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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 sources NASA NTRS DOE OSTI

NASA NTRS1996

Novel Composites for Wing and Fuselage Applications

Design development was successfully completed for textile preforms with continuous cross-stiffened epoxy panels with cut-outs. The preforms developed included 3-D angle interlock weaving of graphite structural fibers impregnated by resin film infiltration (RFI) and shown to be structurally suitable under conditions requiring minimum acquisition costs. Design guidelines/analysis methodology for such textile structures are given. The development was expanded to a fuselage side-panel component of a subsonic commercial airframe and found to be readily scalable. The successfully manufactured panel was delivered to NASA Langley for biaxial testing. This report covers the work performed under Task 3 -- Cross-Stiffened Subcomponent; Task 4 -- Design Guidelines/Analysis of Textile-Reinforced Composites; and Task 5 -- Integrally Woven Fuselage Panel.

Suarez, J. A.↗

DOE OSTI2025

Design Approach for Circulating Fluidized Bed Riser Reactors such as NETL ASURE: A Review for Clustering Flow

Circulating fluidized bed riser reactors have been a commercial reality for some 80 to 90 years. Through all this time and hundreds if not thousands of research papers on the topic, no clear understanding exists on what is required to design and build a process reactor. There are numerous reasons for this, but the most significant reason is likely that riser reactors are chaotic in nature and unless this chaotic behavior is accounted for, there will be wide discrepancies in the predicted performance and in attempts to scale these reactors without significant trial and error. This work puts forth a new methodology to design riser reactors based upon the desired operating range using the chaotic microstructure behavior. This is accomplished through the use of a nondimensional regime map that was developed using chaotic parameters of memory and order/disorder along with higher moments of skewness and kurtosis. Validation of the approach is provided with circulating fluidized bed combustors and applied to the design of the NETL ASURE facility.

42 ENGINEERING↗

NASA NTRS2011

Evolution of Space Shuttle Range Safety Ascent Flight Envelope Design

For every space vehicle launch from the Eastern Range in Florida, the range user must provide specific Range Safety (RS) data products to the Air Force's 45th Space Wing in order to obtain flight plan approval. One of these data products is a set of RS ascent flight envelope trajectories that define the normal operating region of the vehicle during powered flight. With the Shuttle Program launching 135 manned missions over a 30-year period, 135 envelope sets were delivered to the range. During this time, the envelope methodology and design process evolved to support mission changes, maintain high data quality, and reduce costs. The purpose of this document is to outline the shuttle envelope design evolution and capture the lessons learned that could apply to future spaceflight endeavors.

Brewer, Joan↗

NASA NTRS1989

Aircraft integrated design and analysis: A classroom experience

AAE 451 is the capstone course required of all senior undergraduates in the School of Aeronautics and Astronautics at Purdue University. During the past year the first steps of a long evolutionary process were taken to change the content and expectations of this course. These changes are the result of the availability of advanced computational capabilities and sophisticated electronic media availability at Purdue. This presentation will describe both the long range objectives and this year's experience using the High Speed Commercial Transport design, the AIAA Long Duration Aircraft design and RPV design proposal as project objectives. The central goal of these efforts is to provide a user-friendly, computer-software-based environment to supplement traditional design course methodology. The Purdue University Computer Center (PUCC), the Engineering Computer Network (ECN) and stand-alone PC's are being used for this development. This year's accomplishments center primarily on aerodynamics software obtained from NASA/Langley and its integration into the classroom. Word processor capability for oral and written work and computer graphics were also blended into the course. A total of ten HSCT designs were generated, ranging from twin-fuselage aircraft, forward swept wing aircraft to the more traditional delta and double-delta wing aircraft. Four Long Duration Aircraft designs were submitted, together with one RPV design tailored for photographic surveillance.

