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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1989

The use of a Navier-Stokes code in the wing design process

The feasibility was determined of incorporating the Navier-Stokes computational code, CFL3D, into the supersonic wing design process. The approach taken is of two steps. The first step was to calibrate CFL3D against existing experimental data sets obtained on thin sharp edged delta wings. The experimental data identified six flow types which are dependent on the similarity parameters of Mach number and angle of attack normal to the leading edge. The calibration showed CFL3D capable of simulating these various separated and attached flow conditions. The second step was to use CFL3D to study the initial formation of leading edge separation over delta wings at supersonic speeds. This consisted of examining solutions obtained on a 65 deg delta wing at Mach number of 1.6 with varying cross sectional shapes. Reynolds number was held constant at 1000000 and the Baldwin-Lomax turbulence model was used. The study showed that through the use of leading edge radius and/or camber, the onset of leading edge separation can be delayed to a higher angle of attack than observed on a flat sharp edged wing. Based on the geometries studied, three wind tunnel models are being designed to verify these results.

Mcmillin, S. Naomi↗
DOE OSTI2023

Process Design and Techno-Economic Analysis of the Modular Staged Pressurized Oxy-Combustion (SPOC) Power Plant for Biomass

This work describes the process design and techno-economic analysis (TEA) of the modular stage pressurized oxy-combustion (SPOC) power plant for biomass firing and coal-biomass co-firing. The SPOC process was modelled using Aspen Plus®, and largely based on a previous model designed by this group for SPOC coal firing. To enable comparison with current National Energy Technology Laboratory (NETL) Bio-Energy Carbon Capture and Storage (BECCS) studies, a 550 MWe SPOC power plant with a supercritical Rankine cycle (241 bar, 593°C, and 593°C), and 90% carbon capture was modeled, and hybrid poplar biomass was chosen. Two cases were evaluated, namely 100% biomass (carbon negative) and 25% biomass co-firing (carbon neutral), and the 100% Powder River Basin coal firing case was chosen for comparison purposes. In the SPOC process, oxygen is produced via a cryogenic air separation unit (ASU) and the heat generated from the compression of air is integrated into the steam cycle and utilized for boiler feed water regeneration. Unique to the SPOC process, the boilers are arranged in a series-parallel configuration, with minimized flue gas recirculation. The flue gas is cooled and scrubbed in the direct-contact cooler (DCC) column, and the water leaving the bottom of the DCC is at a sufficiently high temperature that it can be used for boiler feed water heating, improving plant thermal efficiency. The SPOC efficiencies were above the BECCS cases with capture, and no efficiency penalty on the SPOC plant was observed with an increase of biomass in the mix mostly due to the higher oxygen content in biomass that resulted in lower oxygen requirement from the ASU, and the higher moisture in biomass that due to the key benefit of the SPOC process can be partially recovered as latent heat.

Magalhaes, Duarte↗
DOE OSTI2022

CO 2 conversion to syngas via electrification of endothermal reactors: Process design and environmental impact analysis

CO 2 utilization via reverse water gas shift (rWGS) reaction has been proposed as a path to the sustainable utilization. Here this work presents a detailed process modelling study where steam methane reforming (SMR) generated hydrogen was combined with rWGS to produce syngas (CO + H 2 ) with various hydrogen-to-carbon oxide ratios. To further decrease CO 2 emissions that may offset the benefits of CO 2 converted in rWGS, electrification of endothermal reactors, both SMR and rWGS was considered where CO 2 emitting fuel burning in the furnace was replaced by the emerging ohmic (resistive) heating. Material and energy inventory obtained from process design calculations was used to perform Life Cycle Analysis (LCA) to calculate environmental impacts of CO 2 consumption and reactor electrification. The results showed that greenhouse gas emissions, in CO 2 kg equivalent, were the lowest when both SMR and rWGS were heated using wind-generated electricity, decreasing from 25 to 10 kg CO 2 equivalent for H 2 :CO = 2:1 while the conventional electricity mix used for furnace electrical heating across the board of scenarios generated highest environmental impacts, much higher than those that used natural gas as fuel. Process economics calculations suggested that, when both SMR and rWGS were electrically heated, the process only showed product syngas cost parity with the conventional fuel heated design when electricity cost was ~$0.008/kWh. This suggests that CO 2 utilization scenarios involving process electrification need to be carefully considered from the total design perspective so they do not produce more greenhouse gases than in conventional non-electrified scenarios.

