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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 883 records · Page 49
All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

System Engineering of Autonomous Space Vehicles

Human exploration of the solar system requires fully autonomous systems when travelling more than 5 light minutes from Earth. This autonomy is necessary to manage a large, complex spacecraft with limited crew members and skills available. The communication latency requires the vehicle to deal with events with only limited crew interaction in most cases. The engineering of these systems requires an extensive knowledge of the spacecraft systems, information theory, and autonomous algorithm characteristics. The characteristics of the spacecraft systems must be matched with the autonomous algorithm characteristics to reliably monitor and control the system. This presents a large system engineering problem. Recent work on product-focused, elegant system engineering will be applied to this application, looking at the full autonomy stack, the matching of autonomous systems to spacecraft systems, and the integration of different types of algorithms. Each of these areas will be outlined and a general approach defined for system engineering to provide the optimal solution to the given application context.

Watson, Michael D.↗
NASA NTRS2010

Pathways and Challenges to Innovation in Aerospace

This paper explores impediments to innovation in aerospace and suggests how successful pathways from other industries can be adopted to facilitate greater innovation. Because of its nature, space exploration would seem to be a ripe field of technical innovation. However, engineering can also be a frustratingly conservative endeavor when the realities of cost and risk are included. Impediments like the "find the fault" engineering culture, the treatment of technical risk as almost always evaluated in terms of negative impact, the difficult to account for expansive Moore's Law growth when making predictions, and the stove-piped structural organization of most large aerospace companies and federally funded research laboratories tend to inhibit cross-cutting technical innovation. One successful example of a multi-use cross cutting application that can scale with Moore's Law is the Evolutionary Computational Methods (ECM) technique developed at the Jet Propulsion Lab for automated spectral retrieval. Future innovations like computational engineering and automated design optimization can potentially redefine space exploration, but will require learning lessons from successful innovators.

Terrile, Richard J.↗
NASA NTRS2016

Enabling Wireless Avionics Intra-Communications

The Electromagnetics and Sensors Branch of NASA Langley Research Center (LaRC) is investigating the potential of an all-wireless aircraft as part of the ECON (Efficient Reconfigurable Cockpit Design and Fleet Operations using Software Intensive, Networked and Wireless Enabled Architecture) seedling proposal, which is funded by the Convergent Aeronautics Solutions (CAS) project, Transformative Aeronautics Concepts (TAC) program, and NASA Aeronautics Research Institute (NARI). The project consists of a brief effort carried out by a small team in the Electromagnetic Environment Effects (E3) laboratory with the intention of exposing some of the challenges faced by a wireless communication system inside the reflective cavity of an aircraft and to explore potential solutions that take advantage of that environment for constructive gain. The research effort was named EWAIC for "Enabling Wireless Aircraft Intra-communications." The E3 laboratory is a research facility that includes three electromagnetic reverberation chambers and equipment that allow testing and generation of test data for the investigation of wireless systems in reflective environments. Using these chambers, the EWAIC team developed a set of tests and setups that allow the intentional variation of intensity of a multipath field to reproduce the environment of the various bays and cabins of large transport aircraft. This setup, in essence, simulates an aircraft environment that allows the investigation and testing of wireless communication protocols that can effectively be used as a tool to mitigate some of the risks inherent to an aircraft wireless system for critical functions. In addition, the EWAIC team initiated the development of a computational modeling tool to illustrate the propagation of EM waves inside the reflective cabins and bays of aircraft and to obtain quantifiable information regarding the degradation of signals in aircraft subassemblies. The nose landing gear of a UAV CAD model was used to model the propagation of a system in a "deployed" configuration versus a "stowed" configuration. The differences in relative field strength provide valuable information about the distribution of the field that can be used to engineer RF links with optimal radiated power and antenna configuration that accomplish the intended system reliability. Such modeling will be necessary in subsequent studies for managing multipath propagation characteristics inside a main cabin and to understand more complex environments, such as the inside wings, landing gear bays, cargo bays, avionics bays, etc. The results of the short research effort are described in the present document. The team puts forth a set of recommendations with the intention of informing the project and program leadership of the future work that, in the opinion of the EWAIC team, would assist the ECON team reach the intended goal of developing an all-wireless aircraft.

