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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Translating Vision into Design: A Method for Conceptual Design Development

One of the most challenging tasks for engineers is the definition of design solutions that will satisfy high-level strategic visions and objectives. Even more challenging is the need to demonstrate how a particular design solution supports the high-level vision. This paper describes a process and set of system engineering tools that have been used at the Johnson Space Center to analyze and decompose high-level objectives for future human missions into design requirements that can be used to develop alternative concepts for vehicles, habitats, and other systems. Analysis and design studies of alternative concepts and approaches are used to develop recommendations for strategic investments in research and technology that support the NASA Integrated Space Plan. In addition to a description of system engineering tools, this paper includes a discussion of collaborative design practices for human exploration mission architecture studies used at the Johnson Space Center.

Carpenter, Joyce E.↗
DOE OSTI2020

Deep Retrofits for Multifamily: Experiences in Scaling to Zero Energy: Preprint

Zero net energy (ZNE) buildings are needed to reverse the growing trend of increasing energy consumption. But to make dramatic changes, existing buildings must be renovated at scale. In addition, the building stock must be electrified so that its energy needs could be met by renewable generation. Such aggressive goals often mean very high custom design and capital construction costs. Suitable options for comprehensive envelope retrofits can be too expensive to be practical, and electrification requires upgrades to building-level electrical infrastructure. This paper is a case study of eight projects—primarily multifamily residential—that strived for zero-energy, all-electric retrofits. The design teams were challenged to create solutions that could be replicated at scale, showing decreasing costs with broader adoption. Key technologies considered in designing cost-effective, scalable solutions include industrialized prefabricated retrofit components, modular HVAC solutions, and innovative domestic hot water systems. We trace the progress toward the goals set and examine the choices made by the teams as they encountered technical, logistical, and cost barriers. We also discuss financial challenges for multifamily retrofits, provide guidance for incentives, and examine procurement processes for design services and technologies.

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION↗
NASA NTRS2011

Engineering the System and Technical Integration

Approximately 80% of the problems encountered in aerospace systems have been due to a breakdown in technical integration and/or systems engineering. One of the major challenges we face in designing, building, and operating space systems is: how is adequate integration achieved for the systems various functions, parts, and infrastructure? This Contractor Report (CR) deals with part of the problem of how we engineer the total system in order to achieve the best balanced design. We will discuss a key aspect of this question - the principle of Technical Integration and its components, along with management and decision making. The CR will first provide an introduction with a discussion of the Challenges in Space System Design and meeting the challenges. Next is an overview of Engineering the System including Technical Integration. Engineering the System is expanded to include key aspects of the Design Process, Lifecycle Considerations, etc. The basic information and figures used in this CR were presented in a NASA training program for Program and Project Managers Development (PPMD) in classes at Georgia Tech and at Marshall Space Flight Center (MSFC). Many of the principles and illustrations are extracted from the courses we teach for MSFC.

Blair, J. C.↗
DOE OSTI2021

AI-based design of a nuclear reactor core

The authors developed an artificial intelligence (AI)-based algorithm for the design and optimization of a nuclear reactor core based on a flexible geometry and demonstrated a 3× improvement in the selected performance metric: temperature peaking factor. The rapid development of advanced, and specifically, additive manufacturing (3-D printing) and its introduction into advanced nuclear core design through the Transformational Challenge Reactor program have presented the opportunity to explore the arbitrary geometry design of nuclear-heated structures. The primary challenge is that the arbitrary geometry design space is vast and requires the computational evaluation of many candidate designs, and the multiphysics simulation of nuclear systems is very time-intensive. Therefore, the authors developed a machine learning-based multiphysics emulator and evaluated thousands of candidate geometries on Summit, Oak Ridge National Laboratory’s leadership class supercomputer. The results presented in this work demonstrate temperature distribution smoothing in a nuclear reactor core through the manipulation of the geometry, which is traditionally achieved in light water reactors through variable assembly loading in the axial direction and fuel shuffling during refueling in the radial direction. The conclusions discuss the future implications for nuclear systems design with arbitrary geometry and the potential for AI-based autonomous design algorithms.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

