphasizing: (1) the determination of location and fishing activity; (2) hand held data inputting and formatting in the fishing work areas; and (3) data manipulation, merging, and editing.

Nagler, R. G.↗
NASA NTRS2014

Life Cycle Analysis of Dedicated Nano-Launch Technologies

Recent technology advancements have enabled the development of small cheap satellites that can perform useful functions in the space environment. Currently, the only low cost option for getting these payloads into orbit is through ride share programs - small satellites awaiting the launch of a larger satellite, and then riding along on the same launcher. As a result, these small satellite customers await primary payload launches and a backlog exists. An alternative option would be dedicated nano-launch systems built and operated to provide more flexible launch services, higher availability, and affordable prices. The potential customer base that would drive requirements or support a business case includes commercial, academia, civil government and defense. Further, NASA technology investments could enable these alternative game changing options. With this context, in 2013 the Game Changing Development (GCD) program funded a NASA team to investigate the feasibility of dedicated nano-satellite launch systems with a recurring cost of less than $2 million per launch for a 5 kg payload to low Earth orbit. The team products would include potential concepts, technologies and factors for enabling the ambitious cost goal, exploring the nature of the goal itself, and informing the GCD program technology investment decision making process. This paper provides an overview of the life cycle analysis effort that was conducted in 2013 by an inter-center NASA team. This effort included the development of reference nano-launch system concepts, developing analysis processes and models, establishing a basis for cost estimates (development, manufacturing and launch) suitable to the scale of the systems, and especially, understanding the relationship of potential game changing technologies to life cycle costs, as well as other factors, such as flights per year.

nanolaunch↗
NASA NTRS2014

Life Cycle Analysis of Dedicated Nano-Launch Technologies

Recent technology advancements have enabled the development of small cheap satellites that can perform useful functions in the space environment. Currently, the only low cost option for getting these payloads into orbit is through ride share programs. As a result, these launch opportunities await primary payload launches and a backlog exists. An alternative option would be dedicated nano-launch systems built and operated to provide more flexible launch services, higher availability, and affordable prices. The potential customer base that would drive requirements or support a business case includes commercial, academia, civil government and defense. Further, NASA technology investments could enable these alternative game changing options.With this context, in 2013 the Game Changing Development (GCD) program funded a NASA team to investigate the feasibility of dedicated nano-satellite launch systems with a recurring cost of less than $2 million per launch for a 5 kg payload to low Earth orbit. The team products would include potential concepts, technologies and factors for enabling the ambitious cost goal, exploring the nature of the goal itself, and informing the GCD program technology investment decision making process. This paper provides an overview of the life cycle analysis effort that was conducted in 2013 by an inter-center NASA team. This effort included the development of reference nano-launch system concepts, developing analysis processes and models, establishing a basis for cost estimates (development, manufacturing and launch) suitable to the scale of the systems, and especially, understanding the relationship of potential game changing technologies to life cycle costs, as well as other factors, such as flights per year.

modeling↗
NASA NTRS1980

Coal gasification systems engineering and analysis, volume 2

The major design related features of each generic plant system were characterized in a catalog. Based on the catalog and requirements data, approximately 17 designs and cost estimates were developed for MBG and alternate products. A series of generic trade studies was conducted to support all of the design studies. A set of cost and programmatic analyses were conducted to supplement the designs. The cost methodology employed for the design and sensitivity studies was documented and implemented in a computer program. Plant design and construction schedules were developed for the K-T, Texaco, and B&W MBG plant designs. A generic work breakdown structure was prepared, based on the K-T design, to coincide with TVA's planned management approach. An extensive set of cost sensitivity analyses was completed for K-T, Texaco, and B&W design. Product price competitiveness was evaluated for MBG and the alternate products. A draft management policy and procedures manual was evaluated. A supporting technology development plan was developed to address high technology risk issues. The issues were identified and ranked in terms of importance and tractability, and a plan developed for obtaining data or developing technology required to mitigate the risk.

Source record↗
NASA NTRS2017

End-to-End Trade-Space Analysis for Designing Constellation

Multipoint measurement missions can provide a significant advancement in science return and this science interest coupled with as many recent technological advances are driving a growing trend in exploring distributed architectures for future NASA missions. Distributed Spacecraft Missions (DSMs) leverage multiple spacecraft to achieve one or more common goals. In particular, a constellation is the most general form of DSM with two or more spacecraft placed into specific orbit(s) for the purpose of serving a common objective (e.g., CYGNSS). Because a DSM architectural trade-space includes both monolithic and distributed design variables, DSM optimization is a large and complex problem with multiple conflicting objectives. Over the last two years, our team has been developing a Trade-space Analysis Tool for Constellations (TAT-C), implemented in common programming languages for pre-Phase A constellation mission analysis. By evaluating alternative mission architectures, TAT-C seeks to minimize cost and maximize performance for pre-defined science goals. This presentation will describe the overall architecture of TAT-C including: a User Interface (UI) at several levels of details and user expertise; Trade-space Search Requests that are created from the Science requirements gathered by the UI and validated by a Knowledge Base; a Knowledge Base to compare the current requests to prior mission concepts to potentially prune the trade-space; a Trade-space Search Iterator which, with inputs from the Knowledge Base, and, in collaboration with the Orbit & Coverage, Reduction & Metrics, and Cost& Risk modules, generates multiple potential architectures and their associated characteristics. TAT-C leverages the use of the Goddard Mission Analysis Tool (GMAT) to compute coverage and ancillary data, modeling orbits to balance accuracy and performance. The current version includes uniform and non-uniform Walker constellations as well as Ad-Hoc and precessing constellations, and its cost model represents an aggregate model consisting of Cost Estimating Relationships (CERs) from widely accepted models. The current GUI automatically generates graphics representing metrics such as average revisit time or coverage as a function of cost. The end-to-end system will be demonstrated as part of the presentation.