Torres, Omar↗
NASA NTRS2019

Feasibility of Electrified Propulsion for Ultra-Efficient Commercial Aircraft Final Report

MIT, Aurora Flight Sciences, and USC have collaborated to assess the feasibility of electric, hybridelectric, and turbo-electric propulsion for ultra-efficient commercial transportation. The work has drawn on the team expertise in disciplines related to aircraft design, propulsion-airframe integration, electric machines and systems, engineering system design, and optimization. A parametric trade space analysis has been carried out to assess vehicle performance across a range of transport missions and propulsion architectures to establish how electrified propulsion systems scale. An optimization approach to vehicle conceptual design modeling was taken to enable rapid multidisciplinary design space exploration and sensitivity analysis. The results of the analysis indicate vehicle aero-propulsive integration benefits enabled by electrification are required to offset the increased weight and loss associated with the electric system and achieve enhanced performance; the report describes the conceptual configurations than can offer such enhancements. The main contribution of the present work is the definition of electric vehicle design attributes for potential efficiency improvements at different scales. Based on these results, key areas for future research are identified, and extensions to the trade space analysis suitable for higher fidelity electrified commercial aircraft design and analysis have been developed.

Hall, D.K.↗
NASA NTRSDate not supplied

A Review Towards the Design Optimization of High-Performance Additively Manufactured Rotating Detonation Rocket Engine Injectors

Rotating Detonation Rocket Engines (RDRE) have been marketed primarily for their higher specific impulse potential over constant pressure (CP) liquid rocket engines. However, several other performance advantages exist such as heat transfer advantages for gas expander cycle, increased completeness of combustion at low chamber L*, compact engine design, reduced coolant channel pressure drop potential, and improved injector C* performance. NASA has paved the way for liquid engine system performance enhancement since the Apollo program and continues to do so with metal additive manufacturing (AM), new advanced materials, and advanced propulsion concepts. A team of propulsion development engineers at NASA are in the process of developing high-performance 7K lbf class RDRE hardware for their potential use in lander, upper stage, and even launch vehicle applications. Clear advantages have been demonstrated with AM including program cost and schedule reductions of up to 50%. It is well known that injector performance is integrally linked to the global performance of a combustion device. This is especially the case for RDREs since detonation stability is heavily dependent on the mixedness of propellants. A major goal of this work is to identify what has been done in the open experimental literature and what injectors design features are conducive to high performance in the detonation cycle. This paper reviews the available literature and reports the primary gaps in the knowledge base needed by the pressure gain combustion (PGC) community. Major conclusions are documented, and suggestions given towards the design of high-performance liquid RDRE injectors. In addition, the integration of metal AM into the design of liquid RDRE injector schemes is included.

rotating detonation rocket engine↗
DOE OSTI2021

Fuel Properties and Kinetics

The Co-Optimization of Fuels and Engines (CoOptima) program is focused on a two-pronged approach to develop new, lower net-carbon fuels and advanced engine technologies in tandem. This effort brings nine national labs and several university and industry partners together to simultaneously identify new fuel candidates and to further engine technology development in the light-, medium-, and heavy-duty vehicle sectors with a focus on fuel economy and emission reduction. The fuel properties and kinetics project is aimed at achieving a better understanding of fuel property kinetics and how they impact engine performance such that more efficient and lower emitting engines can be made a reality. Several promising biofuel candidates were identified through tiered screening approaches and were evaluated utilizing unique bench-scale measurement techniques. Kinetic models were developed to describe autoignition and soot pre-cursor formation mechanisms to identify the most promising candidates that advanced various combustion strategies.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Process Optimization

Process optimization is the discipline of adjusting a process to optimize a specified set of parameters without violating engineering constraints. This article reviews data-driven optimization methods based on genetic algorithms and stochastic models and demonstrates their use in powder-bed fusion and directed energy deposition processes. In the latter case, closed-loop feedback is used to control melt pool temperature and cooling rate in order to achieve desired microstructure.

Sprayberry, Michael↗
DOE OSTI2023

Numerical Optimization of Spray-Guided Spark Assistance for Cold Idle Operation in a Heavy-Duty Gasoline Compression Ignition Engine

