Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Rapid Process Design”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

WarpX: Delivering Unprecedented Particle-in-Cell Simulation Capability

Since 1939, more than 30 percent of all Nobel prizes in physics and four of the past 14 prizes in chemistry have been awarded for work with particle accelerators. These tools are now used to treat cancer and produce medical supplies, support research in applied fields such as pharmaceuticals, create microcircuits, and sterilize food—and the applications list continues to grow. However, the size of the facilities needed to house these machines—which are often dozens of kilometers long—has limited their future potential. Thus, researchers are motivated to create novel particle accelerator designs that provide new imaging capability but have a much smaller footprint. The Exascale Computing Project’s WarpX application captures the full complexity of the acceleration processes within plasma-based design, supporting the rapid and cost-efficient development of tens of thousands of new particle accelerators for various applications from improving human health to nuclear fusion reactors.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1980

Spacecraft loads methodology - Transient vs. shock spectra method

The methodology for the establishment of spacecraft loads is strongly influenced by project constraints which include the cost, schedule and allowable weight. The most rigorous approach is the transient loads analysis which requires a composite mathematical model of the spacecraft and launch vehicle. The structural member loads for the entire composite structure are computed by applying the forcing functions, which represent various dynamic environments during the mission, to the composite model. Although this method ideally leads to a lightweight design, it is costly and time consuming due to complex interfaces involving many organizations. To reduce complexity and cost a shock spectra method has been used to design spacecraft structures. This method utilizes envelopes of shock spectra of launch vehicle accelerations obtained from analysis and/or flight measurements. Since only limited information on the launch vehicle model is involved in this process the design loads iteration cycle can be rapidly performed within the payload organization. In the present paper, these two methods will be evaluated by comparing the loads for several spacecraft. Flight measured loads will also be used in the evaluation.

Chen, J. C.↗
NASA NTRS1995

Micromechanical Machining Processes and their Application to Aerospace Structures, Devices and Systems

Micromechanical machining processes are those micro fabrication techniques which directly remove work piece material by either a physical cutting tool or an energy process. These processes are direct and therefore they can help reduce the cost and time for prototype development of micro mechanical components and systems. This is especially true for aerospace applications where size and weight are critical, and reliability and the operating environment are an integral part of the design and development process. The micromechanical machining processes are rapidly being recognized as a complementary set of tools to traditional lithographic processes (such as LIGA) for the fabrication of micromechanical components. Worldwide efforts in the U.S., Germany, and Japan are leading to results which sometimes rival lithography at a fraction of the time and cost. Efforts to develop processes and systems specific to aerospace applications are well underway.

Friedrich, Craig R.↗
DOE OSTI2022

Evaluating the intrinsic resistance to balling of alloys: A High-throughput physics-informed and data-enabled approach

To date, the vast majority of work on metal additive manufacturing (AM) has been framed in terms of the need to tune processing conditions for a particular AM technology in order to print conventional alloys, oftentimes developed for fabrication methods other than AM. This approach overlooks the fact that historically, many engineering alloy system has been designed with a particular processing route in mind, e.g., ingot metallurgy, powder metallurgy, rapid quenching, etc. There are thus significant opportunities to design alloys specifically for AM. A key challenge is that alloy design requires performance metrics that can be optimized by exploring the alloy chemistry space. Here, we present a study in which we examine how intrinsic thermophysical properties can be used to estimate performance metrics related to the behavior of a solidifying metal droplet under AM-relevant conditions. By identifying these intrinsic properties, it is possible to directly incorporate ‘intrinsic printability’, specifically ‘intrinsic resistance to balling’, into AM-focused alloy design.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Rapid data acquisition and machine learning-assisted composition design of functionally graded alloys via wire arc additive manufacturing

Abstract The lack of high-quality datasets in materials science hinders artificial intelligence (AI)-driven alloy design. To address this challenge, wire arc additive manufacturing (WAAM) was employed to fabricate graded alloys, generating extensive data for machine learning (ML)-assisted property prediction. ML models were developed using high-throughput experiments, computational models, and genetic algorithm to optimize feature selection, successfully predicting hardness and porosity. The ML model demonstrated its efficacy by designing a gradient alloy with enhanced properties. However, scaling up revealed uncertainties in tensile property and porosity due to differences in size and thermal conditions between the designed alloy build and the gradient print used to construct the ML model. This underscores the need for uncertainty quantification and process optimization in WAAM-driven alloy design. Our work advances AI-integrated additive manufacturing, offering a rapid approach to exploring process–structure–property relationships and accelerating materials development.