42 ENGINEERING↗
NASA NTRS1981

A Design Process for the Acoustical System of an Enclosed Space Colony

Sounds of Silence. Using a general systems approach, factors and components of the acoustical design process for an isolated, confined space community in a torus space enclosure are considered. These components include the following: organizational structure and its effect on alternatives; problem definition and limits; criteria and priorities; methods of data gathering; modelling and measurement of the whole system and its components; decision methods; and design scenario of the acoustics of the complex, socio-technical space community system with emphasis on the human factors.

Hawke, Joanne↗
DOE OSTI2024

Process Design and Techno-Economic Analysis of the Modular Staged Pressurized Oxy-Combustion (SPOC) Power Plant for Biomass

This work describes the process design and techno-economic analysis (TEA) of the modular SPOC power plant for biomass firing and coal-biomass co-firing. Two Rankine cycles were considered: a supercritical steam cycle (242 bar, 593°C, 593°C) with 550 MWe net output and a subcritical cycle (166 bar, 566°C, 566°C) with 200 MWe net output. For both cases, 95% carbon capture was modeled, and hybrid poplar biomass was chosen to generate carbon-negative power. In addition, the supercritical 500 MWe case included a 25% biomass co-firing (carbon neutral) case. For both cycles, a 100% Powder River Basin coal firing case was used for comparison purposes. In the SPOC process, oxygen is produced via a cryogenic air separation unit (ASU) and the heat generated from the compression of air is integrated into the steam cycle and utilized for boiler feed water pre-heating. Unique to the SPOC process, the boilers are pressurized and arranged in a series-parallel configuration, with minimized flue gas recirculation. The flue gas is cooled and scrubbed in the direct-contact cooler (DCC) column, and the moisture in the flue gas is condensed, leaving the bottom of the DCC at a sufficiently high temperature such that it can be used for boiler feed water pre-heating, improving plant thermal efficiency. Following drying and purification, CO2 in the flue gas is at the purity required for storage or utilization. The performance data were obtained from process modelling via Aspen Plus®. The stream data from Aspen Plus® were used as an input for the AACE Class 5 cost study. Ultimately, the capital costs, Levelized Cost of Electricity (LCOE), and cost of CO2 captured and avoided were obtained. The HHV efficiency of the carbon negative 550 MWe supercritical SPOC case (34.8%) was clearly above those reported by NETL for the BECCS baseline cases of supercritical pulverized coal with capture (B12B, 31.5%) and the 49% biomass co-firing case with capture (PA3, 29.2%). The HHV efficiency of the carbon-negative subcritical plant is also higher than the subcritical baseline PC plant with capture (case B11B.95) presented by NETL (32% vs 29.7%). The LCOE for the SPOC 100% biomass case was similar to the LCOE for the BECCS 49% biomass with carbon capture case ($147/MWh), and the SPOC carbon neutral case LCOE was lower ($110/MWh) than the cost for the NETL baseline SC coal firing case with 90% carbon capture ($114/MWh).

Magalhaes, Duarte↗
NASA NTRS1995

Properties of a center/surround retinex. Part 1: Signal processing design

The last version of Edwin Land's retinex model for human vision's lightness and color constancy has been implemented. Previous research has established the mathematical foundations of Land's retinex but has not examined specific design issues and their effects on the properties of the retinex operation. Here we describe the signal processing design of the retinex. We find that the placement of the logarithmic function is important and produces best results when placed after the surround formation. We also find that best rendition is obtained for a 'canonical' gain-offset applied after the retinex operation.