This article describes the results of a response surface model (RSM)-based numerical optimization campaign for spray-guided spark assistance at cold operations in a heavy-duty gasoline compression ignition (GCI) engine. On the basis of an earlier work on spark-assisted GCI cold combustion, a space-filling design of experiments (DoE) method was first undertaken to investigate a multitude of hardware design variables and engine operating parameters. The main design variables included the number of injector nozzles, fuel split quantities and injection timings, and spark timing. The objective variables were engine combustion efficiency (ŋ c ), maximum pressure rise rate (MPRR), and engine-out nitrogen oxide (NO x ) emissions. A total of 150 design candidates were automatically generated using the Sobol sequence method provided by the commercial software package, CAESES. Then, closed-cycle computational fluid dynamic (CFD) spark-assisted GCI simulations under cold idling operations were performed. The outcomes from the CFD-DoE design campaign were utilized to construct high-fidelity RSMs that allowed for further design optimization of the spark plug- and fuel injector-related design variables, along with fuel injection strategy parameters. A merit function with respect to objective variables was formulated with an appropriate weight assignment on each objective variable. Finally, the best design candidate was identified from the RSM-based optimization process and further validated in the CFD analysis. The best design candidate showed the potential to significantly improve combustion efficiency (ŋ c > 90%) over the baseline at cold idle while satisfying MPRR and NOx emissions constraints (MPRR < 5 bar/CAD and NO x < 4.5 g/kWh).

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1984

On optimal design for the blade-root/hub interface in jet engines

Two major problems identified with the design of the blade-root/hub interface are discussed. The first is the so-called friction contact problem which has two special features: unilateral contact and Coulomb's friction. One of the difficulties in this problem is that the portions of contact and sticking/sliding surfaces are not known a priori. The second is the shape optimization problem which is characterized either by the minimization of the maximum contact pressure or by the minimization of the equivalent stress on the boundary. Design variables are the shapes of the blade-root and the hub. It is noted that friction contact and shape optimization problems are strongly coupled in the present design problem.

Kikuchi, N.↗
DOE OSTI2026

Composition, Activity, and Stability of IrO x Oxygen Evolution Reaction Electrocatalysts

The oxygen evolution reaction (OER) is integral to several electrochemical energy conversion and storage technologies, including carbon dioxide reduction to value added fuels, nitrogen reduction to ammonia, reversible fuel cells, rechargeable metal−air batteries, and water electrolysis to produce hydrogen. Iridium oxide (IrO x ) is widely recognized as the benchmark OER catalyst for acidic environments. Despite widespread use of IrO x catalysts, most notably in proton-exchange membrane water electrolyzers (PEMWEs), a comprehensive understanding of the physicochemical properties of commercial catalysts and the impact of these properties on both the activity and stability of these catalysts is lacking. Here, we study commercial IrO x catalysts with different physicochemical properties, three nominally considered amorphous and three rutile, to elucidate how structural and compositional variations affect OER activity and stability. Utilizing standardized aqueous electrochemical protocols, time-resolved dissolution quantification using inductively-coupled plasma mass spectrometry, and physicochemical characterization, including multiple synchrotron X-ray techniques, we systematically correlate catalyst properties with OER performance and degradation behavior aided by principal component analysis (PCA). Our results demonstrate the general trend of amorphous IrO x having higher intrinsic activity but limited stability and crystalline rutile IrO 2 having lower activity but enhanced stability against dissolution. The trends within the amorphous and rutile catalyst groups correlate with inherent material properties, including phase composition and structure, crystallinity, particle size, surface area, and surface structure/chemistry. Notably, we identify a rutile catalyst with the largest crystallite/ domain sizes, moderate surface area, a small fraction of hydrous phase, and a favorable pore structure (trimodal distributions of pore sizes ranging from 2−5 nm) that exhibits the best balance between activity and stability among the six catalysts studied here. These findings illustrate a fundamental structure-governed trade-off between activity and stability and highlight the critical role of surface chemistry modification and structure engineering in IrO x catalyst optimization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2015

Improved Rhenium Thrust Chambers

Radiation-cooled bipropellant thrust chambers are being considered for ascent/ descent engines and reaction control systems on various NASA missions and spacecraft, such as the Mars Sample Return and Orion Multi-Purpose Crew Vehicle (MPCV). Currently, iridium (Ir)-lined rhenium (Re) combustion chambers are the state of the art for in-space engines. NASA's Advanced Materials Bipropellant Rocket (AMBR) engine, a 150-lbf Ir-Re chamber produced by Plasma Processes and Aerojet Rocketdyne, recently set a hydrazine specific impulse record of 333.5 seconds. To withstand the high loads during terrestrial launch, Re chambers with improved mechanical properties are needed. Recent electrochemical forming (EL-Form"TM") results have shown considerable promise for improving Re's mechanical properties by producing a multilayered deposit composed of a tailored microstructure (i.e., Engineered Re). The Engineered Re processing techniques were optimized, and detailed characterization and mechanical properties tests were performed. The most promising techniques were selected and used to produce an Engineered Re AMBR-sized combustion chamber for testing at Aerojet Rocketdyne.