Mission Desig↗
DOE OSTI2023

Near-Net-Shape HIP Manufacturing for sCO2 Turbomachinery Cost Reduction

sCO2 turbomachinery that operates above 650°C requires the use of γ' strengthened Ni-based superalloys, leading to high cost and barrier of market adoption. Near-net-shape (NNS) HIP manufacturing with 282® alloy powder is being developed for sCO2 turbine components, with a significant estimated cost reduction. Tensile, creep, low cycle fatigue properties of argon gas atomized and plasma atomized powders were evaluated and compared to sand cast HAYNES® 282®. While tensile strength and fatigue life outperformed sand cast material, a 10~25% debit in the creep stress capability was observed due to the fine grain size and presence of prior particle boundaries (PPBs). Finite element model calibrated by powder rheological properties accurately predicted the nonuniform shrinkage during HIP, providing HIP tooling design to achieve the target dimension. A 20 lbs. turbine nozzle ring was successfully demonstrated within 0.01 inch dimensional tolerance at the vanes. A 1700lbs. turbine casing with complex internal struts and manifolds was also demonstrated being close to the target dimension.

14 SOLAR ENERGY↗
NASA NTRS1976

LANDSAT/MMS propulsion module design. Volume 1: Task 4.3, trade studies

Evaluations are presented of alternative LANDSAT follow-on launch configurations to derive the propulsion requirements for the multimission modular spacecraft (MMS). Two basic types were analyzed including use of conventional launch vehicles and shuttle-supported missions. It was concluded that two sizes of modular hydrazine propulsion modules would provide the most cost-effective combination for future missions of this spacecraft. Conceptual designs of the selected propulsion modules were performed to the depth permitting determination of mass properties and estimated costs.

Mansfield, J. M.↗
NASA NTRS1976

LANDSAT/MMS propulsion module design. Tas4.4: Concept design

Evaluations are presented of alternative LANDSAT follow-on launch configurations to derive the propulsion requirements for the multimission modular spacecraft (MMS). Two basic types were analyzed including use of conventional launch vehicles and shuttle supported missions. It was concluded that two sizes of modular hydrazine propulsion modules would provide the most cost-effective combination for future missions of this spacecraft. Conceptual designs of the selected propulsion modules were performed to the depth permitting determination of mass properties and estimated costs.

Mansfield, J. M.↗
NASA NTRS2000

Approximation Model Building for Reliability & Maintainability Characteristics of Reusable Launch Vehicles

This paper describes the development of parametric models for estimating operational reliability and maintainability (R&M) characteristics for reusable vehicle concepts, based on vehicle size and technology support level. A R&M analysis tool (RMAT) and response surface methods are utilized to build parametric approximation models for rapidly estimating operational R&M characteristics such as mission completion reliability. These models that approximate RMAT, can then be utilized for fast analysis of operational requirements, for lifecycle cost estimating and for multidisciplinary sign optimization.

Unal, Resit↗
DOE OSTI2023

WAVES (Wind Asset Value Estimation System) [SWR-23-81]

The Wind Asset Value Estimation System (WAVES) model is a coupling framework for core NREL techno economic analysis software models to estimate capital expenditures (ORBIT), operational expenditures (WOMBAT), and energy production (FLORIS) for offshore wind power plants. Existing workflows to couple the three models for lifecycle performance and cost estimation require a large amount of manual and error-prone setup to combine both shared inputs and dependent outputs, as such WAVES's primary functionality is to wrap the core logic for running standard modeling workflows to ensure shared settings and entangled results are correctly and efficiently combined every time. SEE ALSO: https://pypi.org/project/WAVES/