3D Printed Carbon Aerogels for Polymer-Electrolyte Fuel Cells

Carbon aerogels (CA) are known for ultra-low density, very high surface area, fine porous structure, and excellent electrical conductivity. Recent advances in high resolution 3D printing at LLNL enable the manufacturing of complex structured CA electrodes which have been demonstrated in electrolysis, flow battery, and supercapacitor applications. Polymer-electrolyte fuel cells (PEFC) may be an excellent candidate for these materials/methods as designers seek to optimize membrane-electrode assemblies to achieve higher efficiencies. A major challenge to PEFC design is two-phase flow due to water production which causes pore flooding and leads to cell instability and degradation. To mitigate these effects, groups have investigated the creation of liquid specific pathways in the porous layers to alleviate liquid buildup and enhance gas diffusion. While some progress has been made, traditionally manufactured GDLs, which consist of randomly distributed carbon fibers, are limiting. 3D printed CAs are a promising solution as complex macroporous electrode structures can be manufactured out of micro and nano porous filaments with a high level of control. Additionally, the process may allow for the consolidation of multiple layers (MPL, GDL, & flow channels) into a single printed architecture. In this work various CA lattice structures were printed using a direct ink write (DIW) method and liquid breakthrough pressures were measured to demonstrate the ability to tune the water pathways to achieve specific pressure thresholds. Furthermore, a discussion of the prospects for printed CA electrodes in PEFC will focus on material properties, synthesis techniques, and current challenges.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Accelerating the design of lattice structures using machine learning

Lattices remain an attractive class of structures due to their design versatility; however, rapidly designing lattice structures with tailored or optimal mechanical properties remains a significant challenge. With each added design variable, the design space quickly becomes intractable. To address this challenge, research efforts have sought to combine computational approaches with machine learning (ML)-based approaches to reduce the computational cost of the design process and accelerate mechanical design. While these efforts have made substantial progress, significant challenges remain in (1) building and interpreting the ML-based surrogate models and (2) iteratively and efficiently curating training datasets for optimization tasks. Here, we address the first challenge by combining ML-based surrogate modeling and Shapley additive explanation (SHAP) analysis to interpret the impact of each design variable. We find that our ML-based surrogate models achieve excellent prediction capabilities (R 2 > 0.95) and SHAP values aid in uncovering design variables influencing performance. We address the second challenge by utilizing active learning-based methods, such as Bayesian optimization, to explore the design space and report a 5 × reduction in simulations relative to grid-based search. Collectively, these results underscore the value of building intelligent design systems that leverage ML-based methods for uncovering key design variables and accelerating design.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Study on Conversion from an Existing Alternating Current Medium-Voltage Line to a Direct Current Line: A Case of Load or Source Expansion

Simultaneous increase of power generation through renewable systems and load due owing to the rapid growth in electrified road transportation systems, leads to new challenges in the design, operation, and protection of distribution-level electrical power systems. This paper addresses challenges related to the integration of new sources or loads to a distribution grid through long alternating current lines. The International Council on Large Electric Systems medium-voltage benchmark model developed for North America was used for simulation studies. Use cases were developed to illuminate the issues related to long alternating current lines and the usefulness of medium-voltage direct current lines in a distribution network.

Jaldanki, Sreenivasa↗
NASA NTRSDate not supplied

Human Interfaces and Management of Information (HIMI) Challenges for “In-time” Aviation Safety Management Systems (IASMS)

The envisioned transformation of the National Airspace System to integrate an In-time Aviation Safety Management System(IASMS)to assure safety in Advanced Air Mobility(AAM)brings unprecedented challenges to the design of human interfaces and management of safety information. Safety in design and operational safety assurance are critical factors for how humans will interact with increasingly autonomous systems. The IASMS Concept of Operations builds from traditional commercial operator safety management and scales in complexity to AAM. The transformative changes in future aviation systems pose potential new critical safety risks with novel types of aircraft and other vehicles having different performance capabilities, flying in increasingly complex airspace, and using adaptive contingencies to manage normal and non-normal operations. These changes compel development of new and emerging capabilities that enable innovative ways for humans to interact with data and manage information. In-creasing complexity of AAM corresponds with use of predictive modeling, data analytics, machine learning, and artificial intelligence to effectively address known hazards and emergent risks. The roles of humans will dynamically evolve in increments with this technological and operational evolution. The interfaces for how humans will interact with increasingly complex and assured systems designed to operate autonomously and how information will need to be presented are important challenges to be resolved.