O'Dell, John Scott↗
DOE OSTI2026

Simultaneous Reduction of NOx and Fuel Consumption for Off-Road Powertrains

Simultaneously reducing criteria pollutants and fuel consumption is important for clean air and improving vehicle total cost of ownership. The goal of this effort was focused on a 90% NOx reduction and 10% fuel savings for an off-road 407 kW diesel engine. The baseline was a production Fiat Powertrain 13L engine and aftertreatment system meeting 0.4 g/kW-hr NOx. The baseline system was quantified over the NRTC, RMC, new low load cycle and five field cycles. A next generation engine was built incorporating several fuel-efficient design features, including a higher compression ratio, increased fuel-rail pressure, low-friction piston rings, and a high-efficiency variable-geometry turbocharger. Cylinder deactivation and EGR pump technologies were added to this engine as well. The combination was optimized prior to adding advanced aftertreatment systems, showing the trade-off of engine out NOx and exhaust temperature. Two next-generation catalyst technologies were employed into a LO-SCR plus main SCR system, both with and without an electric heater upstream of the LO-SCR. These catalysts were hydrothermally aged to simulate significant field use. Dual SCR dosing with newly developed controls played a critical role in achieving the proper split between the upstream LO-SCR and the downstream main SCR. Adding a next generation mixer for the downstream SCR proved essential in obtaining the final results. The optimal configuration required adding an electric heater to elevate the exhaust temperature at the LO-SCR for early cycle NOx reduction. The final results showed a 94.8% NOx reduction and 15.7% fuel savings on the composite NRTC.

McCarthy, James [Eaton Corporation]↗
DOE OSTI2021

RX-PSA

This code is built on top of the ML-PSA utility and implements the ability to implement a multi-fidelity parallel simulated annealing optimization for a range of engineering problems. RX-PSA provides specializations to interact with modern nuclear reactor codes such as VERA to perform assembly and core optimization in a robust way. RX-PSA also provides LWR specific objective functions and constraints to provide a straightforward user interface that reactor designers are familiar with.

Collins, BenjaminS.↗
DOE OSTI2024

Improving Additive Manufactured Component Performance through Multi-Scale Microstructure Simulation and Process Optimization

The purpose of this project was to utilize computational tools to understand the relationships between processing, microstructure, and properties for additively manufactured (AM) aluminum alloys for automotive applications, and to provide an engineering solution for helping to optimize process conditions. The project leverages ORNL developments in computational modeling, including AM process modeling, phase-field based microstructure evolution predictions, and data analytics techniques for mapping process conditions to material outcomes. The project utilized an Al-Cu-Mn-Zr alloy as a model material for studying formation of defects and microstructural features in response to variations in process conditions. Based on both pre-existing experimental data and simulation results, statistical process maps were constructed to identify regions of process space with minimal defect formation and advantageous microstructures and properties. The software tools used for this purpose were successful disseminated to GM, who were able to successful compile the relevant HPC codes within their own computing ecosystem and perform initial calculations to reproduce ORNL results.

36 MATERIALS SCIENCE↗
DOE OSTI2025

CFD modeling of near-wall combustion and unburned methane prediction in natural gas spark ignition engines

Natural gas-powered engines play a critical role in gas drilling, compression, and transmission sectors, but methane (CH 4 ) from engine combustion slip can be significant over their lifespan, contributing to atmospheric pollution and signaling reduced engine efficiency. Here, to address this challenge, computational fluid dynamics (CFD) simulations offer valuable insights into the in-cylinder combustion process, enabling the optimization of combustion strategies and engine designs to minimize unburned CH 4 slip. This study aims to evaluate and improve combustion models for simulating the combustion process and predicting unburned CH 4 concentrations in natural gas spark-ignition (SI) engines, including engines that are part of combined reformer-engine systems. Specifically, the performance of two flamelet-based combustion models—the Extended Coherent Flame Model (ECFM) and the G-equation model—was assessed using experimental engine data collected under varying excess-air ratio (λ) conditions and fuel compositions, including natural gas and syngas blends. In addition, to enhance the predictive capabilities of the G-equation model, a flame-wall interaction (FWI) sub-model was integrated into its framework. The effects of its model parameters, such as quenching and influence distance, on combustion behavior and unburned methane predictions were analyzed in detail. The ECFM tended to predict delayed combustion phasing under diluted mixture conditions, resulting in overprediction of unburned CH 4 concentrations. In contrast, the G-equation model provided reasonable predictions of combustion pressure, while representing higher the CH 4 reduction rate across the operating condition compared to experimental data. Incorporating the FWI sub-model—with the quenching distance calculated based on a pressure-dependent relation (P -0.48 ) and a fixed influence distance of 1.5 mm—further improved the G-equation model’s accuracy in predicting CH 4 reduction rates without compromising its ability to simulate the combustion process.