Wang, Xin↗
NASA NTRS2013

Dawn Orbit Determination Team: Trajectory Modeling and Reconstruction Processes at Vesta

The Dawn spacecraft spent over a year in orbit around Vesta from July 2011 through August 2012. In order to maintain the designated science reference orbits and enable the transfers between those orbits, precise and timely orbit determination was required. Challenges included low-thrust ion propulsion modeling, estimation of relatively unknown Vesta gravity and rotation models, track-ing data limitations, incorporation of real-time telemetry into dynamics model updates, and rapid maneuver design cycles during transfers. This paper discusses the dynamics models, filter configuration, and data processing implemented to deliver a rapid orbit determination capability to the Dawn project.

low thrust↗
NASA NTRS2017

Lessons Learned from Applying Design Thinking in a NASA Rapid Design Study in Aeronautics

In late 2015, NASA's Aeronautics Research Mission Directorate (ARMD) funded an experiment in rapid design and rapid teaming to explore new approaches to solving challenging design problems in aeronautics in an effort to cultivate and foster innovation. This report summarizes several lessons learned from the rapid design portion of the study. This effort entailed learning and applying design thinking, a human-centered design approach, to complete the conceptual design for an open-ended design challenge within six months. The design challenge focused on creating a capability to advance experimental testing of autonomous aeronautics systems, an area of great interest to NASA, the US government as a whole, and an entire ecosystem of users and developers around the globe. A team of nine civil servant researchers from three of NASA's aeronautics field centers with backgrounds in several disciplines was assembled and rapidly trained in design thinking under the guidance of the innovation and design firm IDEO. The design thinking process, while used extensively outside the aerospace industry, is less common and even counter to many practices within the aerospace industry. In this report, several contrasts between common aerospace research and development practices and design thinking are discussed, drawing upon the lessons learned from the NASA rapid design study. The lessons discussed included working towards a design solution without a set of detailed design requirements, which may not be practical or even feasible for management to ascertain for complex, challenging problems. This approach allowed for the possibility of redesigning the original problem statement to better meet the needs of the users. Another lesson learned was to approach problems holistically from the perspective of the needs of individuals that may be affected by advances in topic area instead of purely from a technological feasibility viewpoint. The interdisciplinary nature of the design team also provided valuable experience by allowing team members from different technological backgrounds to work side-by-side instead of dividing into smaller teams, as is frequently done in traditional multidisciplinary design. The team also learned how to work with qualitative data obtained primarily through the 70-plus interviews that were conducted over the course of this project, which was a sharp contrast to using quantitative data with regards to identifying, capturing, analyzing, storing, and recalling the data. When identifying potential interviewees who may have useful contributions to the design subject area, the team found great value in talking to non-traditional users and potential beneficiaries of autonomous aeronautics systems whose impact on the aeronautics autonomy ecosystem is growing swiftly. Finally, the team benefitted from using "sacrificial prototyping," which is a method of rapidly prototyping draft concepts and ideas with the intent of enabling potential users to provide significant feedback early in the design process. This contrasts the more common approach of using expensive prototypes that focus on demonstrating technical feasibility. The unique design approach and lessons learned by the team throughout this process culminated in a final design concept that was quite different than what the team originally assumed would be the design concept initially. A summary of the more usercentered final design concept is also provided.