Lawrence J Prinzel↗
NASA NTRS1991

Next generation: In-space transportation system(s)

The development of the next generation In-Space Transportation System presents a unique challenge to the design of a propulsion system for the Space Exploration Initiative (SEI). Never before have the requirements for long-life, multiple mission use, space basing, high reliability, man-rating, and minimum maintenance come together with performance in one system that must protect the lives of space travelers, support the mission logistics needs, and do so at an acceptable cost. The challenge that is presented is to quantify the bounds of these requirements. The issue is one of degree. The length of acceptable life in space, the time it takes for reuse to pay off, and the degree to which space basing is practical (full, partial, or expended) are the issues that determine the reusable bounds of a design and include dependability, contingency capabilities, resilency, and minimum dependence on a maintenance node in preparation for and during a mission. Missions to planet earth, other non-NASA missions, and planetary missions will provide important but less demanding requirements for the transportation systems of the future. The mission proposed for the SEI require a family of transportation vehicles to meet the requirements for establishing a permanent human presence on the Moon and eventually on Mars. Specialized vehicles are needed to accomplish the different phases of each mission. These large scale missions require assembly in space and will provide the greatest usage of the planned integrated transportation system. The current approach to defining the In-Space Transportation System for the SEI Moon missions with later Mars mission applications is presented. Several system development options, propulsion concepts, current/proposed activities are reviewed, and key propulsion design criteria, issues, and technology challenges for the next generation In-Space Transportation System(s) are outlined.

Huffaker, Fredrick↗
DOE OSTI2025

Parallel derivative-free optimization for simulation-based design of behind-the-meter energy systems

In this work, the integrated design and dispatch of behind-the-meter or distributed resources (e.g. stationary battery storage and solar PV generation) is considered. A simulation-based framework is employed, generating high-fidelity results with closed-loop predictive control at a fine resolution, at the expense of high computational cost (several minutes to a few hours per design point). To address this challenge, parallel derivative-free design methods are considered. Four methods are compared, including state-of-the-art surrogate-based methods (Radial-Basis Functions and Gaussian processes) and sampling strategies, an evolutionary-based method, and a simple sequential grid refinement method. As a case study, two types of design problem with increasing complexity are considered, namely, the design of behind-the-meter resources (three design variables) and the inclusion of grid capacity (four design variables). The second yields a constrained design problem for which violations can only be determined after solving the computationally expensive simulation. For the three-dimensional case, all methods present a good performance, achieving a solution within 1% of the optimum after the first iteration, with the sequential grid refinement exhibiting the fastest convergence and achieving the best final objective value. This indicates that the parallel evaluation of multiple sampling points may be more important than the choice of method for small decision spaces. For the four-dimensional constrained case, the Genetic Algorithm presents the best tradeoff between performance and computational effort, while the rough objective function terrain generated by constraint violation penalties reduces the performance of surrogate-based methods. Contour plots with flat regions indicate flexibility in the optimal design and highlight the importance of characterizing the solution space.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS1995

Summary of EOS flight dynamics analysis

From a flight dynamics perspective, the Earth Observing System (EOS) spacecraft present a number of challenges to mission designers. The Flight Dynamics Support Branch of NASA GSFC has examined a number of these challenges, including managing the EOS constellation, disposing of the spacecraft at the end-of-life (EOL), and achieving the appropriate mission orbit given launch vehicle and ascent propulsion constraints. The EOS program consists of a number of spacecraft including EOS-AM, an ascending node spacecraft, EOS-PM, a descending node spacecraft, the EOS Chemistry mission (EOS-CHEM), the EOS Altimetry Laser (EOS-LALT), and the EOS-Altimetry Radar (EOS-RALT). The orbit characteristics of these missions are presented. In order to assure that downlinking data from each spacecraft will be possible without interference between any two spacecraft, a careful examination of the relationships between spacecraft and how to maintain the spacecraft in a configuration which would minimize these communications problems must be made. The FDSB has performed various analyses to determine whether the spacecraft will be in a position to interfere with each other, how the orbit dynamics will change the relative positioning of the spacecraft over their lifetimes, and how maintenance maneuvers could be performed, if needed, to minimize communications problems. Prompted by an activity at NASA HQ to set guidelines for spacecraft regarding their end-of-life dispositions, much analysis has also been performed to determine the spacecraft lifetime of EOS-AM1 under various conditions, and to make suggestions regarding the spacecraft disposal. In performing this analysis, some general trends have been observed in lifetime calculations. The paper will present the EOS-AM1 lifetime results, comment on general reentry conclusions, and discuss how these analyses reflect on the HQ NMI. Placing the EOS spacecraft into their respective mission orbits involves some intricate maneuver planning to assure that all mission orbit requirements are met, given the initial conditions supplied by the launch vehicle at injection. The FDSB has developed an ascent scenario to meet the mission requirements. This paper presents results of the ascent analysis.