Weisshaar, Terrence A.↗

DOE OSTI2026

Passive Energy-Saving Solutions for Clothes Dryers: A Modeling and Experimental Study for Improved Efficiency and Affordability

Dryers are integral appliances in modern households, yet their significant power consumption remains a critical challenge for reducing energy bills and upgrades. This work presents the outcomes of a comprehensive investigation aimed at lowering the operating energy costs of the dryer through modeling and experimental approaches. Specifically, the objectives of this research are twofold: (1) to reduce energy consumption without negatively impacting drying performance or time; and (2) to ensure affordability by developing retrofittable solutions characterized by low cost and a quick payback period. These strategies promise universal applicability to all dryer categories, encompassing both gas and electric models, by tackling core issues such as unnecessary heat loss and excess energy supply, both prevalent across dryer designs. Our methodology combines robust modeling frameworks and experimental validation to target energy efficiency improvements through three primary pathways: (1) effective heat loss management using ultralow-cost insulation materials tailored for dryer systems; (2) heat management across the drying cycle, facilitated by passive heat transfer mechanisms, and (3) optimization of heat supply to the load to ensure precise energy delivery, minimizing waste. These innovations are designed to seamlessly integrate with existing dryer configurations, providing a scalable and retrofittable solution that ensures affordability without requiring substantial redesigns or expensive components. Using these methods, the study demonstrates improvement opportunities in dryer energy consumption while maintaining the desired performance. The modeling component utilizes computational simulations to evaluate the thermal and energy performance of these innovations under varied operational conditions, providing foundational insights for experimental design. By addressing critical areas such as heat loss, energy recovery, and supply optimization, this work proposes impactful solutions for lowering the energy costs in domestic clothes dryers. The ultralow-cost, retrofittable nature of the proposed strategies ensures widespread adoption potential across diverse dryer categories, making significant strides toward affordable household energy practices.

Cheekatamarla, Praveen [ORNL] (ORCID:0000000248827↗

NASA NTRS1988

Methods for heat transfer and temperature field analysis of the insulated diesel, phase 3

Work during Phase 3 of a program aimed at developing a comprehensive heat transfer and thermal analysis methodology for design analysis of insulated diesel engines is described. The overall program addresses all the key heat transfer issues: (1) spatially and time-resolved convective and radiative in-cylinder heat transfer, (2) steady-state conduction in the overall structure, and (3) cyclical and load/speed temperature transients in the engine structure. These are all accounted for in a coupled way together with cycle thermodynamics. This methodology was developed during Phases 1 and 2. During Phase 3, an experimental program was carried out to obtain data on heat transfer under cooled and insulated engine conditions and also to generate a database to validate the developed methodology. A single cylinder Cummins diesel engine was instrumented for instantaneous total heat flux and heat radiation measurements. Data were acquired over a wide range of operating conditions in two engine configurations. One was a cooled baseline. The other included ceramic coated components (0.050 inches plasma sprayed zirconia)-piston, head and valves. The experiments showed that the insulated engine has a smaller heat flux than the cooled one. The model predictions were found to be in very good agreement with the data.

Morel, Thomas↗

NASA NTRS1988

Aircraft integrated design and analysis: A classroom experience

AAE 451 is the capstone course required of all senior undergraduates in the School of Aeronautics and Astronautics at Purdue University. During the past year the first steps of a long evolutionary process were taken to change the content and expectations of this course. These changes are the result of the availability of advanced computational capabilities and sophisticated electronic media availability at Purdue. This presentation will describe both the long range objectives and this year's experience using the High Speed Commercial Transport (HSCT) design, the AIAA Long Duration Aircraft design and a Remotely Piloted Vehicle (RPV) design proposal as project objectives. The central goal of these efforts was to provide a user-friendly, computer-software-based, environment to supplement traditional design course methodology. The Purdue University Computer Center (PUCC), the Engineering Computer Network (ECN), and stand-alone PC's were used for this development. This year's accomplishments centered primarily on aerodynamics software obtained from the NASA Langley Research Center and its integration into the classroom. Word processor capability for oral and written work and computer graphics were also blended into the course. A total of 10 HSCT designs were generated, ranging from twin-fuselage and forward-swept wing aircraft, to the more traditional delta and double-delta wing aircraft. Four Long Duration Aircraft designs were submitted, together with one RPV design tailored for photographic surveillance. Supporting these activities were three video satellite lectures beamed from NASA/Langley to Purdue. These lectures covered diverse areas such as an overview of HSCT design, supersonic-aircraft stability and control, and optimization of aircraft performance. Plans for next year's effort will be reviewed, including dedicated computer workstation utilization, remote satellite lectures, and university/industrial cooperative efforts.