McGowan, Anna-Maria↗
NASA NTRS2006

An Overview of the Role of Systems Analysis in NASA's Hypersonics Project

NASA's Aeronautics Research Mission Directorate recently restructured its Vehicle Systems Program, refocusing it towards understanding the fundamental physics that govern flight in all speed regimes. Now called the Fundamental Aeronautics Program, it is comprised of four new projects, Subsonic Fixed Wing, Subsonic Rotary Wing, Supersonics, and Hypersonics. The Aeronautics Research Mission Directorate has charged the Hypersonics Project with having a basic understanding of all systems that travel at hypersonic speeds within the Earth's and other planets atmospheres. This includes both powered and unpowered systems, such as re-entry vehicles and vehicles powered by rocket or airbreathing propulsion that cruise in and accelerate through the atmosphere. The primary objective of the Hypersonics Project is to develop physics-based predictive tools that enable the design, analysis and optimization of such systems. The Hypersonics Project charges the systems analysis discipline team with providing it the decision-making information it needs to properly guide research and technology development. Credible, rapid, and robust multi-disciplinary system analysis processes and design tools are required in order to generate this information. To this end, the principal challenges for the systems analysis team are the introduction of high fidelity physics into the analysis process and integration into a design environment, quantification of design uncertainty through the use of probabilistic methods, reduction in design cycle time, and the development and implementation of robust processes and tools enabling a wide design space and associated technology assessment capability. This paper will discuss the roles and responsibilities of the systems analysis discipline team within the Hypersonics Project as well as the tools, methods, processes, and approach that the team will undertake in order to perform its project designated functions.

Robinson, Jeffrey S.↗
NASA NTRSDate not supplied

The Lunar Lab Initiative

Analogous to terrestrial Antarctic basecamps at our south pole, space exploration outposts will be a combination of habitation and science-focused assets. The Artemis Exploration Roadmap endeavors to establish a sustained human presence on the lunar south pole starting in 2028. Within the planned Artemis Base Camp, most efforts to date have focused on the habitation assets or a mixture of science and habitation assets . With the recent advent of commercial lunar landing capabilities, the trade space can be further expanded to include dedicated science focused assets that ensure adequate science capability. To that end, the Forge, an innovation team initiative created at the Johnson Space Center (JSC), explored alternative ways to increase the science capabilities within the basecamp. The Forge uses structured brainstorming and facilitation to increase innovation within the assigned team, while executing its process in a rapid turnaround fashion for ideation and design study. As a pilot study for the Forge, a multi-disciplinary team investigated a lunar lab module to augment the lunar surface plans for Artemis. This formulation study evaluated the scientific and operational considerations for this dedicated crew space that would increase the capabilities of lunar surface science operations. The trade space evaluated single lunar lander delivery versus multiple lunar lander delivery for module assembly, alternative structural designs, the science instrument outfitting with mapping to scientific goals to maximize lunar science objectives, and how the lab would be operated. The lab operations options explored a stand-alone facility, as well as a facility integrated into a larger lunar surface complex, while evaluating crew usage and habitability considerations. The resulting alternatives were evaluated by the Forge team with a set of metrics to determine their originality, feasibility, and science performance, and thereby provide a recommendation to the lunar architecture planning team. Lessons learned from the lunar lab study were compiled to improve the process and tools for future Forge studies. Forward work, open issues, and challenges to further refine the design of the various science-focused asset options were also documented. By providing a robust science capability at humanity’s furthest outpost, we can plan for a sustained human lunar presence once the initial lunar surface access capability is well established.

Lunar outpost↗
NASA NTRS1996

Integrating a Genetic Algorithm Into a Knowledge-Based System for Ordering Complex Design Processes

The design cycle associated with large engineering systems requires an initial decomposition of the complex system into design processes which are coupled through the transference of output data. Some of these design processes may be grouped into iterative subcycles. In analyzing or optimizing such a coupled system, it is essential to be able to determine the best ordering of the processes within these subcycles to reduce design cycle time and cost. Many decomposition approaches assume the capability is available to determine what design processes and couplings exist and what order of execution will be imposed during the design cycle. Unfortunately, this is often a complex problem and beyond the capabilities of a human design manager. A new feature, a genetic algorithm, has been added to DeMAID (Design Manager's Aid for Intelligent Decomposition) to allow the design manager to rapidly examine many different combinations of ordering processes in an iterative subcycle and to optimize the ordering based on cost, time, and iteration requirements. Two sample test cases are presented to show the effects of optimizing the ordering with a genetic algorithm.