Newman, Lauri Kraft↗
NASA NTRSDate not supplied

Developing Procedures to Implement Geometric Imperfections Beyond Right Circular Cylindrical Shells in Finite Element Method Models

Analysis of aerospace structures is frequently conducted using nominal dimensions and frequently assumes ideal conditions in loading, contact, constraints, et cetera. Off-nominal dimensions and nonideal conditions, however, are present in all structures. These are the result of widely ranging causes from coefficient of thermal expansion mismatches, manufacturing tooling anomalies, to assembly procedures that inadvertently alter the structure. Specifically, geometric imperfections can have potentially significant influence on the response of a structural test article observed in an experiment versus the response given by a numerical simulation. The Python Tool for Implementing Geometric Imperfections in Reduced Structures (Py_TIGIRS) was previously presented as a set of Python scripts to calculate and implement as-manufactured geometric midsurface and thickness imperfections into finite element method (FEM) shell models of nominally right circular cylinders. By taking advantage of the simple shape of a right circular cylinder, interpolations of the measured data points were able to be performed along directions that aligned to the cylindrical coordinate system axes of the entire structure. By taking advantage of the shell representation of the real structure as opposed to modeling using a continuum representation, the thickness variation was able to be implemented by shell section definitions instead of having to modify the position of multiple nodes in the thickness direction. Py_TIGIRS is a useful tool that established a procedural example on how to implement geometric imperfections in right circular cylindrical shell structures. Three new procedures, each expanded from concepts established in Py_TIGIRS, are proposed for various test-article designs and are intended to broaden the range of structures that can be modeled with measured geometric imperfections in the structural analysis community. Each test-article design introduces new challenges to successfully implement geometric imperfections into a FEM model. The first test-article design consists of a carbon fiber reinforced polymer square plate with a hat-shaped stiffener co-cured on one side. This test-article design was for a novel seven-point bend test that was also previously presented. Manufacturing and cure-cycle imperfections are observed using digital image correlation (DIC) techniques. As thermal expansion coefficient mismatches between the plate and stiffener materials were anticipated, a thermal analysis study with continuum shell and solid elements was conducted to capture the global shape observed prior to testing. The second test-article design is of a similar hat-stiffened plate configuration, but with a side length ratio near 3:1 with elongation in the stiffener direction. The test article was used to characterize the response to uniaxial compressive loading in the direction of the stiffener. Due to differing manufacturing steps, a thermal analysis like the one developed for the seven-point bend configuration was unable to mimic the observed geometric imperfections. Instead, a strategy based on applying deformations directly to the structure during analysis was developed for continuum shell and solid element representation of a stiffened panel.

Geometric imperfections↗
NASA NTRS1999

DRACO Flowpath Performance and Environments

The Advanced Space Transportation (AST) project office has challenged NASA to design, manufacture, ground-test and flight-test an axisymmetric, hydrocarbon-fueled, flight-weight, ejector-ramjet engine system testbed no later than 2005. To accomplish this, a multi-center NASA team has been assembled. The goal of this team, led by NASA-Marshall Space Flight Center (MSFC), is to develop propulsion technologies that demonstrate rocket and airbreathing combined-cycle operation (DRACO). Current technical activities include flowpath conceptual design, engine systems conceptual design, and feasibility studies investigating the integration and operation of the DRACO engine with a Lockheed D-21B drone. This paper focuses on the activities of the Flowpath Systems Product Development Team (PDT), led by NASA-Glenn Research Center (GRC) and supported by NASA-MSFC and TechLand Research, Inc. The objective of the Flowpath PDT at the start of the DRACO program was to establish a conceptual design of the flowpath aerodynamic lines, determine the preliminary performance, define the internal environments, and support the DRACO testbed concept feasibility studies. To accomplish these tasks, the PDT convened to establish a baseline flowpath concept. With the conceptual lines defined, cycle analysis tasks were planned and the flowpath performance and internal environments were defined. Additionally, sensitivity studies investigating the effects of inlet reference area, combustion performance, and combustor/nozzle materials selection were performed to support the Flowpath PDT design process. Results of these tasks are the emphasis of this paper and are intended to verify the feasibility of the DRACO flowpath and engine system as well as identify the primary technical challenges inherent in the flight-weight design of an advanced propulsion technology demonstration engine. Preliminary cycle performance decks were developed to support the testbed concept feasibility studies but are not discussed further in this paper.