Source record↗

DOE OSTI2023

Monte Carlo Analyses of the FOEHN Experiment

The FOEHN critical experiment, which has been carried out at Cadarache (France) in the reactor EOLE in the early 70s, was designed to verify RHF design analyses. This study focuses on the impact of the FOEHN experiment uncertainties on the calculation of the energy deposition. The latter has been obtained by the Monte Carlo codes Serpent and MCNP. In the calculation of the energy deposition, the first code relies on KERMA factors whereas the latter code relies on Q-values. The two Monte Carlo codes share the same geometry and material specifications. In addition to the design and experiment parameters uncertainties, nuclear data also impacts the calculation of the energy deposition. In this study, the MCNP simulations use three different nuclear data library sets: ENDF/B versions VII.0, VII.1, and VIII.0. Finally, the ksens card of MCNP, using perturbation theory, has been used to identify the cross sections and isotopes with largest impact on the effective multiplication factor. By showing that the use of different software and computational methodologies and design parameters uncertainties do not significantly impact the core power distribution, this work demonstrate the appropriateness of the tools and methods employed for the conversion of involute-plate reactors.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS1992

The NASA-LaRC Controls-Structures Interaction (CSI) technology program

One of the main difficulties encountered in the design and implementation of control systems for spacecraft is the interaction between the control system and the flexibility of the vehicle. This difficulty has resulted in problems for a multitude of spacecraft including the earliest U.S. spacecraft, Explorer I; the Orbiting Geophysical Observatory III; Mariner 10; Galileo; and the Hubble Telescope. Recognizing the importance of the issue, NASA has an ongoing Controls-Structures Interaction (CSI) technology program to develop the methodology to design optimally and simultaneously both the control system and the structure. The CSI program is a multicenter program involving research teams from NASA's Langley Research Center (LaRC), Jet Propulsion Laboratory (JPL), and Marshall Space Flight Center (MSFC). JPL's area of interest is in optics-class vehicles and MSFC's in astrophysics vehicles. The aim of this paper is to explain the ongoing activities at LaRC, which are of a theoretical, ground test, and flight test nature, with focus on applications to spacecraft with multiple experiment-pointing mounts, large space radiometers, Space Station Freedom (SSF), and the Space Shuttle Remote Manipulator System (RMS).

Anderson, Willard W.↗

NASA NTRS2002

Development and Flight Demonstration of a HUMS-Based Helicopter Limit Cueing (HLC) System

A prototype helicopter limit cueing (HLC) system was designed, installed, and evaluated in flight test in early 2002. This paper describes the design, cueing methodology, and interim flight test results of this project. The system described in this paper used available Health and Usage Monitoring System (HUMS) parameters and a simple and cost-effective mechanical spring/electric motor combination to achieve a tactile cue that warned the pilot of impending exceedences of the transmission torque limit. Three high-workload maneuvers were used to evaluate the prototype HLC system. Results indicate that with an appropriate design, inadvertent over-torque events could be eliminated with a HLC system while reducing pilot workload.

Augustin, M.↗

DOE OSTI2022

High Temperature Anode Recycle Blower for Solid Oxide Fuel Cell, Phase II (Final Report)

Broad commercialization of solid oxide fuel cells (SOFCs) requires anode offgas recycle blowers (ARCB) that are specifically designed for handling the challenging operating conditions presented by the SOFC process gases. Otherwise, they can be susceptible to frequent maintenance, low reliability, and short life. This report presents details of a DOE-funded Phase II effort conducted by Mohawk Innovative Technology, Inc. (MiTi®) for the development and testing of an oil-free, low cost, high-temperature centrifugal ARCB based on compliant foil bearing (CFB) technology for support of a 100 kW solid oxide fuel cell power plant. This Phase II builds on the results of a successful Phase I development project that resulted in the demonstration of a low TRL-6 prototype, shown in Figure 1. This Phase II final report presents design improvements over the Phase I prototype, presents the assembled test ARCBs, and discusses the advantages of this novel technology, particularly its long life and maintenance-free operation, which are derived from the use of CFBs. Also included are preliminary techno-economic analysis considerations for cost-effective deployment of the technology. The specific objectives of this project, as stated in the statement of program objectives (SOPO) were 1) to follow the methodology of design for manufacturing (or manufacturability) and assembly for implementing improvements identified as part of the Phase I effort with the purpose of reducing cost, enabling mass production, and facilitating the commercialization of a revised ARCB design, and 2) to fabricate four complete ARCB units based on the revised design and demonstrating their performance in both a laboratory setting and in an actual SOFC power plant. Execution of this SOPO would be supported by a number of technical tasks resulting in the fabrication and testing of the prototypes. To this end, MiTi continued the teaming relationship started during Phase I of the program with subcontracting partner FuelCell Energy, Inc. (FCE), which integrated (under a parallel effort funded by DOE Award DE-FE0026199) a modular 200 kWe SOFC power plant. MiTi and FCE coordinated to ultimately incorporate one of MiTi’s ARCB prototypes into one of the 100 kWe SOFC Modular Power Blocks (MPB) that constitute the core of FCE’s SOFC power plant for in-situ long-duration testing. Additionally, MiTi would explore the scalability and extendibility of the technology to other applications, as well as conduct a basic techno-economic analysis.