Rogers, James L.↗
DOE OSTI2017

New method of automated statistical analysis of polymer-stabilized metal nanoparticles in electron microscopy images

The efficiency of the synthesis and application of metal/nonmetal particles several nanometers in size, prepared in solutions and stabilized with polymers, can be increased by applying a reliable statistical analysis and determining particle-size distributions for different systems. A new method for processing electron microscopy images of nanoparticles ≤10 nm in size and the program Analyzer of Nanoparticles designed for rapid recognition and measurements are presented. The program combines two approaches: threshold image processing for particle recognition and fitting the model of the particles with neighborhood background to the real experimental images.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRSDate not supplied

Rapid Assessment of a Lunar Surface Laboratory Module

Johnson Space Center is piloting an innovation team known as the Forge to perform rapid turnaround, concurrent engineering studies. The Forge is intended to be able to pull together a team of strategically selected domain experts to innovatively solve a specified problem within a short period of time. The Forge’s inaugural project being the development of a Lunar Surface Laboratory Module concept. The lab module is intended as an option for the Artemis program’s Lunar Architecture Team. The lab module may allow for increased science productivity and return on investment than a surface architecture with only the habitat. This paper will discuss the configuration of the Lunar Laboratory module, including the pressure vessel, its placement relative to the Surface Habitat and Pressurized Rover, and internal architecture. In order to determine the suitability of such a design, a human factors evaluation is conducted. Historically, a human factors evaluation of a habitable volume could require a month or longer, including time needed to prepare a test plan, conduct the evaluation, compile the data, and produce a report. The entire Forge effort will only last for five weeks, forcing the creation of a rapid assessment process. This rapid assessment includes three evaluation studies, all conducted and processed in the space of a single day, to determine the acceptability of the resulting design. The first evaluation is a card sort evaluation of the laboratory instruments. A brief discussion of the card sort evaluation is provided. This card sort is focused on the relative positioning of the laboratory instruments, determining whether a given instrument should be adjacent to, or separated from, another. It will use human factors personnel and both life and physical scientists as subject matter experts. The second evaluation is a science productivity tabletop evaluation. This evaluation focuses on the selection of instruments and the number of instruments, attempting to assess the amount of work the crew will be able to use the facility to do. It uses life and physical science personnel as subject matter experts. The third evaluation is a CAD or Virtual Reality human factors walkthrough evaluation. This evaluation focuses on the layout of the lab module and its connectivity to the basecamp’s pressurized elements. If possible, astronauts will be used as subject matter experts. Each of these evaluations will focus primarily on objective data with limited subjective comments, reducing the time required for processing responses. The results of each evaluation and their implications will be discussed. Based on the evaluation data, an overall acceptability of the Lunar Surface Laboratory Module produced by the Forge study can be determined. Lessons learned and recommendations for future use of the human factors rapid assessment process in early design trades will also be provided.

Lunar Laboratory↗
DOE OSTI2018

Born Qualified Grand Challenge LDRD Final Report

This SAND report fulfills the final report requirement for the Born Qualified Grand Challenge LDRD. Born Qualified was funded from FY16-FY18 with a total budget of ~$13M over the 3 years of funding. Overall 70+ staff, Post Docs, and students supported this project over its lifetime. The driver for Born Qualified was using Additive Manufacturing (AM) to change the qualification paradigm for low volume, high value, high consequence, complex parts that are common in high-risk industries such as ND, defense, energy, aerospace, and medical. AM offers the opportunity to transform design, manufacturing, and qualification with its unique capabilities. AM is a disruptive technology, allowing the capability to simultaneously create part and material while tightly controlling and monitoring the manufacturing process at the voxel level, with the inherent flexibility and agility in printing layer-by-layer. AM enables the possibility of measuring critical material and part parameters during manufacturing, thus changing the way we collect data, assess performance, and accept or qualify parts. It provides an opportunity to shift from the current iterative design-build-test qualification paradigm using traditional manufacturing processes to design-by-predictivity where requirements are addressed concurrently and rapidly. The new qualification paradigm driven by AM provides the opportunity to predict performance probabilistically, to optimally control the manufacturing process, and to implement accelerated cycles of learning. Exploiting these capabilities to realize a new uncertainty quantification-driven qualification that is rapid, flexible, and practical is the focus of this effort.