Combustion model↗
DOE OSTI2022

High Temperature Optocoupler for 3D High Density Power Modules

The goal of this proposed research is to develop a reliable high-temperature optocouplers, which can operate at 250°C with at least ten-year lifetime, and replace isolation transforms as the galvanic isolation solution for the 3D integration of high density power modules. The electrification of future transportations (i.e., electric vehicles) will continuously drive the demand for high density power modules. Optocouplers (i.e., packaged light emitter and detector) as a promising candidate to replace bulky isolation transformers are highly desirable to facilitate the continuous scale-down of gate driver circuitry that will lead to 3D high density power modules and achieve disruptive performance in terms of thermal management, power density, power efficiency, reliability and operating environments. However, regular semiconductor optoelectronic materials and devices have significant difficulty functioning in the harsh environments designated for high density power module usage (such as operation at high temperatures). Ultimately, it is not the intrinsic properties of power devices that prevent their use at higher temperatures, but rather the low voltage electronics needed to drive them and the packaging that surrounds them. The typical operating temperature for optocouplers is only up to 100°C, due to the limitations of light emitting diode (LED) devices inside and packaging materials. A systematic characterization methodology will be developed to analyze the performance, lifetime and reliability of LED devices and distinguish multiple failure mechanisms at high temperatures. An original methodology of “design for reliability” will be developed to design the optoelectronic devices with high reliability and long lifetime at high temperatures. A new architecture of high temperature high reliable optocouplers will be developed, fabricated and demonstrated with continuous operating at 250°C. The development of efficient, reliable high density 3D power modules is the foundation for energy efficiency and energy reliability. Enabled with advanced 3D integration and packaging technologies, high density power module solutions can achieve much more superior performance over the conventional discrete solutions in terms of efficiency, thermal management and power density. The proposed concept of high temperature optocouplers as the galvanic isolation solution for high density power modules will bring together interdisciplinary research involving the wide bandgap materials, optoelectronics, high reliable device design, electronics packaging and power modules. A streamline of skilled personnel would be trained including graduate and undergraduate students, local engineers and scientists which are in great demand to both academia and optoelectronics industry. The proposed research topics, such as, solid state lighting and high temperature device reliability, are currently of major interest at the Department of Energy, in particular, Sandia National Laboratories. This project can enhance collaborations between the University of Arkansas (UA) and Sandia National Laboratories. The findings of the proposed research are expected to be integrated into high density 3-D power modules at the Engineering Research Center for Power Optimization for Electro-Thermal Systems (POETS).

42 ENGINEERING↗
DOE OSTI2022

Optimization of matrix viscosity improves polypropylene fiber dispersion and properties of engineered cementitious composites

Engineered cementitious composites (ECC) is a durable cementitious material with high tensile ductility and strain-hardening characteristics. Although considered as a cost-effective fiber for ECC, polypropylene (PP) fiber is reportedly difficult to disperse in mortar matrix due to its high aspect ratio and hydrophobicity. In this study, the matrix viscosity of a low-carbon ECC based on limestone calcined clay cement was tailored as a variable to improve PP fiber dispersion under a pre-determined mixing protocol. The effect of matrix viscosity on the composite fresh and hardened properties was investigated experimentally. Results suggested an optimal range of matrix viscosity (10.3–11.5 Pa . s) favors the composite tensile strength and strain capacity at 28 days. At the optimal state with a 0.1 % viscosity modifying admixture (VMA)-to-binder mass ratio, PP-ECC achieved 7.0 % tensile strain capacity and 3.5 MPa ultimate tensile strength. When matrix viscosity falls outside the desired range, both ultimate tensile strength and strain capacity were diminished. By tailoring the VMA dosage, the matrix viscosity can be adjusted for desired fiber dispersion, workability, and mechanical properties. Finally, the findings of this study provide a technical reference for the practical design and application of PP-ECC.

36 MATERIALS SCIENCE↗