Rahaman, Zia-Ur↗
DOE OSTI2020

The Wave Energy Converter Design Process: Methods Applied in Industry and Shortcomings of Current Practices

Wave energy is among the many renewable energy technologies being researched and developed to address the increasing demand for low-emissions energy. The unique design challenges for wave energy converter design—integrating complex and uncertain technological, economic, and ecological systems, overcoming the structural challenges of ocean deployment, and dealing with complex system dynamics—have lead to a disjointed progression of research and development. There is no common design practice across the wave energy industry and there is no published synthesis of the practices that are used by developers. In this paper, we summarize the methods being employed in WEC design as well as promising methods that have yet to be applied. We contextualize these methods within an overarching design process. We present results from a survey of WEC developers to identify methods that are common in industry. From the review and survey results, we conclude that the most common methods of WEC design are iterative methods in which design parameters are defined, evaluated, and then changed based on evaluation results. This leaves a significant space for improvement of methods that help designers make better-informed decisions prior to sophisticated evaluation, and methods of using the evaluation results to make better design decisions during iteration. Despite the popularity of optimization methods in academic research, they are less common in industry development. We end this paper with a summary of the areas of WEC design in which the testing and development of new methods is necessary, and where more research is required to fully understand the influence of design decisions on WEC performance.

16 TIDAL AND WAVE POWER↗
NASA NTRS2015

Design Process of Flight Vehicle Structures for a Common Bulkhead and an MPCV Spacecraft Adapter

Design and manufacturing space flight vehicle structures is a skillset that has grown considerably at NASA during that last several years. Beginning with the Ares program and followed by the Space Launch System (SLS); in‐house designs were produced for both the Upper Stage and the SLS Multipurpose crew vehicle (MPCV) spacecraft adapter. Specifically, critical design review (CDR) level analysis and flight production drawing were produced for the above mentioned hardware. In particular, the experience of this in‐house design work led to increased manufacturing infrastructure for both Marshal Space Flight Center (MSFC) and Michoud Assembly Facility (MAF), improved skillsets in both analysis and design, and hands on experience in building and testing (MSA) full scale hardware. The hardware design and development processes from initiation to CDR and finally flight; resulted in many challenges and experiences that produced valuable lessons. This paper builds on these experiences of NASA in recent years on designing and fabricating flight hardware and examines the design/development processes used, as well as the challenges and lessons learned, i.e. from the initial design, loads estimation and mass constraints to structural optimization/affordability to release of production drawing to hardware manufacturing. While there are many documented design processes which a design engineer can follow, these unique experiences can offer insight into designing hardware in current program environments and present solutions to many of the challenges experienced by the engineering team.

Aggarwal, Pravin↗
NASA NTRS1999

Reinventing the Design Process: Teams and Models

The future of space mission designing will be dramatically different from the past. Formerly, performance-driven paradigms emphasized data return with cost and schedule being secondary issues.

Design↗
DOE OSTI2022

Thermodynamics-guided alloy and process design for additive manufacturing

In conventional processing, metals go through multiple manufacturing steps including casting, plastic deformation, and heat treatment to achieve the desired property. In additive manufacturing (AM) the same target must be reached in one fabrication process, involving solidification and cyclic remelting. The thermodynamic and kinetic differences between the solid and liquid phases lead to constitutional undercooling, local variations in the solidification interval, and unexpected precipitation of secondary phases. These features may cause many undesired defects, one of which is the so-called hot cracking. The response of the thermodynamic and kinetic nature of these phenomena to high cooling rates provides access to the knowledge-based and tailored design of alloys for AM. Here, we illustrate such an approach by solving the hot cracking problem, using the commercially important IN738LC superalloy as a model material. The same approach could also be applied to adapt other hot-cracking susceptible alloy systems for AM.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Fuel Property-Informed Process Design for the Direct Catalytic Conversion of Cellulosics