36 MATERIALS SCIENCE↗
NASA NTRS2008

Method for the growth of large low-defect single crystals

A method and the benefits resulting from the product thereof are disclosed for the growth of large, low-defect single-crystals of tetrahedrally-bonded crystal materials. The process utilizes a uniquely designed crystal shape whereby the direction of rapid growth is parallel to a preferred crystal direction. By establishing several regions of growth, a large single crystal that is largely defect-free can be grown at high growth rates. This process is particularly suitable for producing products for wide-bandgap semiconductors, such as SiC, GaN, AlN, and diamond. Large low-defect single crystals of these semiconductors enable greatly enhanced performance and reliability for applications involving high power, high voltage, and/or high temperature operating conditions.

Powell, J. Anthony↗
NASA NTRS1995

Library reuse in a rapid development environment

The Aeroscience and Flight Mechanics Division (AFMD) established a Rapid Development Laboratory (RDL) to investigate and improve new 'rapid development' software production processes and refine the use of commercial, off-the-shelf (COTS) tools. These tools and processes take an avionics design project from initial inception through high fidelity, real-time, hardware-in-the-loop (HIL) testing. One central theme of a rapid development process is the use and integration of a variety of COTS tools: This paper discusses the RDL MATRIX(sub x)(R) libraries, as well as the techniques for managing and documenting these libraries. This paper also shows the methods used for building simulations with the Advanced Simulation Development System (ASDS) libraries, and provides metrics to illustrate the amount of reuse for five complete simulations. Combining ASDS libraries with MATRIX(sub x)(R) libraries is discussed.

Uhde, JO↗
NASA NTRS2010

Capabilities and Impact on Wind Analyses of the Hurricane Imaging Radiometer (HIRAD)

The Hurricane Imaging Radiometer (HIRAD) is a new airborne microwave remote sensor for hurricane observations that is currently under development by NASA Marshall Space Flight Center in partnership with the NOAA Atlantic Oceanographic and Meteorological Laboratory/Hurricane Research Division, the University of Central Florida, the University of Michigan, and the University of Alabama in Huntsville. The instrument is being test flown in January and is expected to participate in or collaborate with the tropical cyclone experiment GRIP (Genesis and Rapid Intensification Processes) in the 2010 season. HIRAD is designed to study the wind field in some detail within strong hurricanes and to enhance the real-time airborne ocean surface winds observation capabilities of NOAA and USAF Weather Squadron hurricane hunter aircraft currently using the operational Stepped Frequency Microwave Radiometer (SFMR). Unlike SFMR, which measures wind speed and rain rate along the ground track at a single point directly beneath the aircraft, HIRAD will provide images of the surface wind and rain field over a wide swath (approx.3 x the aircraft altitude) with approx.2 km resolution. See Figure 1, which depicts a simulated HIRAD swath versus the line of data obtained by SFMR.

Miller, Timothy L.↗
NASA NTRS2014

Additive Manufacturing and 3D Printing in NASA: An Overview of Current Projects and Future Initiatives for Space Exploration

NASA, including each Mission Directorate, is investing in, experimenting with, and/or utilizing AM across a broad spectrum of applications and projects; Centers have created and are continuing to create partnerships with industry, other Government Agencies, other Centers, and Universities; In-house additive manufacturing capability enables rapid iteration of the entire design, development and testing process, increasing innovation and reducing risk and cost to projects; For deep space exploration, AM offers significant reduction to logistics costs and risk by providing ability to create on demand; There are challenges: Overwhelming message from recent JANNAF AM for Propulsion Applications TIM was "certification."; NASA will continue to work with our partners to address this and other challenges to advance the state of the art in AM and incorporate these capabilities into an array of applications from aerospace to science missions to deep space exploration.

Clinton, R. G., Jr.↗