Hammond, Robert↗
DOE OSTI2024

Reducing the cost of home energy upgrades in the US: An industry survey

Decarbonizing the US residential building stock requires a substantial acceleration in home energy upgrades. Numerous barriers exist to accelerating adoption of efficient and electric building technologies, but foremost among these is high upfront costs. This study uses an industry survey delivered to a sample of home energy professionals to examine promising cost reduction strategies across a range of project types, including HVAC, water heating, and envelope/insulation projects. The survey included quantitative and qualitative questions to collect evidence on the estimated cost reduction potential of these strategies and their likelihood of use in the construction industry. The 167 survey respondents included contractors, energy consultants, architects, manufacturers, and others with experience in delivering energy upgrades in single-family and multifamily buildings in the US. Results show that significant cost reductions are achievable by minimizing additional infrastructure costs (such as replacing electric panels), streamlining project planning/management, and deploying innovations that simplify installation. We find that for a typical deep retrofit project, including heat pumps for space and water heating in addition to envelope upgrades, the strategies could result in a total installed cost reduction of nearly 50%, dramatically improving the customer economics of such a project. This research makes a novel contribution to the literature on strategies to reduce the costs of residential retrofits. We discuss how our study's insights on the highest-value cost reduction strategies for home energy upgrades can further accelerate their uptake in the US housing stock.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Cost Evaluation of Alternative Radioisotope Disposal Methods at the Livermore Site

The purpose of this cost evaluation was to investigate a hypothetical in which radioisotopes were no longer permitted in the City of Livermore sanitary sewer. Three alternative methods were proposed to determine estimated costs and compare current practice costs to the latter. An assumption from the initial steps of the analysis was significant cost savings would be found with the alternative methods.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1973

Cost analysis of water recovery systems

A methodology was developed to predict the relevant contributions of the more intangible cost elements encountered in the development of flight-qualified hardware based on an extrapolation of past hardware development experience. Major items of costs within water recovery systems were identified and related to physical and/or performance criteria. Cost and performance data from Gemini, Skylab, and other aerospace and biotechnology programs were analyzed to identify major cost elements required to establish cost estimating relationships for advanced water recovery systems. The results of the study are expected to assist NASA in long-range planning and allocation of resources in a cost effective manner in support of earth orbital programs. This report deals with the cost analysis of the five leading water reclamation systems, namely: (1) RITE waste management-water system, (2) reverse osmosis system, (3) multifiltration system, (4) vapor compression system, and (5) closed air evaporation system with electrolytic pretreatment.

Yakut, M. M.↗
NASA NTRS1979

Solar power satellite system definition study. Volume 1: Executive summary

Configuration concepts, option sizes, and systems definitions study design evolutions are reviewed. The main features of the present reference design silicon solar cell solar power satellite are described, as well as the provisions for space construction and support systems. The principal study accomplishments and conclusions are summarized according to the following tasks: (1) baseline critique; (2) construction and maintenance; (3) industrial complex needs, cost estimates, and production capacity; (4) launch complex requirements at KSC or at an offshore facility; (5) integration of the SPS/ground power network; (6) technology advancement and development; (7) costs and schedules; and (8) exploratory technology: laser annealing of solar cells degraded by proton irradiation, and a fiber-optic phase distribution link at 980 MHz.

Source record↗
NASA NTRS1997

Mechanical System Reliability and Cost Integration Using a Sequential Linear Approximation Method

The development of new products is dependent on product designs that incorporate high levels of reliability along with a design that meets predetermined levels of system cost. Additional constraints on the product include explicit and implicit performance requirements. Existing reliability and cost prediction methods result in no direct linkage between variables affecting these two dominant product attributes. A methodology to integrate reliability and cost estimates using a sequential linear approximation method is proposed. The sequential linear approximation method utilizes probability of failure sensitivities determined from probabilistic reliability methods as well a manufacturing cost sensitivities. The application of the sequential linear approximation method to a mechanical system is demonstrated.

Kowal, Michael T.↗
DOE OSTI2022

Commercial-Scale Front-End Engineering Design (Feed) Study for MTR’s Membrane CO 2 Capture Process

This is the final report for a DOE sponsored project (DE-FE00031846) where MTR, Sargent & Lundy (S&L), Trimeric Corporation (Trimeric), in cooperation with Basin Electric Power Cooperative (BEPC), and Electric Power Research Institute (EPRI), completed a full-scale Front End Engineering and Design (FEED) study to evaluate the retrofit of MTR’s membrane-based post-combustion carbon dioxide (CO2) capture technology to the BEPC Dry Fork Station (DFS) Unit 1. The capture plant is designed to treat the entire flue gas flow from DFS; it is estimated that this system will capture 6,560 tonnes per day (TPD) of carbon dioxide. The overall goal of the project was to develop an AACE Level 2 Capital Cost Estimate with an accuracy of ±15% to demonstrate the economic feasibility of constructing and operating the MTR CO2 capture plant.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1973

DCS - A global satellite environmental data collection system.

This paper presents a summary of the results of a comparative study of satellite data collection systems which utilize remote ground data collection platforms transmitting data directly to a satellite and down to low-cost direct read-out local user terminals. The general objective of the study was to evaluate cost and technical feasibility of five medium orbiting and six geo-synchronous satellite data collection system (DCS) configurations with varying degrees of spacecraft and local user terminal (LUT) complexity. The goal of trading spacecraft and LUT complexity was to determine practical feasible systems with low-cost terminals, yet with a reasonable overall system cost the would permit the broad worldwide utilization of a highly beneficial data collection system. Results presented include data collection system analyses, satellite and local user terminal designs, and estimated costs. A summary of the types of local users and their requirements is also included.

Claire, E. J.↗