The direct catalytic conversion of cellulosics (DC3) with supercritical methanol presents a promising pathway to completely solubilize woody biomass and produce >60% mass yield of C2-C6 oxygenates for light duty vehicle applications. Although the oxygenate composition can be tuned by modifying catalyst and process conditions, limited efforts to date have examined DC3 fuel properties for light duty fuel applications to iteratively inform conversion process design. In this work, we designed and evaluated multi-component surrogate bioblendstocks that represent major DC3 light oxygenates and refined catalyst formulations and distillation parameters to improve the resulting light duty fuel quality. Surrogate design for this novel fuel production pathway was based on a preliminary product slate that was systematically adjusted to determine impacts on fuel properties of interest including heating value, oxidative stability, and heat of vaporization, among others. The resulting predictions and measurements of these surrogates were then used to inform improvement of conversion process, and specifically, reformulation of the catalyst which resulted in production of a higher energy density fuel product primarily comprised of saturated alcohols. Fuel testing outcomes also informed downstream oxygenate separations requirements. This resulted in the production of a promising DC3 light-duty fuel blendstock with >15% greater energy density relative to ethanol, while maintaining high octane number and octane sensitivity.

BIOMASS FUELS↗
NASA NTRS2002

Reliability Methods for Shield Design Process

Providing protection against the hazards of space radiation is a major challenge to the exploration and development of space. The great cost of added radiation shielding is a potential limiting factor in deep space operations. In this enabling technology, we have developed methods for optimized shield design over multi-segmented missions involving multiple work and living areas in the transport and duty phase of space missions. The total shield mass over all pieces of equipment and habitats is optimized subject to career dose and dose rate constraints. An important component of this technology is the estimation of two most commonly identified uncertainties in radiation shield design, the shielding properties of materials used and the understanding of the biological response of the astronaut to the radiation leaking through the materials into the living space. The largest uncertainty, of course, is in the biological response to especially high charge and energy (HZE) ions of the galactic cosmic rays. These uncertainties are blended with the optimization design procedure to formulate reliability-based methods for shield design processes. The details of the methods will be discussed.

Tripathi, R. K.↗
DOE OSTI2025

New machine protection system at the Spallation Neutron Source – design process and performance analysis

A New Machine Protection System (MPS) at the Spallation Neutron Source (SNS) was developed and implemented on µTCA-based hardware platforms. The system monitors more than 2500 field inputs and shuts off the beam within 10 µs if adverse events occur. We will present system level design process of various firmware and software components as well as the system integration into EPICS environment. The performance analysis of the MPS after two SNS run cycles will also be presented.