03 NATURAL GAS↗

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↗

NASA NTRS2006

Implementing Scientific Simulation Codes Highly Tailored for Vector Architectures Using Custom Configurable Computing Machines

The motivation for this work comes from an observation that amidst the push for Massively Parallel (MP) solutions to high-end computing problems such as numerical physical simulations, large amounts of legacy code exist that are highly optimized for vector supercomputers. Because re-hosting legacy code often requires a complete re-write of the original code, which can be a very long and expensive effort, this work examines the potential to exploit reconfigurable computing machines in place of a vector supercomputer to implement an essentially unmodified legacy source code. Custom and reconfigurable computing resources could be used to emulate an original application's target platform to the extent required to achieve high performance. To arrive at an architecture that delivers the desired performance subject to limited resources involves solving a multi-variable optimization problem with constraints. Prior research in the area of reconfigurable computing has demonstrated that designing an optimum hardware implementation of a given application under hardware resource constraints is an NP-complete problem. The premise of the approach is that the general issue of applying reconfigurable computing resources to the implementation of an application, maximizing the performance of the computation subject to physical resource constraints, can be made a tractable problem by assuming a computational paradigm, such as vector processing. This research contributes a formulation of the problem and a methodology to design a reconfigurable vector processing implementation of a given application that satisfies a performance metric. A generic, parametric, architectural framework for vector processing implemented in reconfigurable logic is developed as a target for a scheduling/mapping algorithm that maps an input computation to a given instance of the architecture. This algorithm is integrated with an optimization framework to arrive at a specification of the architecture parameters that attempts to minimize execution time, while staying within resource constraints. The flexibility of using a custom reconfigurable implementation is exploited in a unique manner to leverage the lessons learned in vector supercomputer development. The vector processing framework is tailored to the application, with variable parameters that are fixed in traditional vector processing. Benchmark data that demonstrates the functionality and utility of the approach is presented. The benchmark data includes an identified bottleneck in a real case study example vector code, the NASA Langley Terminal Area Simulation System (TASS) application.

Rutishauser, David↗

DOE OSTI2021

Design of heterogeneous structured Al alloys with wide processing window for laser-powder bed fusion additive manufacturing

Required microstructural attributes of an alloy vary with structural applications. The microstructural fine-tuning capability of laser-powder bed fusion (L-PBF) additive manufacturing (AM) enables application specific manufacture of the components. Such manufacture with L-PBF AM requires alloys that exhibit wide processing window and are amenable to multiple deformation mechanisms. However, high hot cracking susceptibility of Al alloys poses a barrier to such printability-performance synergy. In this work we show that an integration of, a) grain refinement through heterogeneous nucleation, and b) eutectic solidification, leads to crack-free parts at wide range of process parameters, microstructural heterogeneity, and hierarchy in the Al-Ni-Ti-Zr alloy. Such an integration targets hot cracking at multiple stages of solidification in L-PBF as opposed to the contemporary alloy design strategies that target hot-cracking at only specific stages of solidification. The Al-Ni-Ti-Zr alloy exhibits excellent printability and a high as-built tensile performance. Due to the wide processing window and amenability to multiple deformation mechanisms, the alloy microstructure and subsequently the performance, can be fine-tuned. Here, such strategy opens the gateway for application-specific manufacture of Al alloys with L-PBF AM and establishes a fundamental shift in current methodologies for design of these alloys for L-PBF AM.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Creating Portfolio Management Concepts for Highly Agile and Innovative Government Research Programs Using Design Thinking and Lean Startup Methodologies