Komar, D. R.↗
NASA NTRS1999

The Submillimeter-Wave Astronomy Satellite: On-Orbit Thermal Performance and Design Retrospective

A large telescope aperture, stringent thermal stability and temperature range requirements, and a passively-cooled 1500K module presented major challenges in thermal design and hardware fabrication of this Small Explorer satellite. This paper reviews briefly the thermal design of the SWAS science instrument, and examines the first three months of on-orbit thermal history. Measured temperatures for both the science payload and the spacecraft module and solar arrays are compared with those predicted by the correlated analytical model. Similarities and differences are interpreted in terms of the major uncertainties remaining after thermal-balance testing, especially those of MLI performance and telescope aperture properties. Review of the thermal model adequacy and thermal design verification are included to suggest improvements in the thermal design process for future missions.

Boyd, David A.↗
DOE OSTI2022

Simulated Detector Performance at the Muon Collider

In this paper we report on the current status of studies on the expected performance for a detector designed to operate in a muon collider environment. Beam-induced backgrounds (BIB) represent the main challenge in the design of the detector and the event reconstruction algorithms. The current detector design aims to show that satisfactory performance can be achieved, while further optimizations are expected to significantly improve the overall performance. We present the characterization of the expected beam-induced background, describe the detector design and software used for detailed event simulations taking into account BIB effects. The expected performance of charged-particle reconstruction, jets, electrons, photons and muons is discussed, including an initial study on heavy-flavor jet tagging. A simple method to measure the delivered luminosity is also described. Overall, the proposed design and reconstruction algorithms can successfully reconstruct the high transverse-momentum objects needed to carry out a broad physics program.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
NASA NTRS1995

Design and Development of High Voltage Direct Current (DC) Sources for the Solar Array Module Plasma Interaction Experiment

Two programmable, high voltage DC power supplies were developed as part of the flight electronics for the Solar Array Module Plasma Interaction Experiment (SAMPIE). SAMPIE's primary objectives were to study and characterize the high voltage arcing and parasitic current losses of various solar cells and metal samples within the space plasma of low earth orbit (LEO). High voltage arcing can cause large discontinuous changes in spacecraft potential which lead to damage of the power system materials and significant Electromagnetic Interference (EMI). Parasitic currents cause a change in floating potential which lead to reduced power efficiency. These primary SAMPIE objectives were accomplished by applying artificial biases across test samples over a voltage range from -600 VDC to +300 VDC. This paper chronicles the design, final development, and test of the two programmable high voltage sources for SAMPIE. The technical challenges to the design for these power supplies included vacuum, space plasma effects, thermal protection, Shuttle vibrations and accelerations.

Bibyk, Irene K.↗
NASA NTRSDate not supplied

Adapting Waste Processing for Space Applications

It has been estimated that on a 1-year mission, a four-astronaut crew will produce approximately 2,600 kg of waste materials. The current International Space Station practice for waste management is a stow and jettison model in which the trash is simply ejected. The immediate challenge waste poses for long duration space flight is that it represents unproductive mass. Longer term, waste accumulation on planetary surfaces will also pose challenges. A waste management/disposal solution is greatly needed. Simultaneously, significant research and development efforts are being made to enable in-situ resource extraction and recovery for lunar and Mars surface operations. A waste management solution could free up volume, reduce mass and thereby propellant needs, as well as contribute to resource recovery for spacecraft, and eventually, surface operations. The adaptation of many chemical engineering unit operations to the microgravity environment is critical to achieve this goal. An ideal spacecraft waste treatment system would convert waste into useful gases. It should be largely self-sustaining in that it should have the ability to recycle commodities to avoid imposing mass penalties associated with transporting feedstock on the spacecraft at launch. At NASA KSC, a model of what such a system would look like is being developed. In addition, the team has recently completed a suborbital flight campaign with a combustion reactor to demonstrate rudimentary conversion in a microgravity environment and identify challenges for future design. This presentation will discuss what a full waste treatment system could look like, point out challenges relating to various unit operations involved in such a system, and highlight recent progress in space waste management research and development.

Waste Processing↗