Bobrek, Miljko [ORNL] (ORCID:0000000332763451)↗
NASA NTRS1997

Predictive Modeling in Plasma Reactor and Process Design

Research continues toward the improvement and increased understanding of high-density plasma tools. Such reactor systems are lauded for their independent control of ion flux and energy enabling high etch rates with low ion damage and for their improved ion velocity anisotropy resulting from thin collisionless sheaths and low neutral pressures. Still, with the transition to 300 mm processing, achieving etch uniformity and high etch rates concurrently may be a formidable task for such large diameter wafers for which computational modeling can play an important role in successful reactor and process design. The inductively coupled plasma (ICP) reactor is the focus of the present investigation. The present work attempts to understand the fundamental physical phenomena of such systems through computational modeling. Simulations will be presented using both computational fluid dynamics (CFD) techniques and the direct simulation Monte Carlo (DSMC) method for argon and chlorine discharges. ICP reactors generally operate at pressures on the order of 1 to 10 mTorr. At such low pressures, rarefaction can be significant to the degree that the constitutive relations used in typical CFD techniques become invalid and a particle simulation must be employed. This work will assess the extent to which CFD can be applied and evaluate the degree to which accuracy is lost in prediction of the phenomenon of interest; i.e., etch rate. If the CFD approach is found reasonably accurate and bench-marked with DSMC and experimental results, it has the potential to serve as a design tool due to the rapid time relative to DSMC. The continuum CFD simulation solves the governing equations for plasma flow using a finite difference technique with an implicit Gauss-Seidel Line Relaxation method for time marching toward a converged solution. The equation set consists of mass conservation for each species, separate energy equations for the electrons and heavy species, and momentum equations for the gas. The sheath is modeled by imposing the Bohm velocity to the ions near the walls. The DSMC method simulates each constituent of the gas as a separate species which would be analogous in CFD to employing separate species mass, momentum, and energy equations. All particles including electrons are moved and allowed to collide with one another with the stipulation that the electrons remain tied to the ions consistent with the concept of ambipolar diffusion. The velocities of the electrons are allowed to be modified during collisions and are not confined to a Maxwellian distribution. These benefits come at a price in terms of computational time and memory. The DSMC and CFD are made as consistent as possible by using similar chemistry and power deposition models. Although the comparison of CFD and DSMC is interesting, the main goal of this work is the increased understanding of high-density plasma flowfields that can then direct improvements in both techniques. This work is unique in the level of the physical models employed in both the DSMC and CFD for high-density plasma reactor applications. For example, the electrons are simulated in the present DSMC work which has not been done before for low temperature plasma processing problems. In the CFD approach, for the first time, the charged particle transport (discharge physics) has been self-consistently coupled to the gas flow and heat transfer.

Hash, D. B.↗
NASA NTRSDate not supplied

Designing the Design Process for Early Problem Discovery for a Complex Aeronautics Systems Challenge

The earliest stage in the innovation lifecycle, problem formulation, is crucial for setting direction in an innovation effort. When faced with an interesting problem, engineers commonly assume the approximate solution area and focus on ideating innovative solutions. However, in this project, NASA and their contracted partner, Accenture, collaboratively conducted problem discovery to ensure that solutioning efforts were focused on the right problems, for the right users, and addressing the most critical needs—in this case, exploring weather tolerant operations (WTO) to further urban air mobility (UAM) – known as UAM WTO. The project team leveraged generative, qualitative methods to understand the ecosystem, players, and where challenges in the industry are inhibiting development. The complexity of the problem area required that the team constantly observe and iterate on problem discovery, effectively “designing the design process.” This report discusses the approach, methodologies, and selected results, including insights on the application of early-stage design methodologies to a complex, system-level problem.

Problem formulation↗
NASA NTRS2017

NASA Collaborative Design Processes

This is Block 1, the first evolution of the world's most powerful and versatile rocket, the Space Launch System, built to return humans to the area around the moon. Eventually, larger and even more powerful and capable configurations will take astronauts and cargo to Mars. On the sides of the rocket are the twin solid rocket boosters that provide more than 75 percent during liftoff and burn for about two minutes, after which they are jettisoned, lightening the load for the rest of the space flight. Four RS-25 main engines provide thrust for the first stage of the rocket. These are the world's most reliable rocket engines. The core stage is the main body of the rocket and houses the fuel for the RS-25 engines, liquid hydrogen and liquid oxygen, and the avionics, or "brain" of the rocket. The core stage is all new and being manufactured at NASA's "rocket factory," Michoud Assembly Facility near New Orleans. The Launch Vehicle Stage Adapter, or LVSA, connects the core stage to the Interim Cryogenic Propulsion Stage. The Interim Cryogenic Propulsion Stage, or ICPS, uses one RL-10 rocket engine and will propel the Orion spacecraft on its deep-space journey after first-stage separation. Finally, the Orion human-rated spacecraft sits atop the massive Saturn V-sized launch vehicle. Managed out of Johnson Space Center in Houston, Orion is the first spacecraft in history capable of taking humans to multiple destinations within deep space. 2) Each element of the SLS utilizes collaborative design processes to achieve the incredible goal of sending human into deep space. Early phases are focused on feasibility and requirements development. Later phases are focused on detailed design, testing, and operations. There are 4 basic phases typically found in each phase of development.

Jones, Davey↗