Managing a research and development (R&D) portfolio presents numerous challenges, such as prioritizing research areas, remaining agile, strategic workforce planning, and measuring return on investment, impact, and innovation. One government R&D program is charged with producing a high degree of innovative, transformational breakthroughs in aviation technology. A practical, structured methodology for strategically prioritizing emerging aviation R&D in such an environment is lacking. The existing multi-criteria decision aid tools are primarily utilized at an enterprise level, take months to set up and collect data, require large teams of experts, are used on an infrequent basis, and are not conducive to a highly innovative, high-risk portfolio. Prior to audaciously creating a new portfolio prioritization process, the exact challenges with portfolio management for R&D projects were identified using the design thinking and lean start-up methods. A key part of this discovery process was interviewing stakeholders, as well as other managers of organizations charged with producing innovative portfolios. These interviews, as well as additional techniques, were used to develop a deeper understanding of the challenges and, subsequently, lay the foundation for development of an effective portfolio prioritization process. Four potential concepts that represent key findings emerged: carefully selected criteria for portfolio assessment and selection, targeted portfolio turnover rate, dynamic portfolio prioritization framework, and streamlined transition or commercialization of R&D. Acting on any one of the resulting portfolio management concepts will increase the transparency and confidence in portfolio decisions and, ideally, result in a greater degree of transformational breakthroughs in aviation technology.

project portfolio management↗

NASA NTRSDate not supplied

Sonic Boom Ground Noise Minimization Via the Adjoint Method

A multidisciplinary design optimization methodology to directly minimize the ground-level noise generated by the sonic boom of a high altitude supersonic body is presented. A Cartesian Euler flow solver is coupled with an atmospheric propagation tool to create a ground-noise analysis capability for supersonic bodies. Adjoint formulations for both the flow solver and propagation tool are also coupled to compute sensitivities of shape variations in the body in a highly efficient manner. A gradient-based optimizer is then introduced to forge a valuable design capability. Output-based mesh adaptation that is driven directly by ground-level noise is employed to increase accuracy and provide error estimation. The design method is demonstrated first on a simple axisymmetric body with few design variables to evaluate the efficacy of the optimization scheme. Guided by the results of this initial case, the problem is then repeated with somewhat different design variables to further demonstrate the capabilities of the design method. Finally, the method is applied to a real-world problem by optimizing control surface deflection settings of a low-boom aircraft to minimize ground noise while maintaining trimmed, level flight.

ARMD↗

NASA NTRS1999

A Computational/Experimental Study of Two Optimized Supersonic Transport Designs and the Reference H Baseline

Two supersonic transport configurations designed by use of non-linear aerodynamic optimization methods are compared with a linearly designed baseline configuration. One optimized configuration, designated Ames 7-04, was designed at NASA Ames Research Center using an Euler flow solver, and the other, designated Boeing W27, was designed at Boeing using a full-potential method. The two optimized configurations and the baseline were tested in the NASA Langley Unitary Plan Supersonic Wind Tunnel to evaluate the non-linear design optimization methodologies. In addition, the experimental results are compared with computational predictions for each of the three configurations from the Enter flow solver, AIRPLANE. The computational and experimental results both indicate moderate to substantial performance gains for the optimized configurations over the baseline configuration. The computed performance changes with and without diverters and nacelles were in excellent agreement with experiment for all three models. Comparisons of the computational and experimental cruise drag increments for the optimized configurations relative to the baseline show excellent agreement for the model designed by the Euler method, but poorer comparisons were found for the configuration designed by the full-potential code.

Cliff, Susan E.↗

NASA NTRS1978

Thermal design analysis of shuttle cargo bay payloads

The thermal design analysis methodology, the thermal control philosophy, and preliminary thermal analysis results associated with specific shuttle payloads are presented. The payloads considered are the Get-Away Special canisters being developed by NASA Goddard, which may be flown on a variety of missions, and the six experiments which are mounted on the GSFC pallet to be flown on Operational Flight test No. 4 (OFT-4). The thermal control alternatives currently available to OFT-4 instruments are the use of pallet cold plates (if available) or operational constraints which allow passive thermal control without the use of excessive heater power. The characteristics of a completely passive thermal control design are evidenced by the results of the Get-Away Special canister analysis.

Bartoszek, J. T.↗